Summary
I purchased a headlight kit from my ebike powertrain manufacturer (CYC Motor eBike headlights). It had nice aluminum mounting brackets for handle bars, but the brackets have no right/left adjustment. The only way the lights will project straight is if they are mounted to a perfectly straight pipe. my handlebars have a slight angle to them, as do most mountain bikes, therefore, the lights would have pointed outwards. This wasnt going to work for me, so now we have The Diggie Braggit.
Print Settings
Printer Brand:
Creality
Printer:
Ender 3
Rafts:
No
Supports:
No
Resolution:
.20
Infill:
50% cubic subdivision
Notes:
-235 extruder
-70 bed
-glass plate with hair spray
-i used 55mm/s
-i used 5 top layers, 5 bottom layers, and 5 walls.
-you can go with more walls if you wish. this will result in the verticals being solid without infill, but also give the holes more structure and support when squeezed by the fasteners , also can give you more material if your application requires a bigger hole/fastener.
-clean up the holes with the correct size drill bit for your fastener
-use washers to spread the load across the surface of the plastic.
-the two "primary mount washers" on each side of the stem are wide fender washers.
-menard's was out of stainless fender washers that day
-the current stem width is 35.5mm.
-you will need the stem width to be slightly larger than the stem if you wish to use "bicycle tube insulator thingies" (1.5 inch section of bicycle inner tube, qty=2)
-the "bicycle tube insulator thingies" stopped the mount drifting down while riding off-road, i highly recommend them
-you will need to put a pretty good squeeze on it with the cross bolt to squeeze both sides of the mount into the stem.
-use the cross bolt tension to adjust the flexibility/firmness of the mount to the stem. i had to tighten mine pretty good.
-You will have to adjust this to get it tight enough to stop drifting down, but loose enough to move in a wreck
-use a nyloc nut so it doesn't loosen.
-cut off and file smooth any excess thread so you don't get hurt from it during an accident.
-it will cut your knee as you go over the handlebars
-The 35.5 width is almost too narrow for my stem, i will upload a second file with 39mm spacing. This will allow me more room for the "bicycle tube insulator thingies"
-if another size is needed, you could measure your stem with dial calipers and adjust the size of the object in cura accordingly using the convenient scaling tool.
not the cleanest design, but it works well, and it is pretty lightweight. it has almost 1000 miles on it. I broke one, but redesigned it with a thicker bottom plate and added the fillets.
yes im going to route the wires between the mount and The Diggie Braggit :-)
UPDATE - v4
added 39mm Diggie Braggit
increased fillet size on joint between vertical and horizontal
Custom Section

yes, i will be rerouting the wiring through the bracket :-)

yes, i will be rerouting the wiring through the bracket :-)
Modellquelle
