The New Hotness

The grip plug is the upper part of the assembly changing the angle of the HQ Sixteen’s front grips:

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

It sticks into the machine’s handlebar control base in place of the original aluminum tube grips:

HQ Sixteen - handlebar ribbon cable entry — HQ Sixteen – handlebar ribbon cable entry

Only the two lower setscrews held the original grip in place, but I made the plug tall enough to engage all four, which meant it needed a side port to ease the ribbon cable through on its way to the PCB inside:

Handlebar Grip Mount - plug cable port - solid model — Handlebar Grip Mount – plug cable port – solid model

The plastic tube is obviously thicker than the aluminum tube, with four dents capturing the 10-32 setscrews (using a 3/32 inch wrench) to align it within the hole; the bore juuust passes the original connector.

The plug glues into the angle block, which means all the stress from the grips passes through a thin ring of plastic just above the joint. So I added five 1.2 mm OD hard steel wires about 20 mm long:

HQ Sixteen - grip plug steel wires — HQ Sixteen – grip plug steel wires

Five wires, because four didn’t seem like quite enough and six seemed like crowding too much steel into too little plastic. The holes are offset to avoid the setscrew dents, with one lined up directly under the cable port.

A pair of alignment marks help get the orientation right while gluing:

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

The control base angles away from the grip, leaving a little more than half unsupported:

HQ Sixteen - base angle vs grip block - rear — HQ Sixteen – base angle vs grip block – rear

Pondering that picture suggested adding those steel wires.

The angle block prints with its upper surface against the MK4’s platform to get good dimensions inside the recess for the plug, so I can’t add a wedge to that surface, nor can it go on the plug. Maybe a separate wedge glued around the plug?

However, the pin header for that cable sits directly inside the base and a transparent cover (not shown here) extends outward over the casting against the grip:

HQ Sixteen - left LED PCB — HQ Sixteen – left LED PCB

So maybe it’s like that and that’s the way it is.

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 Plug