Bike Light Mount

thingiverse

An appropriately sized handlebar mount is available for cylindrical flashlights, with an ID of 25.5mm on the bar mount and 23mm on the flashlight clamp. Please share your custom measurements in a comment, and alternating STL files will be provided accordingly. The required parts include: M5 12mm screw for handlebar clamp hinge, M5 10mm screw for handlebar clamp, M5 16mm screw to secure the handlebar clamp to the light holder, and M5 10mm hex head for the light holder thumb nut. Four M5 nuts are also needed. To assemble, print out the required parts. Be sure to trim any excess flash on the bottom of the light holder that might hinder the tab's flexibility. Insert two M5 nuts into the recesses on the light holder, followed by screwing in the hex-headed screw into the thumb nut. Then, attach the assembled thumb nut to the captive nut next to the tab on the light holder without breaking the tab. Next, use the 12mm M5 screw to join the two sides of the clamp, possibly with Loctite or a nyloc nut for additional security. Lastly, connect the light holder to the handlebar clamp.