Cargo Cover Reel Repair, Volvo 850 and V70

Grrrrrrrr, I really don't like old Volvo plastic. The other day I noticed that my cargo cover was not rolling out smoothly. Seems like it was bent. So, a few days later it went from not rolling out smoothly to not rolling out at all. What had happened was one side broke loose putting pressure on the other side which followed suite, both sides broke loose and it would not real in or out. Call the stealer and they want to sell you a new one for $280+. Ah, no thanks. I'll figure something else out.

I checked with a few forum members and one suggestion popped up that was hard to understand but had a few good pics. From that thread my idea was brewed and I spend about 4 hours messing with what should take you less than an hour.

Small cross tip screw driver.	Straight razor.
Small plumbing pipe cutter or hack saw. (They may cut your metal pipe for you at the store).	File or something to cut plastic out of a narrow slot.
Ruler	Marker

Instructions:

Go to a self help hardware store and get less than 1 foot of 1/2" copper pipe and the shortest 3/8" plastic pipe you can find. (You will only need 7" of the plastic pipe and 3" of the copper pipe). I ended up with 1' of copper ($2.47) and 6' of the plastic pipe ($1.80).
Cut 2 pieces of the plastic pipe to 3-1/2".
Cut 2 groves in the plastic pipe. One 1-1/4" and the other 2". Counter the cuts so they are 90 degrees from each other. I used a straight razor to make the cuts. I tried several things, the straight razor won.
Heat and bend the 1-1/4" plastic pipe so it's shaped like a T.
Cut 2 pieces of the copper tube to 1-1/2".
Remove the ends of the cover ends.
Remove the inner ends of the cargo cover. Small cross tip screw driver, 3 screws.
Look in the end and remove the thin outer plastic sleeve that is on the end of the shaft.
Remove the broken sleeve from the inside of the shaft, do your best not to damage the end of the shaft and the shaft itself.
Slide the copper tube in the end of the outer plastic sleeve to give the new plastic extra support. I used hand lotion to help it slide on.
Slide the outer plastic sleeve back over the shaft with the copper end out.
Re-install the inner plastic end pieces, 3 small screws.
Slide the new plastic inner sleeves into the end caps. Align them to go over the shaft and inside the copper sleeve. The cut bent T ends will be out of the inner end caps.
Sit down in a chair and set the cover on your legs and real the cover in with the new plastic pieces you just installed. I reeled it all the way in and then 5 more turns. Then I had someone help me by pulling it out and letting it back in to make sure it worked, while I held the ends.
Slide the otter end caps on.
Install the cover.