How I got a replacement cover piece for my smart light track without buying the whole kit

Had the same problem with a garden wall washer, the end cap went brittle after two winters and one of the clips snapped off. Before printing anything I tried making a temporary fix with a bit of two-part epoxy putty pressed into the original cap as a mould. Looked rough but held the diffuser in place for a whole summer untill I sorted a proper replacement.

The sizing tip matters more than people think. Mine was 22mm across the flats but the depth was the thing that caught me out, the first spare I bought was the right width but sat proud of the housing and let water in. Check the depth too if it's an outdoor fitting.

One thing that worked better than emailing support was going thru the retailer I bought it from. The shop contacted the distributor on my behalf and got the part in about a week, whereas my direct email to the manufacturer got a reply telling me to buy a new unit. Worth a try if you still have the receipt. Also had luck searching for the part name in other languages on auction sites, some of the listings that came up were for identical fittings sold under diffrent brand names. Saved me a fiver compared to the official spare.

Ha, this takes me back. Before 3D printers were a thing we'd do the same trick with a wax or plasticine impression and get a local model shop to cast it, or just carve one from a block of nylon with a file. Crude but it lasted years on a few fittings.

One thing I'd add, if the cap is only cracked rather than gone, a bit of careful bonding with plastic weld or even a zip tie pulled round as a retaining lip has kept caps on my old porch light for a decade now. Ugly, but who's looking at the eaves at night.

This whole thread is handy because I broke one of those little round knobs on my bathroom light last month and just gave up, the cover has been sat in a drawer since. I never even thought about asking the company directly, I assumed they'd tell me to buy a whole new one. When you measured with a ruler, how did you know where to measure from? I can picture the flat sides but not which bits matter. Also does the printed one look odd if the light is somewhere visible, like can you notice it's not the original?

The retailer tip is spot on, mine did the same for me. Popped into the local electrical wholesaler where I'd bought the fixture, expecting nothing, and the bloke behind the counter had a drawer of odds and ends from returns and old stock. Found a cap that fit in about two minutes and he charged me next to nothing for it. Might be worth asking at any trade counter even if you're not a regular, they often know which fittings share parts across brands.