The New Hotness

The stock Handi-Quilter HQ Sixteen has serviceable black rubber caps covering the holes for the grips:

HQ Sixteen - original front handlebar mount — HQ Sixteen – original front handlebar mount

Because we live in the future, I can do better than that:

HQ Sixteen - grip cap left — HQ Sixteen – grip cap left

In truth, the plastic grip plug now sticks up into the hole just beyond the top setscrews, leaving not enough room for the black plugs, so I had to make new covers.

They’re a multi-material print using white PETG to kinda-sorta match the machine and blue PETG-CF to match the other plastic parts. The colors in the solid model just distinguish the two materials:

Handlebar Grip Mount - plug caps - solid model — Handlebar Grip Mount – plug caps – solid model

The white covers have recesses exactly fitting the text:

Handlebar Grip Mount - cap text recess - solid model — Handlebar Grip Mount – cap text recess – solid model

In some cases that’s not needed, but I’m unsure how PrusaSlicer knows what I intend and chopping the text out was easy, so that’s how I did it.

I did not realize applying a transformation, like translate() or BOSL2’s syntactic sugar left(), to both the cover and the text implicitly joins them into a single “object”, so the slicer can’t distinguish them as separate materials. As a result, the OpenSCAD code must move the pieces separately:

if (Layout == "Covers") {
     left(Plug[OD]) GripCover(LEFT,"Cover");
     left(Plug[OD]) GripCover(LEFT,"Text");

     right(Plug[OD]) GripCover(RIGHT,"Cover");
     right(Plug[OD]) GripCover(RIGHT,"Text");
}

Which is awkward, but not insurmountable.

Export the model as a 3mf file, import it into PrusaSlicer, and you get separate objects for the cover and the text. Assign different materials and slice to produce a multi-material result, with the Wipe Tower in the background:

Handlebar Grip Mount - cap first layer - PrusaSlicer — Handlebar Grip Mount – cap first layer – PrusaSlicer

They must print face down to merge the two colors into a single flat surface with a nubbly texture from the steel sheet’s coating.

Disks of adhesive sheet will eventually stick them atop the plugs, but for now they’re just dropped into the holes.

The OpenSCAD source code as a GitHub Gist:

	// Handiquilter HQ Sixteen front handlebar grip angle mount
	// Ed Nisley – KE4ZNU
	// 2024-11-29

	include <BOSL2/std.scad>

	Layout = "Show"; // [Show,Build,Plug,Block,Covers,Cover]

	Material = "All"; // [All,Cover,Text]

	// Angle w.r.t. base
	GripAngle = 20; // [10:30]

	// Plug glued, not screwed
	PlugGlue = true;

	// Square nuts, not inserts
	SquareNuts = true;

	// Additional length of bottom
	AddLength = 0; // [0:20]

	// Separation in Show display
	Gap = 5; // [0:20]

	/* [Hidden] */

	HoleWindage = 0.1;
	Protrusion = 0.1;
	NumSides = 234;

	ID = 0;
	OD = 1;
	LENGTH = 2;

	Grip = [19.7,22.4,20.0]; // (7/8)*INCH = 22.2 mm + roughness, LENGTH=OEM insertion depth
	GripRadius = Grip[OD]/2; // used everywhere

	Plug = [15.0,Grip[OD],45.0]; // inserts into handlebar base
	PlugRim = [Plug[ID],25.0,10.0]; // … sits against handlebar base

	BaseScrewPositions = [[11.0,12.0],[27.0,29.0]]; // setscrew offsets from rim top: side,rear

	BaseCutout = [Plug[OD]/2,Plug[ID],10]; // cable cutout into base
	BaseCutoutOffset = 18.0; // … centerline position w.r.t. rim

	WallThick = 7.0; // should at least fit insert length

	SupportSag = 0.4; // vertical sag over support structure

	MidLength = AddLength + 3.0; // total length allowing for grip tube stop

	TopOD = PlugRim[OD] + 2*WallThick;
	BotOD = Grip[OD] + 2*WallThick;

	BaseScrew = [4.0,4.8 + HoleWindage,1.0]; // HQ 10-32 screws, LENGTH=capture dent

	Insert = [5.4,6.0,6.0]; // M4 inserts in plug rim
	//Insert = [4.0,5.0,5.0]; // M4 inserts in plug rim
	Screw = [3.5,4.0,1]; // M4 screws through angle block to inserts
	ScrewHeadOD = 7.4 + 0.4; // M4 BHCS head + comfort
	SquareNut = [4.0,7.0,3.0 + 0.4]; // M4 square nut LENGTH + inset allowance
	NutInset = GripRadius – sqrt(pow(GripRadius,2) – pow(SquareNut[OD],2)/4);

	PinOD = 1.2; // plug reinforcing pins
	NumPins = 5;

	CoverThick = [3.5,9.5]; // low and high sides of grip covers
	CoverAngle = atan((CoverThick[1] – CoverThick[0])/Plug[OD]);

	LogoText = ["Sew","Fine"];
	LogoFont = "Fira Sans Condensed:style=SemiBold";
	LogoSize = 7.5;
	LogoColor = "Red";
	LogoThick = 0.8;

	//———-
	// Simulator for aluminum plug replacing handlebar in base

	module BasePlug() {

	difference() {
	union() {
	tube(Plug[LENGTH],(Plug[OD] – HoleWindage)/2,Plug[ID]/2,anchor=DOWN);
	tube(PlugRim[LENGTH],PlugRim[OD]/2,PlugRim[ID]/2,anchor=DOWN);
	}

	up(BaseCutoutOffset + PlugRim[LENGTH])
	left(Plug[OD]/4)
	resize(BaseCutout)
	yrot(90) zrot(180/8)
	cylinder(d=1,h=1,$fn=8,center=true);

	up(PlugRim[LENGTH])
	right(PlugRim[OD]/2 – 1.0)
	cube([2.0,1.0,1.0],center=true);

	for (i = [0:NumPins – 1])
	zrot(i*360/NumPins + 180/NumPins)
	down(Protrusion)
	right((Plug[OD] + Plug[ID])/4)
	zrot(180/6)
	cylinder(d=PinOD,h=2*PlugRim[LENGTH],$fn=6);


	for (k = [0:1]) // recesses in plug to capture base setscrews
	for (a = [0:1])
	up(PlugRim[LENGTH] + BaseScrewPositions[k][a])
	zrot(a*90)
	right(Plug[OD]/2)
	yrot(90) zrot(180/8)
	cylinder(d=BaseScrew[OD],h=2*BaseScrew[LENGTH],$fn=8,center=true);

	if (!PlugGlue)
	for (a = [0:1]) // inserts for angle block screws
	up(PlugRim[LENGTH]/2)
	zrot(a*90)
	yrot(90) zrot(180/8)
	cylinder(d=Insert[OD],h=2*PlugRim[OD],$fn=8,center=true);

	}
	}

	//———-
	// Block fitting against handlebar base with handlebar angle

	module AngleBlock() {

	difference() {
	hull() {
	up((TopOD/2)*sin(GripAngle))
	xrot(GripAngle)
	cylinder(d=TopOD,h=PlugRim[LENGTH],$fn=NumSides);
	for (a = [1:2:GripAngle+1])
	up((TopOD/2)*sin(a-1))
	hull() {
	xrot(a)
	cylinder(d=TopOD,h=0.1,$fn=NumSides);
	xrot(a-1)
	cylinder(d=TopOD,h=0.1,$fn=NumSides);
	}

	down(Grip[LENGTH] + MidLength)
	cylinder(d=(Grip[OD] + 2*WallThick),h=0.1,$fn=NumSides);
	}

	up((TopOD/2)*sin(GripAngle))
	xrot(GripAngle)
	down(SupportSag)
	cylinder(d=(PlugRim[OD] + HoleWindage),
	h=PlugRim[LENGTH] + SupportSag + Protrusion,
	$fn=NumSides);

	up((TopOD/2)*sin(GripAngle))
	sphere(d=PlugRim[ID],$fn=NumSides);

	cylinder(d=PlugRim[ID],h=(TopOD/2)*sin(GripAngle),$fn=NumSides);

	down(MidLength + Protrusion)
	cylinder(d=(Grip[ID] – 2.0),h=(MidLength + 2*Protrusion),$fn=NumSides);

	down(Grip[LENGTH] + MidLength + Protrusion)
	cylinder(d=(Grip[OD] + HoleWindage),h=(Grip[LENGTH] + Protrusion),$fn=NumSides);

	up((TopOD/2)*sin(GripAngle))
	xrot(GripAngle)
	up(PlugRim[LENGTH])
	right(PlugRim[OD]/2 + 0.9)
	cube([2.0,1.0,1.0],center=true);

	if (!PlugGlue) {
	for (a = [0:1])
	up((TopOD/2)*sin(GripAngle))
	xrot(GripAngle)
	up(PlugRim[LENGTH]/2)
	zrot(a*90)
	yrot(90) zrot(180/8)
	cylinder(d=Screw[OD],h=3*PlugRim[OD],$fn=8,center=true);
	for (a = [0:3])
	up((TopOD/2)*sin(GripAngle))
	xrot(GripAngle)
	up(PlugRim[LENGTH]/2)
	zrot(a*90)
	right(TopOD/2 – 2.0)
	yrot(90) zrot(180/8)
	cylinder(d=ScrewHeadOD,h=TopOD,$fn=8,center=false);
	}

	if (SquareNuts) {
	for (a = [0:1])
	for (k = [1,3])
	down(k*Grip[LENGTH]/4 + MidLength)
	zrot(a*90)
	right(BotOD/2)
	yrot(90) zrot(180/8)

	cylinder(d=SquareNut[ID],h=BotOD,$fn=8,center=true);
	for (a = [0:1])
	for (k = [1,3])
	down(k*Grip[LENGTH]/4 + MidLength)
	zrot(a*90)
	right(GripRadius + SquareNut[LENGTH]/2 – NutInset/2)
	yrot(90)
	cube([SquareNut[OD],SquareNut[OD],SquareNut[LENGTH] + NutInset],center=true);
	}
	else {
	for (a = [0:1])
	for (k = [1,3])
	down(k*Grip[LENGTH]/4 + MidLength)
	zrot(a*90)
	right(BotOD/2)
	yrot(90) zrot(180/8)
	cylinder(d=Insert[OD],h=BotOD,$fn=8,center=true);

	}
	}

	}

	//———-
	// Chip fitting against handlebar base matching top angle
	// Text will be invisible until sliced

	module GripCover(loc=LEFT,matl="Cover") {

	if (matl == "Text" \|\| matl == "All")
	color(LogoColor)
	down(matl == "All" ? 0.01 : 0.0)
	text3d(LogoText[loc == LEFT ? 0 : 1],LogoThick,LogoSize,LogoFont,
	orient=DOWN,anchor=TOP,atype="ycenter");

	if (matl == "Cover" \|\| matl == "All")
	difference() {
	intersection() {
	yrot(loc == RIGHT ? -CoverAngle : CoverAngle)
	cylinder(d=Plug[OD],h=(CoverThick[0] + CoverThick[1]),anchor=CENTER);
	cube(2*Plug[OD],anchor=BOTTOM);
	}
	text3d(LogoText[loc == LEFT ? 0 : 1],LogoThick,LogoSize,LogoFont,
	orient=DOWN,anchor=TOP,atype="ycenter");
	}

	}


	//———-
	// Build things

	if (Layout == "Cover") {
	GripCover(LEFT,Material);
	}

	if (Layout == "Covers") {
	left(Plug[OD]) GripCover(LEFT,"Cover");
	left(Plug[OD]) GripCover(LEFT,"Text");

	right(Plug[OD]) GripCover(RIGHT,"Cover");
	right(Plug[OD]) GripCover(RIGHT,"Text");
	}

	if (Layout == "Plug")
	BasePlug();

	if (Layout == "Block")
	AngleBlock();

	if (Layout == "Show") {

	up((TopOD/2)*sin(GripAngle) + Protrusion)
	xrot(GripAngle)
	up(Plug[LENGTH] + CoverThick[1] + Gap)
	yrot(180 + CoverAngle)
	GripCover(RIGHT,"All");

	up((TopOD/2)*sin(GripAngle) + Protrusion)
	xrot(GripAngle)
	up(Gap)
	color("Lime",0.75)
	BasePlug();
	render()
	difference() {
	AngleBlock();
	back(50) right(50)
	cube(100,center=true);
	}

	color("Silver",0.5)
	down(MidLength + Gap)
	tube(3*Grip[LENGTH],GripRadius,Grip[ID]/2,anchor=TOP);

	}

	if (Layout == "Build") {
	mirror_copy([1,0,0]) {
	right(BotOD) {
	up((TopOD/2)sin(GripAngle) + PlugRim[LENGTH]cos(GripAngle) + Protrusion)
	xrot(180 – GripAngle)
	AngleBlock();
	back(1.5*max(TopOD,BotOD))
	BasePlug();
	}
	}

	fwd(60) {
	left(Plug[OD]) GripCover(LEFT,"Cover");
	right(Plug[OD]) GripCover(RIGHT,"Cover");
	}

	fwd(60) {
	left(Plug[OD]) GripCover(LEFT,"Text");
	right(Plug[OD]) GripCover(RIGHT,"Text");
	}

	}

view raw Handlebar Grip Mount.scad hosted with ❤ by GitHub

The New Hotness

HQ Sixteen: Grip Angle Caps