So I purchased a 10x10 Ozark Canopy and had it setup the other day and a wind gust flipped it and snapped one of the legs. So I thought I'd just order a replacement leg. Well you can't get one, I tried online etc. So then I thought I'd just buy from Grainger a replacement Aluminum tube and I'd drill some holes and I'd be all set. Well Ozark(A Walmart Company) purposely makes all the adapters for the leg in a non squared, angled corner shape so you can not fix it yourself. They'd rather you go and spend another $200 for a new canopy. Well I decided to take some time and design replacements for all the connectors of the leg that are square in shape and will accommodate square tubing. Listed below is a link to my original canopy from Walmart, a link to Grainger website where you can purchase the aluminum tube from. And of course, my STL files for all the replacements. Please validate that your canopy uses the same types of connectors before you start down this path. It seems looking at my other canopys that I own that they are all similar.
Original Canopy - https://www.walmart.com/ip/Ozark-Trail-10x10-Commercial-Canopy-With-Sidewalls/400459949
Grainger Website for Aluminum Tubing - https://www.grainger.com/product/GRAINGER-APPROVED-Square-Tube-6ALR0?searchBar=true&searchQuery=6ALR0
Raptor PLA PLA
Due to the overhang on certain connectors I used supports.
Also use 100% infill for strength.
So far the connectors have held up good without any issues. I used a high strength Raptor PLA which is suppose to be stronger than ABS. If for some reason these break, I'll print in Nylon the replacements.
Please note you will need a drill and a hacksaw (I used my Miter Saw) for the installation.
Print the 3 connectors: Leg Bottom, Canopy Support, and Leg Top
The Original Connector for the Leg Bottom and Canopy Support have a Push button as part of it.
Remove the original connectors from the Canopy Frame. Leg Top and Canopy support both have 3 connector rods that need to be disconnected.
Remove the button(Red in my case) from the original connectors by using a small nail to push the pin out that holds the button and spring to the connector.
Save the 3 parts (Button, Spring, pin)
Re-install the button on the corresponding new connectors.
Cut the new Aluminum tubing the same size as one of the existing Canopy legs corresponding sections (the lower legs slides into this main leg)
Measure the location and size for each hole in an existing good leg, and drill corresponding holes in the new Leg.
Install the new Leg Top and Canopy Support connectors(re-attach all the rods)
Install Lower Leg Adapter onto New Leg Tube
Install new Leg thru Canopy Support Connector and into Leg Top connector and screw in.
- Install lower leg into bottom of New Leg.
Process of Design
I took all 3 connectors off the broken leg.
I measured each hole location and size
I modeled each connector in Tinkercad