Mod for the Loud Bicycle Classic horn

thingiverse

This is a modification to the Loud Bicycle Classic Horn. The horn's two speakers hang fairly loose inside its plastic casing, which my guess is intended to create a proper resonance chamber for sound. Unfortunately, in my case, this design allowed the speakers to move and vibrate significantly during cycling, leading to repeated failures of the wires connecting them. Even though these wires are thick, they would eventually shear off due to movement over time. To mitigate this issue, I printed two 5 mm thick rings using NinjaFlex, which absorb the worst movements while still allowing for a small gap towards the outer casing. This modification has provided some much-needed stability to the horn's components. In addition to addressing the wire failures, I also encountered another problem with the original cushioning pad attached to the bike frame. It lacked holes for screws, making it difficult to reattach after disassembling the horn to replace broken wires. To resolve this issue, I created a new 2 mm thick replacement pad using NinjaFlex, which includes pre-drilled holes for easy attachment. Print Settings: Printer Brand: LulzBot Printer: Mini Rafts: No Supports: No Resolution: 0.325 mm Infill: 20% Notes: * Bottom/top thickness: 1 mm * A single layer for the outer shell works fine, but increasing the layer count or infill will result in stiffer parts. * Use a PVA gluestick on the printbed before printing. Post-Printing: Rings: The rings are flexible and can be easily pulled over the speakers without disassembling the outer casing. Pad: Attach the pad with glue or use thin double adhesive tape for secure attachment.