Cygolite bar clamp

thingiverse

The mount that comes with the Cygolite Metro didn't fit in the middle of the handlebars of my bikes, so I made this adapter to clamp onto the bars. ### Materials You'll need the top piece of the stock clamp, where the light slides into, and two pairs of around 15mm m4 bolts and nuts. I think you can use the m3 bolt and captive nut that come with the stock clamp, but you'll want to make sure that the bolt isn't too long (probably no more than 10-12 mm) or it could contact your handlebars as you tighten it. I also put a strip of rubber from an old tube in between the clamp and the bars to help it stay in place, and protect the bars from scratches. In list form: * top part of the stock clamp (hereafter referred to as the top slidey piece) * m3 bolt and nut, around 10-12mm bolt * 2x - m4 bolt and nut, around 15mm * some old inner tube or other thin rubber to cut small pieces from ### Installation 1. print the appropriate part for your handlebar / stem diameter, 31.8 or 35mm 1. cut two small rectangular pieces of thin rubber, from an old inner tube or similar, to fit between the clamp and the bars - 15mm x 50mm or so 1. cut one small square piece of thin rubber, to fit between the stock sliding light lock piece and the printed clamp - 15mm x 15mm or so, and put a small hole in the middle for the m3 bolt to pass through 1. unscrew the bolt holding the top slidey piece to the stock clamp 1. test fit the printed piece without the captive nut underneath of the clamp, and ensure your m3 bolt from the top slidey piece doesn't extend past the bottom of the clamp (where your bars will be) 1. place an m3 nut in the space underneath the printed clamp, and a strip of rubber over that, and place on your handlebar near the stem 1. place two m4 nuts in each of the sides of the lower clamp, and the other strip of rubber inside, and place on the handlebar opposite the other piece 1. feed bolts through the sides of the top piece of the clamp, and thread them into the captive nuts on the bottom. This step can be tricky, and might need additional hands, or temporarily taping the nuts in place 1. once loosely connected, place the square piece of rubber over the bolt coming from the top slidey piece and thread into the captive m3 nut in the clamp. Remember the little release tab needs to face backwards. 1. tighten all the screws just enough that the clamp stays in place, test fit your light and adjust the vertical aim to where you want it to be 1. once vertical is approximately set, remove it and tighten all bolts down snug. Note that the two side pieces will not touch, and that is ok 1. slide your light back on, and go for a ride in the dark!