Headlight mount for LED headlight on 31.7mm handlebar

thingiverse

I ordered a 6000 Lumen headlight for my fat tire bike, but the bracket that came with it was only suitable for smaller handlebars, so I had to get creative. I used a thick rubber band to hold it in place while searching for a solution, but none of the brackets I found would fit on the larger 31.7mm diameter handlebars, which are a standard feature of my bike. To fix this problem, I designed and printed a custom bracket using my 3D printer. The headlight is an excellent 6000 Lumen three-LED light, which can be purchased from Amazon: http://www.amazon.com/Bicycle-HeadLight-Headlamp-6400mAh-Battery/dp/B00YDRGRXU. The design is still a work in progress, and I plan to make some tweaks to reduce the need for drill-outs of the holes after printing. So far, the bracket has been working well, but there's always room for improvement! To create the initial printed part, I used orange PLA (to match my bike) with 3 shells and 15 percent infill settings. Feel free to experiment with different settings! Eventually, I'll print a fresh version using ABS to provide added protection from sun exposure. Once the printed part was completed, I cleaned out and enlarged the holes using drills and attached it to my bike using the original screw that came with the bracket. To keep the assembly in place on the handlebar, you can wrap a few loops of electrical tape or apply a small piece of double-faced tape to prevent rotation.