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Tour Easy 1 W Amber Running Light: Holder and First Light
Wrapping a left-side ball mount around the PVC case produced a holder:
Fairing 1 W LED Mount – Left side – show view Which looks like this in real life:
1 W Amber Running Light – installed front The support structure under the arch required a bit more cleanup than it got, so the clamp didn’t quite close around the ball on the first full test:
1 W Amber Running Light – installed side Both the phone camera and the eyeballometer report the 1 W amber LED isn’t quite as bright as the 400 lumen Anker flashlight on its low setting:
1 W Amber Running Light – First Light Stir the unusual (for a bike) amber color together with some blinkiness, though, and it’s definitely attention-getting.
The OpenSCAD source code as a GitHub Gist:
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Learn more about bidirectional Unicode characters// Tour Easy Fairing Flashlight Mount // Ed Nisley KE4ZNU – July 2017 // August 2017 – // August 2020 – add reinforcing columns under mount cradle // August 2021 – 1 W Amber LED /* [Build Options] */ FlashName = "1WLED"; // [AnkerLC40,AnkerLC90,J5TactV2,InnovaX5,Sidemarker,Clearance,Laser,1WLED] Component = "BallClamp"; // [Ball, BallClamp, Mount, Plates, Bracket, Complete] Layout = "Build"; // [Build, Show] Support = true; MountSupport = true; /* [Hidden] */ 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] */ Side = "Right"; // [Right,Left] ToeIn = -10; // inward from ahead Tilt = 20; // upward from forward (M=20 E=10) Roll = 0; // outward from top //- Screws and inserts /* [Hidden] */ ID = 0; OD = 1; LENGTH = 2; /* [Hidden] */ 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], ["Sidemarker",15.0,20.0], ["Clearance",50.0,20.0], ["Laser",10.0,30.0], ["1WLED",25.4,40.0], ]; //- 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; ClampOD = BallOD + 2*5; 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)); TiltMirror = (Side == "Right") ? [0,0,0] : [0,1,0]; //- 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 in the middle of the plate module PlateBlank() { difference() { 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([BracketHoleOC,0,-Protrusion]) // punch screw holes PolyCyl(BracketHoleOD,2*Plate[2],8); translate([-BracketHoleOC,0,-Protrusion]) PolyCyl(BracketHoleOD,2*Plate[2],8); } } //- Inner plate module InnerPlate() { difference() { PlateBlank(); translate([-BracketHoleOC,0,Plate[2] – Bracket[2] + Protrusion]) // punch fairing bracket Bracket(); } } //- Outer plate // With optional legend for orientation and parameters module OuterPlate(Legend = true) { TextRotate = (Side == "Left") ? 0 : 180; difference() { PlateBlank(); if (Legend) 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]) rotate(TextRotate) text(text=str("Toe ",ToeIn),size=5,spacing=1.20,font="Arial",halign="center",valign="center"); translate([-BracketHoleOC,-8,0]) rotate(TextRotate) text(text=str("Tilt ",Tilt),size=5,spacing=1.20,font="Arial",halign="center",valign="center"); translate([BracketHoleOC,-8,0]) rotate(TextRotate) text(text=Side,size=5,spacing=1.20,font="Arial",halign="center",valign="center"); translate([BracketHoleOC,8,0]) rotate(TextRotate) text(text=str("Roll ",Roll),size=5,spacing=1.20,font="Arial",halign="center",valign="center"); translate([0,0,0]) rotate(90) text(text="KE4ZNU",size=4,spacing=1.20,font="Arial",halign="center",valign="center"); } } } //- 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,(Layout == "Build") ? BallLength/2 : 0]) rotate([0,(Layout == "Show") ? 90 : 0,0]) difference() { intersection() { sphere(d=BallOD,$fn=2*BallSides); // basic ball cube([2*BallOD,2*BallOD,BallLength],center=true); // trim to length } translate([0,0,-LightBodies[FlashIndex][F_GRIPOD]]) rotate(180/BallSides) PolyCyl(LightBodies[FlashIndex][F_GRIPOD],2*BallOD,BallSides); // remove flashlight body for (i=[0:NumSlots/2 – 1]) { // cut slots a=i*(2*360/NumSlots); SlotCutterLength = LightBodies[FlashIndex][F_GRIPOD]; rotate(a) translate([SlotCutterLength/2,0,SlotBaseThick]) cube([SlotCutterLength,SlotWidth,BallLength],center=true); rotate(a + 360/NumSlots) translate([SlotCutterLength/2,0,-SlotBaseThick]) cube([SlotCutterLength,SlotWidth,BallLength],center=true); } } color("Yellow") if (Support && (Layout == "Build")) { for (i=[0:NumSlots-1]) { a = i*360/NumSlots; rotate(a + 180/NumSlots) translate([(LightBodies[FlashIndex][F_GRIPOD] + RibLength)/2 + ThreadWidth,0,BallLength/(2*4)]) cube([RibLength,2*ThreadWidth,BallLength/4],center=true); } } } //- Clamp around flashlight ball BossLength = ClampScrew[LENGTH] – 1*ClampScrewWasher[LENGTH]; BossOD = ClampInsert[OD] + 2*(6*ThreadWidth); module BallClamp(Section="All") { difference() { union() { intersection() { sphere(d=ClampOD,$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 -0*(BossLength/2 – ClampInsert[LENGTH] – 3*ThreadThick) + Protrusion]) 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,$fn=6); } if (Section == "Top") translate([0,0,-ClampOD/2]) cube([2*ClampOD,2*ClampOD,ClampOD],center=true); else if (Section == "Bottom") translate([0,0,ClampOD/2]) cube([2*ClampOD,2*ClampOD,ClampOD],center=true); } color("Yellow") if (Support) { // ad-hoc supports NumRibs = 6; RibLength = 0.5 * BallOD; RibWidth = 1.9*ThreadWidth; SupportOC = ClampLength / NumRibs; if (Section == "Top") // base plate for adhesion translate([0,0,ThreadThick]) cube([ClampLength + 6*ThreadWidth,RibLength,2*ThreadThick],center=true); else if (Section == "Bottom") translate([0,0,-ThreadThick]) cube([ClampLength + 6*ThreadWidth,RibLength,2*ThreadThick],center=true); render(convexity=2*NumRibs) intersection() { sphere(d=BallOD – 0*ThreadWidth); // cut at inner sphere OD cube([ClampLength + 2*ThreadWidth,RibLength,BallOD],center=true); if (Section == "Top") // select only desired section translate([0,0,ClampOD/2]) cube([2*ClampOD,2*ClampOD,ClampOD],center=true); else if (Section == "Bottom") translate([0,0,-ClampOD/2]) cube([2*ClampOD,2*ClampOD,ClampOD],center=true); union() { // ribs for E-Z build for (j=[-1,0,1]) translate([0,j*SupportOC,0]) cube([ClampLength,RibWidth,1.0*BallOD],center=true); for (i=[0:NumRibs]) // allow NumRibs + 1 to fill the far end translate([i*SupportOC – ClampLength/2,0,0]) rotate([0,90,0]) cylinder(d=BallOD – 2*ThreadThick, h=RibWidth,$fn=BallSides,center=true); } } } } //- Mount between fairing plate and flashlight ball // Build with support for bottom of clamp screws! module Mount() { MountShift = [ClampOD*sin(ToeIn/2),0,ClampOD/2]; OuterPlate(); mirror(TiltMirror) { intersection() { translate(MountShift) rotate([-Roll,ToeIn,Tilt]) BallClamp("Bottom"); translate([0,0,Plate.x/2 + 3*ThreadThick]) cube(Plate.x,center=true); } if (MountSupport) // anchor outer corners at worst overhang color("Yellow") { RibWidth = 1.9*ThreadWidth; SupportOC = 0.1 * ClampLength; intersection() { difference() { rotate([0,0,Tilt]) translate([(ClampOD – BallOD)*sin(ToeIn/2),0,3*ThreadThick]) // Z = avoid legends 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); translate(MountShift) rotate([-Roll,ToeIn,Tilt]) sphere(d=ClampOD – 2*ThreadWidth,$fn=BallSides); } translate([0,0,ClampOD/2]) cube([Plate.x,Plate.y,ClampOD],center=true); } } } } //- Build things if (Component == "Bracket") Bracket(); if (Component == "Ball") SlotBall(); if (Component == "BallClamp") if (Layout == "Show") BallClamp("All"); else if (Layout == "Build") BallClamp("Top"); if (Component == "Mount") Mount(); if (Component == "Plates") { translate([0,0.7*Plate[1],0]) InnerPlate(); translate([0,-0.7*Plate[1],0]) OuterPlate(Legend = false); } if (Component == "Complete") { OuterPlate(); mirror(TiltMirror) { translate([0,0,ClampOD/2 + BossOD*abs(sin(ToeIn))]) { rotate([-Roll,ToeIn,Tilt]) SlotBall(); rotate([-Roll,ToeIn,Tilt]) BallClamp(); } } }
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The Smell of Molten Projects in the Morning 