The Smell of Molten Projects in the Morning

The fairing mount must aim the flashlight generally parallel to the ground and slightly toed-in toward the bike’s frame, ideally holding the ball more-or-less in the center of its adjustment range. I eyeballed a protractor for the initial estimates and got it reasonably close on the third try:

Tour Easy – J5 Tactical V2 – front

One more skilled in math than I could define a matrix transformation between the solid model’s XYZ coordinate space and the fairing’s XYZ space, then figure the reverse transformation allowing you to convert real-world angles back to the model’s space. I winged it by setting up adjustments to rotate the ball clamp ring on all three axes around its center:

Lifting the ring upward by half its OD leaves it tangent to the XY plane, firmly embedded in the blank fairing clamp plate, and, through the magic of 3D printing, looking like it grew there.

In practice, aligning the ring isn’t too difficult. Align an eyeball along each of the mount’s axes, center a protractor on the ball with it perpendicular to the line of sight, rotate it so the baseline is level / straight-ahead / crosswise, read off the angle, then type it in. Of course you’ll get the sign wrong at least once.

For a given set of those angles, the mount looks like this:

Fairing Flashlight Mount – Mount – rear view – no support – solid model

You can determine by inspection there’s no way to orient the shape for E-Z building, although putting the plate flat on the platform has a lot to recommend it.

The outside being a spherical section, the overhangs will curl upward, so (as with the ball around the flashlight) rows of fins anchor the perimeter threads:

Fairing Flashlight Mount – Mount – rear view – solid model

The fins are just under two threads wide to eliminate any possible infill, with a simple sphere chopping their tops to fit just inside the clamp:

Slic3r built support structures under the overhanging screw bosses:

Fairing Flashlight Mount – Mount – rear view – Slic3r

It also added weird little towers that don’t come close to touching the clamp’s lower surfaces, which is why I added those fins. The automatic support should extend to one thread thickness from the bottom surface, but that’s a hard calculation to make for a spherical section represented by tesselating triangles.

After a few test rides, the whole affair seems to be both holding together and holding the flashlight, so it’s good enough for now. A twilight ride around the block may be needed for better aiming, though.

With the flashlight firmly clamped inside its ball, a surrounding clamp ring holds the ball on the mount:

Tour Easy – J5 Tactical V2 – front

The solid model chops a sphere to a completely empirical 70% of the inner ball’s length (which, itself, may be truncated to fit the flashlight grip) and glues on a hull containing the M3x50 mm screws:

The complete ring looks about like you’d expect, although it’s never built like this:

Fairing Flashlight Mount – Clamp – show view – solid model

The top half builds as an arch on the platform:

Fairing Flashlight Mount – Clamp – build view – solid model

The uppermost layers on the inside of the arch have terrible overhang pulled upward by the cooling plastic, so the builtin support structure hold the layers downward. The preview shows they don’t quite touch, but in actual practice the support bonds to the arch and requires a bit of effort to crack off:

Fairing Flashlight Mount – support structures

The ones on the right come from my (failed) attempts to build the ball hemispheres in the obvious orientation. It’s worth noting that my built-in “support” both bonds to the part and breaks off in one piece, quite unlike the pitched battle required to separate Slic3r’s automatic support structures; I think that’s the difference between the minimum feasible and maximum possible support.

Anyhow, the inside of the arch requires only a bit of cleanup with a ball mill before it clamps firmly around the flashlight ball. In the normal orientation, the space over the missing ball cap snuggles into the cleaned-up part of the arch and there’s enough friction on the remaining ball to hold it in place. If it does joggle loose, a wrap of tape should provide enough griptivity.

I started by assuming socket-head cap screws and brass inserts embedded in the clamp ring could provide enough force to hold everything together:

Fairing Flashlight Mount – Clamp – screw inserts – solid model

The head recesses into the top opening and the insert sits just below the split line on the XY plane. That turned out to be asking a lot from a pair of 3 mm knurled brass inserts, even with JB Weld in full effect, and I wasn’t at all confident they wouldn’t pop out under duress and fling the flashlight away.

Each screw now compresses the entire boss between a pair of washers and the nyloc nut won’t vibrate loose. The screws also serve to stiffen the clamp ring front-to-back, although I’m not convinced it needs any reinforcement.

I also considered splitting the ring parallel to the front, right down the middle, with screws extending through both halves:

Fairing Flashlight Mount – Clamp – Front Back split – solid model

It’d be trivially easy to build the front half face-down on the platform, but the rear would have only half the surface area bonded to the plate against the fairing, which seemed like a Bad Idea. Worse, I couldn’t figure out how to align the rear half on the plate with enough room for the nuts / inserts / whatever and alignment space around the front half.