Tour Easy Daytime Running Light

Pending more test rides, the flashlight fairing mount works well:

Tour Easy Fairing Flashlight Mount - front overview
Tour Easy Fairing Flashlight Mount – front overview

Despite all my fussing with three rotational angles, simply tilting the mount upward by 20° with respect to the fairing clamp aims the flashlight straight ahead, with the ball nearly centered in the clamp:

Tour Easy Fairing Flashlight Mount - front detail
Tour Easy Fairing Flashlight Mount – front detail

That obviously depends on the handlebar angle and the fairing length (which affects the strut rotation), but it’s close enough to make me think a simpler mount will suffice: clamp the flashlight into a cylinder with a slight offset angle, maybe 2°, then mount the cylinder into a much thinner ring clamp at the 20° tilt. Rotating the cylinder would give you some aim-ability, minus the bulk of a ball mount.

Or dispense with the separate cylinder, build the entire mount at the (now known) aim angle, clamp the flashlight directly into the mount, then affix mount to fairing strut. Rapid prototyping FTW!

For now, it’s great riding weather …

The OpenSCAD source code as a GitHub Gist:

// Tour Easy Fairing Flashlight Mount
// Ed Nisley KE4ZNU - July 2017
/* [Build Options] */
FlashName = "AnkerLC40"; // [AnkerLC40,AnkerLC90,J5TactV2,InnovaX5]
Component = "Mount"; // [Ball, BallClamp, Mount, Plates, Bracket]
Layout = "Show"; // [Build, Show]
Support = false;
MountSupport = true;
/* [Extrusion] */
ThreadThick = 0.25; // [0.20, 0.25]
ThreadWidth = 0.40; // [0.40]
function IntegerMultiple(Size,Unit) = Unit * ceil(Size / Unit);
Protrusion = 0.01; // [0.01, 0.1]
HoleWindage = 0.2;
/* [Fairing Mount] */
ToeIn = 0; // inward from ahead
Tilt = 20; // upward from forward
Roll = 0; // outward from top
Shift = -5; // realign to plate center
//- Screws *c
/* [Hidden] */
ID = 0;
OD = 1;
LENGTH = 2;
/* [Screws and Inserts] */
BallInsert = [2.0,3.5,4.0];
BallScrew = [2.0,3.5,2.0];
ClampInsert = [3.0,4.2,8.0];
ClampScrew = [3.0,5.9,50.0]; // thread dia, head OD, screw length
ClampScrewWasher = [3.0,6.75,0.5];
ClampScrewNut = [3.0,6.1,4.0]; // nyloc nut
/* [Hidden] */
F_NAME = 0;
F_GRIPOD = 1;
F_GRIPLEN = 2;
LightBodies = [
["AnkerLC90",26.6,48.0],
["AnkerLC40",26.6,55.0],
["J5TactV2",25.0,30.0],
["InnovaX5",22.0,55.0]
];
NumSides = 8*4;
echo(str("Flashlight: ",FlashName));
FlashIndex = search([FlashName],LightBodies,1,0)[F_NAME];
BallThick = IntegerMultiple(5.0,ThreadWidth); // thickness of ball wall
echo(str("Ball wall: ",BallThick));
BallOD = max(45,IntegerMultiple(LightBodies[FlashIndex][F_GRIPOD] + 2*(BallThick + BallInsert[OD]),2.0));
echo(str(" OD: ",BallOD));
BallScrewOC = BallOD - BallThick - BallInsert[OD]; // from OD to allow different body diameters
echo(str(" screw OC: ",BallScrewOC));
BallLength = min(sqrt(pow(BallOD,2) - pow(LightBodies[FlashIndex][F_GRIPOD],2)),
LightBodies[FlashIndex][F_GRIPLEN]);
echo(str(" hole len: ",BallLength));
ClampThick = 2*ClampInsert[OD];
echo(str("Clamp wall: ",ClampThick));
ClampOD = BallOD + 2*ClampThick;
echo(str(" OD: ",ClampOD));
ClampScrewOC = BallOD + 2*ClampInsert[OD];
echo(str(" screw OC: ",ClampScrewOC));
ClampLength = 0.70 * BallLength;
echo(str(" length: ",ClampLength));
//- Adjust hole diameter to make the size come out right
module PolyCyl(Dia,Height,ForceSides=0) { // based on nophead's polyholes
Sides = (ForceSides != 0) ? ForceSides : (ceil(Dia) + 2);
FixDia = Dia / cos(180/Sides);
cylinder(r=(FixDia + HoleWindage)/2,h=Height,$fn=Sides);
}
//- Ball around flashlight
// Must print two!
module BodyBall() {
difference() {
intersection() {
sphere(d=BallOD,$fn=2*NumSides); // basic ball
cube([BallLength,2*BallOD,2*BallOD],center=true); // max of flashlight grip length
}
translate([-LightBodies[FlashIndex][F_GRIPOD],0,0])
rotate([0,90,0]) rotate(180/NumSides)
PolyCyl(LightBodies[FlashIndex][F_GRIPOD],2*BallOD,NumSides); // flashlight body
for (j=[-1,1])
translate([0,j*BallScrewOC/2,0]) // commmon screw offset
translate([0,0,-BallOD])
PolyCyl(BallInsert[ID],2*BallOD,6); // punch screw shaft through everything
translate([0,BallScrewOC/2,-Protrusion])
PolyCyl(BallInsert[OD],(BallInsert[LENGTH] + 3*ThreadThick + Protrusion),6); // threaded insert
translate([0,-BallScrewOC/2,BallThick])
PolyCyl(BallScrew[OD],BallOD,6); // screw head clearance
translate([0,0,-BallOD/2]) // remove bottom half
cube(BallOD,center=true);
translate([0,0,BallOD - BallThick/2]) // slice off top = bottom for E-Z build
cube(BallOD,center=true);
}
if (Support) {
NumRibs = 24;
RibHeight = (BallOD - LightBodies[FlashIndex][F_GRIPOD]/cos(180/NumSides) - BallThick) / 2;
ChordC = 2*sqrt(BallThick*BallOD/2 - pow(BallThick/2,2));
intersection() {
cube([BallLength,2*BallOD,2*BallOD],center=true); // max of flashlight grip length
translate([0,0,BallOD/2 - BallThick/2])
for (i=[0:NumRibs - 1])
rotate(i*360/NumRibs + 180/NumRibs) // avoid screw holes
translate([ChordC/2 + BallOD/8,0,-RibHeight/2])
cube([BallOD/4,2*ThreadWidth,RibHeight],center=true);
}
}
}
//- Fairing Bracket
// Magic numbers taken from the actual fairing mount
// Centered on screw hole
/* [Hidden] */
inch = 25.4;
BracketHoleOD = 0.25 * inch; // 1/4-20 bolt holes
BracketHoleOC = 1.0 * inch; // fairing hole spacing
// usually 1 inch, but 15/16 on one fairing
Bracket = [48.0,16.3,3.6 - 0.6]; // fairing bracket end plate overall size
BracketHoleOffset = (3/8) * inch; // end to hole center
BracketM = 3.0; // endcap arc height
BracketR = (pow(BracketM,2) + pow(Bracket[1],2)/4) / (2*BracketM); // ... radius
module Bracket() {
linear_extrude(height=Bracket[2],convexity=2)
difference() {
translate([(Bracket[0]/2 - BracketHoleOffset),0,0])
offset(delta=ThreadWidth)
intersection() {
square([Bracket[0],Bracket[1]],center=true);
union() {
for (i=[-1,0,1]) // middle circle fills gap
translate([i*(Bracket[0]/2 - BracketR),0])
circle(r=BracketR);
}
}
circle(d=BracketHoleOD/cos(180/8),$fn=8); // dead center at the origin
}
}
//- General plate shape
// Centered on the hole for the fairing bracket
Plate = [100.0,30.0,6*ThreadThick + Bracket[2]];
PlateRad = Plate[1]/4;
echo(str("Base plate thick: ",Plate[2]));
module PlateBlank() {
difference() {
translate([BracketHoleOC,0,0])
intersection() {
translate([0,0,Plate[2]/2]) // select upper half of spheres
cube(Plate,center=true);
hull()
for (i=[-1,1], j=[-1,1])
translate([i*(Plate[0]/2 - PlateRad),j*(Plate[1]/2 - PlateRad),0])
resize([2*PlateRad,2*PlateRad,2*Plate[2]])
sphere(r=PlateRad); // nice rounded corners!
}
translate([2*BracketHoleOC,0,-Protrusion]) // screw holes
PolyCyl(BracketHoleOD,2*Plate[2],8);
translate([0,0,-Protrusion])
PolyCyl(BracketHoleOD,2*Plate[2],8);
}
}
//- Inner plate
module InnerPlate() {
difference() {
PlateBlank();
translate([0,0,Plate[2] - Bracket[2] + Protrusion]) // punch out fairing bracket
Bracket();
}
}
//- Clamp around flashlight ball
module BallClamp() {
BossLength = ClampScrew[LENGTH] - ClampScrewNut[LENGTH] - 2*ClampScrewWasher[LENGTH] - 4*ThreadThick;
difference() {
union() {
intersection() {
sphere(d=ClampOD,$fn=NumSides); // exterior ball blamp
cube([ClampLength,2*ClampOD,2*ClampOD],center=true); // aiming allowance
}
for (i=[0])
hull() {
for (j=[-1,1])
translate([i*(ClampLength/2 - ClampScrew[OD]),j*ClampScrewOC/2,-BossLength/2])
rotate(180/8)
cylinder(d=(ClampScrewWasher[OD] + 2*ThreadWidth),h=BossLength,$fn=8);
}
}
sphere(d=(BallOD + 1*ThreadThick),$fn=NumSides); // interior ball
for (i=[0] , j=[-1,1]) {
translate([i*(ClampLength/2 - ClampScrew[OD]),j*ClampScrewOC/2,-ClampOD]) // screw clearance
rotate(180/8)
PolyCyl(ClampScrew[ID],2*ClampOD,8);
}
}
color("Yellow")
if (Support) { // ad-hoc supports for top half
NumRibs = 6;
RibLength = 0.5 * BallOD;
RibWidth = 1.9*ThreadWidth;
SupportOC = ClampLength / NumRibs;
cube([ClampLength,RibLength,4*ThreadThick],center=true); // base plate for adhesion
intersection() {
sphere(d=BallOD - 0*ThreadWidth); // cut at inner sphere OD
cube([ClampLength + 2*ThreadWidth,RibLength,BallOD],center=true);
union() { // ribs for E-Z build
for (j=[-1,0,1])
translate([0,j*SupportOC,0])
cube([ClampLength,RibWidth,1.0*BallOD],center=true);
for (i=[0:NumRibs]) // allow +1 to fill the far end
translate([i*SupportOC - ClampLength/2,0,0])
rotate([0,90,0])
cylinder(d=BallOD - 2*ThreadThick,
h=RibWidth,$fn=NumSides,center=true);
}
}
}
}
//- Mount between fairing plate and flashlight ball
module Mount() {
translate([-BracketHoleOC,0,0])
PlateBlank();
translate([Shift,0,ClampOD/2])
rotate([-Roll,ToeIn,Tilt])
intersection() {
translate([0,0,-ClampOD/2])
cube([2*ClampOD,2*ClampOD,ClampOD],center=true);
BallClamp();
}
if (MountSupport) { // anchor outer corners during worst overhang
RibWidth = 1.9*ThreadWidth;
SupportOC = 0.1 * ClampLength;
difference() {
rotate([0,0,Tilt])
translate([Shift + 0.3,0,0])
for (i=[-4.5,-2.5,0,2.0,4.5])
translate([i*SupportOC - 0.0,0,(ClampThick + Plate[2])/2])
cube([RibWidth,0.8*ClampOD,(ClampThick + Plate[2])],center=true);
# translate([Shift,0,ClampOD/2])
rotate([-Roll,ToeIn,Tilt])
sphere(d=ClampOD - 2*ThreadWidth,$fn=NumSides);
}
}
}
//- Build things
if (Component == "Ball")
if (Layout == "Show")
BodyBall();
else if (Layout == "Build") {
translate([0,+1*(BallOD/2 + BallThick/2),0])
translate([0,0,BallOD/2 - BallThick/2])
rotate([180,0,0])
BodyBall();
translate([0,-1*(BallOD/2 + BallThick/2),0])
translate([0,0,BallOD/2 - BallThick/2])
rotate([180,0,0])
BodyBall();
}
if (Component == "BallClamp")
if (Layout == "Show")
BallClamp();
else if (Layout == "Build") {
Both = false;
difference() {
union() {
translate([Both ? ClampLength : 0,0,0])
BallClamp();
if (Both)
translate([-ClampLength,0,0])
rotate([180,0,0])
BallClamp();
}
translate([0,0,-ClampOD/2])
cube([2*ClampOD,2*ClampOD,ClampOD],center=true);
}
}
if (Component == "Mount")
Mount();
if (Component == "Plates") {
translate([0,0.7*Plate[1],0])
InnerPlate();
translate([0,-0.7*Plate[1],0])
PlateBlank();
}
if (Component == "Bracket")
Bracket();