Braze-On Light Mount

thingiverse

Problem Solvers Braze-On Light Mount (http://problemsolversbike.com/products/braze_on_light_mount) adapts for 3D printing. Ideal for securing a light anywhere you have a braze-on on your frame. It requires standard 4 mm threading. Perfect for the midblade fork braze-ons found on numerous Surly forks. I Designed This http://problemsolversbike.com/products/braze_on_light_mount General dimensions come from here. I made an educated guess for much of it, but it's probably acceptable. For the cylinder ID, I calculated a 6 mm offset from the OD, resulting in a 32 - 6 = 26 mm ID. The mating faces of the end caps were designed with a radius of (32-3)/2-1, yielding a 27 mm ID, plus a 1 mm by 1 mm 45-degree chamfer to better accommodate the fitting. The inside of the cylinder features a 45-degree chamfer on both ends as a transition between the 32 mm OD and the 26 mm ID, again for improved fit. I hope it functions properly. I measured the OD of a random 4 mm socket head bolt: 8.90 mm, so 115% of that is approximately 10.22 mm, which became the inset on the end of the end cap to recess the head. The head was 5.09 mm tall, but I aimed to keep the cap relatively short, so I cut it from the end to 2.5 mm from the inside face, resulting in about a total of 5.34 mm of sinking height. It should shield most 4 mm socket bolt heads below the outside edge. Assembly & Materials Refer to the Problem Solvers website linked above for instructions. Reverse the end cap to adjust the effective length of the mount as necessary. You will need an extremely long 4 mm bolt. Print all three pieces: cylinder, reversible end cap, and end cap.