The New Hotness

The angle block joins the aluminum grip with the plug sticking into HQ Sixteen’s handlebar control base:

Handlebar Grip Mount - show view - solid model — Handlebar Grip Mount – show view – solid model

Because I don’t know the exact angle until Mary puts more hours on the machine, the OpenSCAD code can tilt the plug from 10° to 30° with respect to the original grip. The bent part of the model consists of a succession of hulls around adjacent slices:

Handlebar Grip Mount - bend slices - solid model — Handlebar Grip Mount – bend slices – solid model

An overall hull() then gloms everything into one solid lump, with all the negative features removed from it:

Handlebar Grip Mount - show detail - solid model — Handlebar Grip Mount – show detail – solid model

After a brief flirtation with heat-staked brass inserts, four setscrews threaded into steel square nuts secure the original grip in the bottom:

HQ Sixteen - grip angle square nuts — HQ Sixteen – grip angle square nuts

A screw behind that big washer pulled the nuts firmly into their sockets, where they stay without any adhesive. The square recesses include a little adder based on the curvature of the hole to sink the nuts deep enough:

Handlebar Grip Mount - nut inset - solid model — Handlebar Grip Mount – nut inset – solid model

I made the block’s OD large enough to accommodate the brass inserts and hope it’s chunky enough to withstand the force from the setscrews. The inserts tended to creep outward after being snugged down, but the square nuts seem stable against the recesses.

The block prints with the top surface against the platform to produce a clean recess for the plug, which requires support material for the ring around the bore. Because the ring sags slightly against the support, the model makes the recess 0.4 mm deeper, but the next iteration gets a little more:

HQ Sixteen - grip angle alignment marks — HQ Sixteen – grip angle alignment marks

Not that it makes much difference.

The bore from the grip meets the bore from the plug in a sphere centered at the bottom of the plug recess:

Handlebar Grip Mount - sphere joint - solid model — Handlebar Grip Mount – sphere joint – solid model

A ball joint seems the best way to join a pair of intersecting cylinders, if you have room for the sphere, and eliminates a whole bunch of computations figuring the cylinder lengths; they just meet at about the center of the sphere and you’re done without anything sticking out. I’d like to pretend that was the first idea I had, but …

The OpenSCAD code can add more length to the bottom of the block, in the event Mary wants the grips lower:

Handlebar Grip Mount - added length - solid model — Handlebar Grip Mount – added length – solid model

That obviously increases the lever arm applied to the plug, but we’ll burn that bridge when we come to it.

This lineup shows the progression from the first pass to something that might actually work:

HQ Sixteen - grip angle block evolution — HQ Sixteen – grip angle block evolution

Rapid prototyping FTW!

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 Block