Interesting. I'm assuming that you're using solid fill? My main concerns would be the fatigue life of the crossbars and the ABS-to-wood bond strength. Is there some kind of a lip on the outer cone to keep it from being pulled through the hole?

If I was doing this, I'd make up a fitting, mount it in wood, hang a swinging weight equivalent to the entire weight of the boat from it and let it swing until the fitting breaks or enough time has passed that I feel comfortable about putting it in my boat.

Cool idea, wish my printer would print ABS (it only does PLA). Good luck,

Laszlo

   I can definitely see the required lip.

As Laslo says, fatigue could be an issue with the crossbar.

Maybe consider increasing the radii where the bar meets the body. Redesign as a 2piece unit that allows a stainless steel pin to be used.

What type of adhesive will you use?  Cheers

   Thanks.

Like the idea of using a stainless pin. Would also make it smaller. Currently the bar is 10mm diameter. 

Was not so concerned about fatigue as item only under stress for a few minutes every weekend. Important not to overtighten lines in rest state.

For glue was assuming epoxy would be ok. I normally roughen surfaces with a file before gluing. Given most likely force is compression I hadn't considered this much. Does epoxy and ABS match? ( actual filament is ASA, dedicate of ABS).

Just remember that a fully loaded kayak with camping gear weighs two to three times as much as it normally does. My C-17 took four of us to pick it up one weekend.  (we ate good though)