The New Hotness

With the handlebar assembly angled to let Mary see the LCD panel, the grips no longer meet her hands at the proper angle:

HQ Sixteen - remounted handlebars in use — HQ Sixteen – remounted handlebars in use

Each grip has two buttons intended for thumb operation, but at that angle her thumbs lack oomph.

So I added a compensating angle just under the handlebar control assembly:

HQ Sixteen - grip angle blocks installed — HQ Sixteen – grip angle blocks installed

Restoring the front part to vertical means she can walk up to the machine, grab the grips at a neutral wrist angle, and start sewing.

Which required several iterations:

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

The pictures show various setups as we installed, tried, tweaked, and replaced nearly everything along that progression from left to right. They’re similar, but the details made all the difference.

This is an overview of the adapter, with details to follow over the next few days.

The solid model shows how the pieces go together:

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

The white chip on top fills the space between the surface of the base and the top of the plug, with some lettering just for pretty.

The greenish plug (not its real color!) sticks into the handlebar control base, where its dimples capture four setscrews. The original grips extended only halfway into the base, leaving the top pair of tapped setscrew holes empty:

HQ Sixteen - unused grip setscrews — HQ Sixteen – unused grip setscrews

The ribbon cable carries signals from the pushbuttons into the base assembly:

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

Looks like a guillotine to me, too, but the foam rubber cover prevents the grips from sliding any further into the base:

HQ Sixteen - base angle vs original grip — HQ Sixteen – base angle vs original grip

Despite the metric socket head cap screws used elsewhere on the machine, those are 10-32 setscrews. Took me a while to figure that out, as 10-32 setscrews are visually indistinguishable from M5 setscrews, but neither screw will thread into the other’s nuts even though their wrenches are equally sloppy fits in the other screw.

The angle adapter block has an intricate geometry:

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

Because I don’t know the proper angle, the OpenSCAD model includes enough trig to adjust from 10° to 30°, with the default at 20° to set the front of the grips vertical. The lower part of the block can extend to lower the grips if that turns out to be necessary, but we’ll start with zero millimeters.

The grips slide into the bottom of the angle block where they’re captured by four M4 setscrews threaded through square nuts:

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

The big washer over on the right sits under the screw I used to pull the nuts into their recesses, where they sit firmly without adhesive.

The first iterations used heat-staked brass inserts that didn’t provide enough griptivity against the torque generated by shoving the grips sideways. I probably applied more force than they’ll ever see in real life, but I’m no Hulk and I didn’t like the feel.

The upper plug gets glued into the lower angle with JB PlasticBonder urethane adhesive. Had they been finished, the first two iterations would have had screws through the angle block into brass inserts in the plug, but I realized adhesives would work much better. A pair of index marks aligns the two pieces:

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

It’s early days, but the machine fits her much better than it did before.

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

Handi-Quilter HQ Sixteen: Handlebar Grip Angle Adjustment