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I have some sweet (old) Ortlieb bike bags (they look like Bike Packer Plus 42L, though an older version than what is currently offered). The latches on the bottom side of the fly tie down snapped. Sure, you can buy new ones, or even maybe even print your own latch, but you know what else you can do? Make your own toggles!
Mine uses an 8-in section of paracord for the toggle, and a 13-in section of paracord for the hold-down. I made 4 sets for a pair of bags. You will need an M3 nylock nut for each, as well as a M3X16-mm or M3X18-mm flat-head screw to hold the toggle to the bag.
The parts are printed in yellow Hatchbox ABS. Fill is 50% and layer height is 0.35-mm. If I were making these again I would go with 0.1-mm layer height on the toggles to show off the contours. Material choice is flexible, but it is easier to use something you can solvent weld together easily, like ABS or ASA.
The parts pictured are over 3 years old and they have been working like a champ!
OrtliebBagToggleMount - print two. No support, no brim. It works better if you glue the pieces together around the paracord (mine are welded with acetone). That makes it easier so you don't have to drag a melted end through the 180° turn (it probably won't fit!). If you do it this way you will want to move the cord back and forth when you glue it to keep the ABS squeeze out boogers from freezing the paracord in the turn.
OrtliebBagToggle - print two copies, with support. Knock out the support and glue the bed-facing faces together. Thread the paracord ends from the OrtliebBagToggleMount through and tie a simple overhand knot to keep the toggle on.
OrtliebBagToggleMountNutPlateII - Install an M3 nylon lock nut.
I use a midshipman's hitch for adjustment on the fly retention. The paracord loops through the upper latch attachment nylon webbing and just hangs out with the original catch.
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