Drop bar dropper post remote lever Version 3

thingiverse

This is yet another iteration of a dropper lever for drop handlebars, as the remix links should indicate. I have redesigned it so that it clamps lower on the drops for a better hand position when holding on in the drops. It still uses the same brake lever bar clamp as the previous design, but now instead of using a single 608 bearing, it uses two 625 bearings with a spacer to separate them and keep the bolt from side loading them too much. If there is too much friction when the lever is bolted to the body, reprint the bearing_spacer with slightly scaled up Z. There are two kinds of brake lever band clamps * One with a T-headed bolt that sticks out of the clamp and is bolted on with a recessed nut that's round on the outside. **This is the kind you should use.** * One that has a threaded part welded to the clamp and uses a regular M6 bolt. **This project is not designed for this style.** It is too big. Parts needed: * Dropper post with cable, housing, ferrules, and cable clamp if necessary * Bar clamp cannibalized from drop bar brake levers * 2 625 cartridge bearings (5x16x5mm IDxODxthickness) * M5x30mm bolt and nylon lock nut This particular model is partially tuned for my particular 3D printer. That means that many of the inside dimensions- bearing seats, and nut and bolt clearances- may differ from your machine. Loose bearings should not be much of a problem since they are constrained by the main body, spacer and retaining bolt. Just make sure that the inside of the spacer is a loose fit over the bolt, or it will be difficult to bolt the lever to the body. This is designed for my dropper post which has the cable head in the post and a clamp at the lever. In fact, there are two places for the cable clamp- one at the bottom of the lever and one as pictured. There is also a place to tuck the spare cable. I only did it this way because I can probably reassemble this a few times with the same cable, clipping the frayed end of the cable shorter and clamping higher up as necessary. A bare cable head can probably fit easily enough at either clamp position in case your dropper has the ends switched around. Assembly: After checking that the bolt clears the spacer, use a hobby knife to clean up the edges of the lever so there is no lip inside the bearing surfaces. Press one bearing in with some sort of clamp or vise. Insert spacer and press the other bearing in. Put lever in body, press nut into body if necessary, and thread M5 bolt through body, lever, and nut. Install shim onto brake clamp nut, push into body (hole may need to be enlarged), and thread on clamp. When installing on the bar, make sure it is low enough on the drops that the shift lever has enough room to clear the dropper lever in any reasonable it may be used in.