E-Bike Controller Mount for Seat tube

thingiverse

Since I was fed up with turning controllers mounted to my seat tube with somewhat makeshift bottle mount adapters, I designed this mount to be glued directly to the seat tube. Please understand that it's a work in progress rather than a finished product. To use this mount, you'll need a controller with two mounting holes on each end. Simply measure the distance between them. After that, open up the OpenSCAD file and adjust it to your needs (variable "length_controller"). Then export it to a slicer format of your choice, like STL. A suggestion for stress-free printing is to face the flat part downward on your print bed. You'll most likely get away without any support since the structure doesn't have much overhang. I suggest using a wider brim to get a flat surface. There are two controllers pre-defined in the OpenSCAD file, which are also included as STL. The first one is a Grinfineon 4825 from Ebikes.ca: https://www.ebikes.ca/shop/electric-bicycle-parts/controllers/c4825-gr.html The second one is a 12 FET controller from the German company EBS: https://www.ebike-solutions.com/de/shop/pedelec-e-bike-teile/controller/ebs-programmierbarer-controller-12-fet.html To mount the controller to the adapter itself, you'll need two M5 nuts, two M5 washers, and two M5x10-12 screws. I used M5x11 Allen key screws, which are also used for 3D printers. For the M5 nuts, any model will do, but I suggest using some self-securing versions. They're a bit higher, but at least the ones I bought fit perfectly in the hole in the bottom. Before mounting your e-bike controller, you'll need to use longer M5 screws plus a big washer and "pull" the nuts into the holes. Work carefully so as not to damage the adapter. While I've included all standard diameters for seat tubes out there, I guess the oversized version is the most common measurement. For attaching both the adapter and your controller to the seat tube, I can imagine multiple options. Personally, I'll use Sikaflex, which is marine glue. But something like double-sided sticky tape or sealing compound will do. I wouldn't encourage you to use anything more permanent than this, such as Epoxy, in case the adapter ever breaks. For filament, I went with normal PLA and 100% infill. While PLA doesn't have the best reputation, I guess this part will be fine for an e-bike that's used for recreational riding only. For daily exposure to sunlight and other weather, I'd go for more resistant stuff: PETG at least or preferably ASA / ABS.