Drop bar dropper post remote lever Version 3

thingiverse

This iteration of a dropper lever for drop handlebars represents another attempt at redesigning the component. The remix links should provide an indication of this effort. I have revised the design so that it clamps lower on the drops, allowing for a better hand position when gripping the drops. It still utilizes the same brake lever bar clamp as the previous design, but now instead of employing a single 608 bearing, it uses two 625 bearings with a spacer to separate them and prevent excessive side loading. If there is too much friction when the lever is attached to the body, reprinting the bearing_spacer with slightly enlarged dimensions may be necessary. There are two types of brake lever band clamps available: * One features a T-headed bolt protruding from the clamp and is secured using a recessed nut that is round in appearance. This is the recommended type. * The other type has a threaded component welded to the clamp, requiring a regular M6 bolt for attachment. However, this style is not suitable for this project due to its excessive size. Required components include: * A dropper post with cable, housing, ferrules, and cable clamp if necessary * A bar clamp salvaged from drop bar brake levers * 2 x 625 cartridge bearings (5x16x5mm IDxODxthickness) * M5x30mm bolt and nylon lock nut This particular model is partially optimized for my specific 3D printer. Consequently, several internal dimensions – bearing seats, nut, and bolt clearances – may differ from your machine's specifications. Loose bearings should not pose a significant issue since they are constrained by the main body, spacer, and retaining bolt. It is essential to ensure that the inside of the spacer provides a loose fit over the bolt to facilitate easy assembly. This design is tailored for my dropper post, which features a cable head located within the post and a clamp at the lever. In fact, there are two potential locations for the cable clamp – one at the bottom of the lever and another as depicted in the image. There is also a designated area to store spare cables. This design was adopted because it allows for repeated assembly with the same cable, clipping the frayed end shorter and re-clamping higher up as necessary. Assembly Instructions: Before commencing, ensure that the bolt clears the spacer. Utilize a hobby knife to clean up any excess material within the lever's edges, eliminating any lip inside the bearing surfaces. Press one bearing into place using a suitable clamp or vise. Insert the spacer and press the second bearing in. Next, position the lever within the body, pressing the nut into place if necessary. Thread the M5 bolt through both components. Install the shim onto the brake clamp nut, push it into the body (if necessary), and thread on the clamp. When attaching the dropper lever to the bar, verify that its positioning is low enough on the drops to accommodate sufficient clearance for the shift lever in any potential configuration.