The flashlight mount need not be symmetric after applying all the rotations, so recording how it’s aimed and which end goes forward seemed appropriate:
Optionally, with rounded ends just for pretty:
Because the rounding comes from resized spheres, the plate gets a ridge along the top to (maybe) lock the nylon screws / wing nuts in place:
Or discourage them from turning, which would be OK, too. After the second tightening, they don’t seem to come loose, so this may be overthinking the problem.
All in all, they look pretty good in cyan PETG:
Believe it or not, that’s aimed so the top edge of the beam is roughly horizontal to keep the hot spot out of oncoming traffic. They’re plenty bright, even on the “low power” setting.
The flashlight mounting balls produce a decorative brim that ought to be useful for something:
Maybe earrings?
The OpenSCAD source code as a GitHub Gist:
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| // Tour Easy Fairing Flashlight Mount | |
| // Ed Nisley KE4ZNU - July 2017 | |
| // August 2017 - | |
| /* [Build Options] */ | |
| FlashName = "AnkerLC40"; // [AnkerLC40,AnkerLC90,J5TactV2,InnovaX5] | |
| Component = "Plates"; // [Ball, BallClamp, Mount, Plates, Bracket] | |
| Layout = "Build"; // [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 (M=20 E=15) | |
| Roll = 0; // outward from top | |
| Shift = 0; // Finagle Constant for support ribs | |
| //- Screws *c | |
| /* [Hidden] */ | |
| ID = 0; | |
| OD = 1; | |
| LENGTH = 2; | |
| /* [Screws and Inserts] */ | |
| ClampInsert = [3.0,4.2,8.0]; | |
| ClampScrew = [3.0,5.9,35.0]; // 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] | |
| ]; | |
| //- Fairing Bracket | |
| // Magic numbers taken from the actual fairing mount | |
| /* [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 | |
| //- Base plate dimensions | |
| Plate = [100.0,30.0,6*ThreadThick + Bracket[2]]; | |
| PlateRad = Plate[1]/4; | |
| RoundEnds = true; | |
| echo(str("Base plate thick: ",Plate[2])); | |
| //- Select flashlight data from table | |
| echo(str("Flashlight: ",FlashName)); | |
| FlashIndex = search([FlashName],LightBodies,1,0)[F_NAME]; | |
| //- Set ball dimensions | |
| BallWall = 5.0; // max ball wall thickness | |
| echo(str("Ball wall: ",BallWall)); | |
| BallOD = IntegerMultiple(LightBodies[FlashIndex][F_GRIPOD] + 2*BallWall,1.0); | |
| echo(str(" OD: ",BallOD)); | |
| BallLength = IntegerMultiple(min(sqrt(pow(BallOD,2) - pow(LightBodies[FlashIndex][F_GRIPOD],2)) - 2*4*ThreadThick, | |
| LightBodies[FlashIndex][F_GRIPLEN]),1.0); | |
| echo(str(" length: ",BallLength)); | |
| BallSides = 8*4; | |
| //- Set clamp ring dimensions | |
| ClampOD = 50; | |
| echo(str("Clamp OD: ",ClampOD)); | |
| ClampLength = min(20.0,0.75*BallLength); | |
| echo(str(" length: ",ClampLength)); | |
| ClampScrewOC = IntegerMultiple((ClampOD + BallOD)/2,1); | |
| echo(str(" screw OC: ",ClampScrewOC)); | |
| //- 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,$fn=Sides); | |
| } | |
| //- Fairing Bracket | |
| // This part of the fairing mount supports the whole flashlight mount | |
| // Centered on screw hole | |
| module Bracket() { | |
| linear_extrude(height=Bracket[2],convexity=2) | |
| difference() { | |
| translate([(Bracket[0]/2 - BracketHoleOffset),0,0]) | |
| offset(delta=ThreadWidth) | |
| intersection() { | |
| square([Bracket[0],Bracket[1]],center=true); | |
| union() { | |
| for (i=[-1,0,1]) // middle circle fills gap | |
| translate([i*(Bracket[0]/2 - BracketR),0]) | |
| circle(r=BracketR); | |
| } | |
| } | |
| circle(d=BracketHoleOD/cos(180/8),$fn=8); // dead center at the origin | |
| } | |
| } | |
| //- General plate shape | |
| // Centered on the hole for the fairing bracket | |
| module PlateBlank() { | |
| difference() { | |
| translate([BracketHoleOC,0,0]) | |
| intersection() { | |
| translate([0,0,Plate[2]/2]) // select upper half of spheres | |
| cube(Plate,center=true); | |
| hull() | |
| if (RoundEnds) | |
| for (i=[-1,1]) | |
| translate([i*(Plate[0]/2 - PlateRad),0,0]) | |
| resize([Plate[1]/2,Plate[1],2*Plate[2]]) | |
| sphere(r=PlateRad); // nice round ends! | |
| else | |
| 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 round corners! | |
| } | |
| translate([2*BracketHoleOC,0,-Protrusion]) // punch 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 fairing bracket | |
| Bracket(); | |
| } | |
| } | |
| //- Slotted ball around flashlight | |
| // Print with brim to ensure adhesion! | |
| module SlotBall() { | |
| NumSlots = 8*2; // must be even, half cut from each end | |
| SlotWidth = 2*ThreadWidth; | |
| SlotBaseThick = 10*ThreadThick; // enough to hold finger ends together | |
| RibLength = (BallOD - LightBodies[FlashIndex][F_GRIPOD])/2; | |
| translate([0,0,BallLength/2]) | |
| difference() { | |
| intersection() { | |
| sphere(d=BallOD,$fn=2*BallSides); // basic ball | |
| cube([2*BallOD,2*BallOD,BallLength],center=true); // trim to length | |
| } | |
| translate([0,0,-LightBodies[FlashIndex][F_GRIPOD]]) | |
| rotate(180/BallSides) | |
| PolyCyl(LightBodies[FlashIndex][F_GRIPOD],2*BallOD,BallSides); // remove flashlight body | |
| for (i=[0:NumSlots/2 - 1]) { // cut slots | |
| a=i*(2*360/NumSlots); | |
| SlotCutterLength = LightBodies[FlashIndex][F_GRIPOD]; | |
| rotate(a) | |
| translate([SlotCutterLength/2,0,SlotBaseThick]) | |
| cube([SlotCutterLength,SlotWidth,BallLength],center=true); | |
| rotate(a + 360/NumSlots) | |
| translate([SlotCutterLength/2,0,-SlotBaseThick]) | |
| cube([SlotCutterLength,SlotWidth,BallLength],center=true); | |
| } | |
| } | |
| color("Yellow") | |
| if (Support) { | |
| for (i=[0:NumSlots-1]) { | |
| a = i*360/NumSlots; | |
| rotate(a + 180/NumSlots) | |
| translate([(LightBodies[FlashIndex][F_GRIPOD] + RibLength)/2 + ThreadWidth,0,BallLength/(2*4)]) | |
| cube([RibLength,2*ThreadWidth,BallLength/4],center=true); | |
| } | |
| } | |
| } | |
| //- Clamp around flashlight ball | |
| module BallClamp() { | |
| BossLength = ClampScrew[LENGTH] - 1*ClampScrewWasher[LENGTH]; | |
| BossOD = ClampInsert[OD] + 2*(6*ThreadWidth); | |
| difference() { | |
| union() { | |
| intersection() { | |
| sphere(d=ClampOD,$fn=BallSides); // exterior ball clamp | |
| cube([ClampLength,2*ClampOD,2*ClampOD],center=true); // aiming allowance | |
| } | |
| hull() | |
| for (j=[-1,1]) | |
| translate([0,j*ClampScrewOC/2,-BossLength/2]) | |
| cylinder(d=BossOD,h=BossLength,$fn=6); | |
| } | |
| sphere(d=(BallOD + 1*ThreadThick),$fn=BallSides); // interior ball with minimal clearance | |
| for (j=[-1,1]) { | |
| translate([0,j*ClampScrewOC/2,-ClampOD]) // screw clearance | |
| PolyCyl(ClampScrew[ID],2*ClampOD,6); | |
| translate([0,j*ClampScrewOC/2, // insert clearance | |
| -(BossLength/2 - ClampInsert[LENGTH] - 3*ThreadThick)]) | |
| rotate([0,180,0]) | |
| PolyCyl(ClampInsert[OD],2*ClampOD,6); | |
| translate([0,j*ClampScrewOC/2, // insert transition | |
| -(BossLength/2 - ClampInsert[LENGTH] - 3*ThreadThick)]) | |
| cylinder(d1=ClampInsert[OD]/cos(180/6),d2=ClampScrew[ID],h=6*ThreadThick,$fn=6); | |
| } | |
| } | |
| color("Yellow") | |
| if (Support) { // ad-hoc supports for top half | |
| NumRibs = 6; | |
| RibLength = 0.5 * BallOD; | |
| RibWidth = 1.9*ThreadWidth; | |
| SupportOC = ClampLength / NumRibs; | |
| cube([ClampLength,RibLength,4*ThreadThick],center=true); // base plate for adhesion | |
| render(convexity=2*NumRibs) | |
| intersection() { | |
| sphere(d=BallOD - 0*ThreadWidth); // cut at inner sphere OD | |
| cube([ClampLength + 2*ThreadWidth,RibLength,BallOD],center=true); | |
| union() { // ribs for E-Z build | |
| for (j=[-1,0,1]) | |
| translate([0,j*SupportOC,0]) | |
| cube([ClampLength,RibWidth,1.0*BallOD],center=true); | |
| for (i=[0:NumRibs]) // allow NumRibs + 1 to fill the far end | |
| translate([i*SupportOC - ClampLength/2,0,0]) | |
| rotate([0,90,0]) | |
| cylinder(d=BallOD - 2*ThreadThick, | |
| h=RibWidth,$fn=BallSides,center=true); | |
| } | |
| } | |
| } | |
| } | |
| //- Mount between fairing plate and flashlight ball | |
| // Build with support for bottom of clamp screws! | |
| module Mount() { | |
| difference() { | |
| translate([-BracketHoleOC,0,0]) // put bracket center at origin | |
| PlateBlank(); | |
| mirror([0,1,0]) | |
| translate([0,0,-Protrusion]) | |
| linear_extrude(height=3*ThreadThick + Protrusion) { | |
| translate([BracketHoleOC + 15,0,0]) | |
| text(text=">>>",size=5,spacing=1.20,font="Arial",halign="center",valign="center"); | |
| translate([-BracketHoleOC,8,0]) | |
| text(text=str("Toe ",ToeIn),size=5,spacing=1.20,font="Arial",halign="center",valign="center"); | |
| translate([-BracketHoleOC,-8,0]) | |
| text(text=str("Tilt ",Tilt),size=5,spacing=1.20,font="Arial",halign="center",valign="center"); | |
| translate([BracketHoleOC,8,0]) | |
| text(text=str("Roll ",Roll),size=5,spacing=1.20,font="Arial",halign="center",valign="center"); | |
| translate([-(BracketHoleOC + 15),0,0]) | |
| rotate(90) | |
| text(text="KE4ZNU",size=4,spacing=1.20,font="Arial",halign="center",valign="center"); | |
| } | |
| } | |
| rotate([0,ToeIn,Tilt]) | |
| translate([0,0,ClampOD/2]) | |
| rotate([-Roll,0,0]) | |
| intersection() { | |
| translate([0,0,-ClampOD/2]) | |
| cube([2*ClampOD,2*ClampOD,ClampOD],center=true); | |
| BallClamp(); | |
| } | |
| color("Yellow") | |
| if (MountSupport) { // anchor outer corners at worst overhang | |
| RibWidth = 1.9*ThreadWidth; | |
| SupportOC = 0.1 * ClampLength; | |
| difference() { | |
| rotate([0,0,Tilt]) | |
| translate([Shift,0,0]) | |
| for (i=[-4.5,-2.5,0,2.0,4.5]) | |
| translate([i*SupportOC - 0.0,0,(5 + Plate[2])/2]) | |
| cube([RibWidth,0.7*ClampOD,(5 + Plate[2])],center=true); | |
| rotate([0,ToeIn,Tilt]) | |
| translate([Shift,0,ClampOD/2]) | |
| rotate([-Roll,0,0]) | |
| sphere(d=ClampOD - 2*ThreadWidth,$fn=BallSides); | |
| } | |
| } | |
| } | |
| //- Build things | |
| if (Component == "Ball") | |
| SlotBall(); | |
| 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(); |
The Smell of Molten Projects in the Morning 