How to (not) replace a broken rafter attachment on the Fiamma F45s awning

As the previous owner was showing me how to work the awning on the 2018 Liberty Deluxe I recently purchased, a small plastic piece fell to the ground.  It turns out that piece is pretty essential if you want to use the rafter on the Fiamma F45S awning that comes with the Casita.

It looks like this:

This particular part works by slipping the top into the groove on the awning assembly and the bottom clamps down on the bottom lip of the awning when you tighten the screws.  The rafter (the center beam) connects to it on the Casita side of the awning.  Unfortunately that thin piece of plastic (bottom of the right piece in the above photo) has a tendency to snap.  

It took me a minute to track down what exactly this part was called since the numbers printed on it don't correspond to the part number. (If you're shopping for it, you want the "Awning Rafter Fixing Kit" and the part number is 98655-542). It turns out you can buy it online, and the going rate seems to be in the ballpark of $25 with shipping.

However, never one to shell out a (relatively) large amount of cash for a tiny piece of plastic, I examined my options.  

My first thought was to try some plastic welding with acetone.  Unfortunately this particular plastic chemistry doesn't lend itself to this solution.  I thought of trying glue or epoxy but they wouldn't be strong enough to hold with the physics acting on it.  

My next thought was simply to dispense with the extra piece entirely and just bolt the main part directly onto the awning.  Seems simple and plenty strong and Fiamma was kind enough to provide the screw holes.  I gathered my nuts, bolts, and washers and then took a peek behind the awning to see what I was working with.  

Unfortunately the bracket mounting the awning to the Casita is directly behind where I would want to drill so it would be pretty darn difficult to get a nut back there.

So no dice on bolting it in so I figured I would use the slightly weaker sheet metal screws and just screw it in place.  I positioned the part with the Fiamma writing upside down so I could take advantage of the screw holes already in place.  The bottom part of the plastic piece tucked neatly behind the bolt that's there and the screws would hold in the top.

I drilled out the holes with a 9/64 bit.  It was a tight fit and I discovered that the rotating head on my drill got a little too close to the awning fabric and abraded a hole in it. Oops!  Some repair tape will fix that right up and, if my girlfriend asks, the previous owner must have done it.

Nevertheless, using the same screws that originally held it in place I screwed it in and it felt really secure.  Brilliant!!

...almost.  I then tried to attach the rafter and it turns out that it can't attach to that piece upside down.  

And if I tried to flip the rafter, it would just fall out.  So back to the drawing board.

I flipped the piece right side up and, using the same screw holes, drilled new holes below the first ones.  I screwed the screws in place and gave it a tug.  Not bad.  Not as secure as when the screws were on top but this does have the advantage of allowing the rafter to attach to it. 

Success!!

Total cost: 1 piece of repair tape