Parts for Bicycle Turn and Stop Signals with Front and Rear Lights

prusaprinters

3D Printed Parts for Bicycle Turn and Stop Signals with Front and Rear LightsDOWNLOAD Version 1.3.4 (2022-03-28) ZIP ~8MBDetailed HELP with images on how to assemble parts (external link)...INTROBelow you will find parts and tools, which will help you to add turn and stop signals to your bicycle. Not all tools, like multimeter or label printer, are necessary. If you noticed mistakes, have questions or suggestions, know better components (available in EU and US), please write to info@jocys.com • Project page: Jocys.com/BicycleParts were printed from PETG with Prusa3D i3 MK3 Printer. If your printer is not precise enough, printed parts may not fit into each other.If you made your own updates or (file) changes, related to this project, please send me a link. I will add this link to your work on this page.This project is based on 12 Volts. Bicycle dynamos and lights are, usually, 6 Volts. USB is 5 Volts. Be careful and don't mix wires.UPDATES1.3.4 (2021-10-06) • Handlebar Box Plate updated to make 2 bottom screws more accessible.1.3.3 (2021-10-06) • Screw covers for Touratech folding mirrors added.1.3.2 (2021-06-17) • Cargo box parts (control box and rear light box) redesigned.1.3.1 (2020-10-02) • Added knob for 6.1mm knurled shaft... to fit easier on 6mm plastic shaft.1.3 (2019-10-28) • Handlebar center parts updated and handlebar box added.1.2 (2019-09-06) • Indicator-mirror-button holders redesigned.0.1 (2018-06-05) • ...PARTSM-Wave • Amsterdam Cargo Box1 x The M-Wave Amsterdam HardboxM-Wave Amsterdam Cargo Box Holes PDF FileA4 (210 x 297mm) file will help you to drill holes in right places:1. Print2. Cut3. Puncture4. DrillNC-17 • 254 Trekking Pro Handlebar1 x NC-17 254 Trekking Pro HandlebarBBB • HighSix BHS-28 Adjustable Handlebar Stem1 x Adjustable Handlebar StemSRAM • A3.0 COMP 7 Speed Twist ShifterMy bicycle is equipped with "SRAM 3.0 COMP 7 Speed Twist Shifter". You may not be able to fit 3D printed indicator-mirror holder perfectly between brake lever and different shifter model.Ningbo Jietong Electronics • E751 (MIRS-201)2 x Amber color LED for left and right turn indicators.These switches are more intuitive than Ulincos push buttons, especially, during cycling with gloves.Operation type: ON/OFFPole/way: 1 pole / 1 wayRating: 16A@12VLever type: Illuminated paddleTerminals: 4.8mm bladeIllumination: BulbPanel hole size: 20mm dia.Overall dims (inc. terminals): 23 (Dia) x 40 (D) mmUlincos • U19C2B Latching Push Button Switch1 x White color LED for front and tail light1 x Blue color LED for hand brake leversTDH (Jiaxing HongFa Motor Vehicle Fittings) • Bike It • Mini Amber Indicators4 x Mini Amber IndicatorYou should change standard halogen or incandescent bulbs to LED bulbs. Some LED bulbs are larger than standard halogen or incandescent bulbs and will not fit inside.Osram • LEDriving PREMIUM 3850WWNot as bright as Bonlux LED bulb.Bonlux • BA9S LED Bulb 12V4 x Bonlux BA9S LED Bulb 12VDimension: 10x30mmBase Shape: BA9sLumen: 300lmOrafol • ORACAL 8300 Transparent Cal (034 Orange)White LED lamps can be covered with orange transparent film.PsmGoods • LED Flasher Relay1 x LED flasher relayShin Yo • 255-700 Universal Stop and Taillight OVAL1 x Shin Yo Oval Universal Stop and Tail Light (12v 21/5w bulb)You should change standard halogen or incandescent bulbs to LED bulbs. Some LED bulbs are larger than standard halogen or incandescent bulbs and will not fit inside. LUYED (China) 1157 3014 78-EX red LED bulb: Brighter than OSRAM LED bulb. All LEDs are lit in “tail only” mode. On pressing brake lever (“stop” mode), all LEDs become brighter. Difference between “tail only” and “stop” mode is minimal and not very distinguishable. You can increased difference between “tail only” and “stop” modes by dimming tail light slightly with 1 kΩ potentiometer.Osram (Germany) • 1457R red LED bulb: Not as bright as LUYED LED bulb. Only 6 LEDs are lit in “tail only” mode. On pressing brake lever (“stop” mode), another 12 LEDs light up. Not as bright as LUYED bulb in both modes, but difference between “tail only” and “stop” modes is more distinguishable without dimming tail light with 1 kΩ potentiometer. Currently I prefer LUYED with 1 kΩ potentiometer setup.CTS Corporation • 026TB32R102B1A1 1 kΩ Potentiometer1 x 1 kΩ potentiometer for tail lightSome LED bulbs have very small difference between “tail only” and “stop” modes. You can increase this difference by slightly dimming tail light with 1 kΩ potentiometer.Star Union (Wuxing) • Brake Lever2 x E-bike brake leverIf you know EU or US e-brake lever manufacturer, please send link to info@jocys.com.I use "noname" brake levers closest to this model: 89PDD.BS68.AWASD • O-Ring Switch Dampeners4 x Blue o-ring (optional)Stop light didn't turn-off with my "noname" brake levers sometimes. I added 2 blue o-rings (2 x 0.4mm = 0.8mm Reduction) under each switch to fix it.DBPower • Portable Car Jump Starter Battery1 x DBPower Portable Car Jump Starter BatteryAmazon • EC5 Female 10cm Adapter Wire1 x EC5 Female 10cm Adapter WireNew jump cable version has box at the end of the cable. You will need to buy additional cable with EC5 female connector and add 6.3mm / 2.5 - 6.0mm² non-insulated male and female blade crimp terminal connectors at the ends.Voltaic Systems (USA) • Solar Panel KitsGlory Solar • GS6.5-CC Solar Panel ChargerLetsolar • SH51 6.5V/7W Solar Panel Charger1 x Solar panel chargerHole diameters are 10mm.12voltplanet • MTA UniVal Blade FuseAll LED lights draw about 1A in my setup. I used 11A (0.5mm²) cables and 2A (Grey) fuse.MTA • UniVal 2A Blade Fuse2 x 2A blade fuseBlade Fuse Holder2 x Blade fuse holderSecond version, I bought, was made from harder plastic. To open cap easily, you need to push it sideways first.12voltplanet • Single 0.5mm² 11A50m Reel of Single 0.5mm² 11A48 x 2.8mm / 0.5 - 1.5mm² female32 x 2.8mm / 0.5 - 1.5mm² male6 x 6.3mm / 0.5 - 1.5mm² female3 x 6.3mm / 0.5 - 1.5mm² male1 x 6.3mm / 2.5 - 6.0mm² female for DBPower battery jump cable1 x 6.3mm / 2.5 - 6.0mm² male for DBPower battery jump cable~2m ... 3.2mm / 1.6mm Heat Shrink Tubing (2:1 ratio)~1m ... 6.4mm / 3.2mm Heat Shrink Tubing (2:1 ratio)12voltplanet • Non-Insulated Male Blade Crimp Terminal Connectors2.8mm / 0.5 - 1.5mm² • 3.2mm / 1.6mm Heat Shrink Tubing (2:1 ratio)6.3mm / 0.5 - 1.5mm² • 6.4mm / 3.2mm Heat Shrink Tubing (2:1 ratio)6.3mm / 1.5 - 2.5mm² • 6.4mm / 3.2mm Heat Shrink Tubing (2:1 ratio)6.3mm / 2.5 - 6.0mm² • 6.4mm / 3.2mm Heat Shrink Tubing (2:1 ratio)12voltplanet • Non-Insulated Female Blade Crimp Terminal Connectors2.8mm / 0.5 - 1.5mm² • 3.2mm / 1.6mm Heat Shrink Tubing (2:1 ratio)6.3mm / 0.5 - 1.5mm² • 6.4mm / 3.2mm Heat Shrink Tubing (2:1 ratio)6.3mm / 1.5 - 2.5mm² • 6.4mm / 3.2mm Heat Shrink Tubing (2:1 ratio)6.3mm / 2.5 - 6.0mm² • 6.4mm / 3.2mm Heat Shrink Tubing (2:1 ratio)12voltplanet • Heat Shrink TubingGoCableTies • Heat Shrink Tubing Mini Reels (7 Colours)Magazi • Stark Mirrors MG-18502 x Magazi Stark Mirrors MG-1850orTouratech • Folding Mirror M10x1.25 01-040-0771-0To attach Touratech mirror you will need to replace M10x1.25 bolt with parts:M8x50mm flanged or standard screw with M8x17mm outer diameter washerM8 10x8.2x12mm nylon spacerM8x20mm outer diameter washerM8 nylon locking nutPro-Bolt • Aluminium Washer M8 20mm O/D4 x M8 20mm Outer Diameter Washer.Mirrors can be screwed with M8 40mm screws, included with Magazi MG-1850 mirrors.Accu • Washer M5 15mm O/D8 x M5 15mm Outer Diameter Washer.DBA Hardware • M5 20mm hexagonal stud connector nuts12 x M5 20mm Hexagonal Stud Connector Nut (main holders, handlebar box, control box).Open Builds (US) • Low Profile M5 Bolt 30mmOoznest (UK) • Low Profile M5 Bolt 30mm4 x M5 10mm (main holders).8 x M5 15mm (handlebar box).4 x M5 30mm (control box).6 x M5 30mm (rear light holder, solar panel holders).2 x M5 35mm (solar panel holders).4 x M5 40mm (battery holder).4 x M5 55mm (or 50mm) (front box).2 x M5 60mm (main holder).Draper • 3.0 mm Hexagon and Ball End Hexagon Key (33602)Tip allows the hexagon key to be used up to 30 degree angle from the screw head recess.Pro-Bolt • M5 Nyloc Nut • M8 Nyloc Nut4 x M8 Nyloc Nut.22 x M5 Nyloc Nut.Accu • M3 8mm Cup Point Grub Screw (DIN 916)2 x M3 8mm Cup Point Grub Screw (DIN 916) for knob.Accu • M3 Square Nut (DIN 562)2 x M3 Square Nut (DIN 562) for knob.Henkel • Loctite 243NOTE: Do not apply too much - I could not unscrew one bolt and broke plastic.General purpose medium bond strength threadlocker.Secures and seal bolts, nuts and studs to prevent loosening due to vibration.Hama • 00178113 Bicycle Bell2 x Hama 00178113 Bicycle BellBicycle bell for greater road safety with a plastic holder for all common bicycle handlebars.Busch + Müller • Lumotec AVY E1 x Busch + Müller Lumotec AVY EKing Serry • KS-SF22R AlarmAlarm Volume: 113dBAdjustable Sensitivity Level: 7Waterproof: IP55 LoudspeakerBell Sound Types: 6Batteries: 3 x 1.5V AAA (included)Remote Controller: 1 (included)TOOLSPrusa • i3 MK3 3D PrinterPrint technology: Fused Filament Fabrication / Fused Deposition Modeling.0.4mm nozzle (easy changeable) for 1.75 mm filament.Build volume 11,025 cm3 (25 x 21 x 21 cm).Layer height (layer resolution) from 0.05 mm (50 microns).Accuracy: 0.01 x 0.01 x 0.005 mm (10 x 10 x 5 microns).Max extruder temperature: 280 °C.Max heated bed temperature: 120 °C.Supported materials: PLA, ABS, PET, HIPS, Flex PP, Ninjaflex, Laywood, Laybrick, Nylon, Bamboofill, Bronzefill, ASA, T-Glase, Carbon-fibers enhanced filaments, Polycarbonates...WIRE STRIPPING AND CUTTING TOOLSC.K Tools • 495001 Wire StripperStripping: 0.2 - 6.0mm²;Cutting: HRC 40 - 50;Crimping: 0.5 - 6.0mm² insulated and non-insulated terminalsC.K Tools • Wire Stripping Pliers T3894For safe and damage-free stripping of fine, insulated solid wires. Suitable for cutting soft copper wires.Stripping capacities mm: 0.4, 0.5, 0.6, 0.8, 1.0, 1.3Stripping capacities AWG: 26, 24, 22, 20, 18, 16C.K Tools • Side Cutters T3887Precision side cutters. Suitable for cutting soft copper wires of up to 1.6mmØ / 14AWG.CRIMPING PLIERSChoosing a Tool • PressmasterLaser • 1913 Crimping PliersYou can crimp terminals with “C.K 495001”, but with “Laser 1913” it is much easier and faster.For use on non-insulated terminals, the ratchet motion assures complete crimping. Forged jaws (spare jaws Part No 2927).For use with non-insulated terminals:0.5-1.0mm², 1.5-2.5mm², 4-6mm²20-18AWG, 16-14AWG, 12-10AWGKlein Tools • VDV205-036 Die SetHozan • P-70712voltplanet • P00456 (YTH-202B)I used 0.5mm² / 20AWG / 1.7mm diameter cable. Laser 1913 Crimping Pliers (0.5-1.0mm² / 20-18AWG) did not crimp insulated part well. I used P00456 (YTH-202B) non-insulated terminal crimping tool (0.3-0.5mm² / 20-22AWG) to crimp insulation part better.DRILLING AND SCREWINGBosch • GSR 12V-35 FC Professional (06019H3000)Some holes must be drilled in plastic. I used wood drill bits for that.Bosch • X103TiTackLife (China) • PDH06A Step Drill KitFor drilling 19mm hole in cargo box with 3-5-7-9-11-13-15-17-19mm drill bit.TackLife drill bits are not very precise. For example 10mm part diameters: 9.84mm, 9.50mm, 9.94mmSHRINK TUBINGDremel • VersaFlame Butane TorchYou can use gas lighter for heat shrink tubing, but it is much easier to work with Dremel VersaFlame.Newport • Butane GasExtra Purified Near Zero Impurities Gas to use with Turboflame Lighters, Refilling Butane Lighters, other Butane-Powered Products And other personal needs.MEASURINGSpreadsheet • FlukeBrymen • BM235 MultimeterBrymen • BM867S MultimeterI used multimeter for some measurements and to find right cable ends in “Continuity Test” mode during cable labelling process.MARKINGDymo • LabelManager 280For marking cables with labels. D1 Standard Labels 12mm (S0720610) settings:Font Size: 16ptLength: Fixed 1.5" (38mm)Align: RightDymo • D1 Standard Labels 12mm (S0720610)Black on White, Clear, Yellow, Blue, Green, RedWhite on Clear, BlackBlue on White, ClearRed on White, ClearSOLDERINGWeller • BP865CEUWeller • PU 81For soldering wires to potentiometer.Weller • Tip-ActivatorFor regeneration of oxidized tips. Cleaning only possible in hot state of the soldering tip.Weller • WP 65 SetWP 65 - Soldering iron 65 W, 24 V with Power-Response Heating Technology.XNT A - Soldering tip chisel 1,6 x 0,4 mm.WDH 10 - Safety rest with Stop+Go function and dry cleaner.Weller • EL60/40-100Kester • 44 Flux-Cored WireSn60Pb40 - 0.8mm - 3.3% Flux - melting range 183-190°CSn63Pb37 - 0.8mm - 3.3% Flux - melting point 183°CAndroid boy's Lab • Smart Tool AppTo set precise 0° angle for indicator-mirror-button holders.PETG FILAMENTYou will need about 1.1 kg with 80% infillI would not recommend to print parts from ABS (shrinkage is too big) or PLA (low heat resistance).I had no problems with these filaments:Prusa3D • Jet Black Prusament PETG 1.75MCPP • BasicFil Black PETG 1.75Amazon • AmazonBasics Black PETG 1.75PC Johnson • Windex Original Glass CleanerFor preparing-cleaning heated printer bed... Spring Steel Sheet with Smooth Double-sided PEI before printing with PETG filament.Water: WaterCleaning Agent: 2-Hexoxyethanol, Isopropanolamine, Ammonium HydroxideWetting Agent: Lauryl Dimethyl Amine Oxide, Sodium Dodecylbenzene SulfonateFragrance: FragranceDye: Liquitint® Sky Blue DyeSHL • Isopropanol / Isopropyl Alcohol / IPANOTE: I didn't test-print parts for this project on Textured PEI Powder-coated Spring Steel Sheet.For preparing-cleaning heated printer bed... Double-sided Textured PEI Powder-coated Spring Steel Sheet before printing with PETG filament.For thin parts to stick correctly, you may need to adjust height of first layer perfectly and to reduce "Elephant foot compensation" from default value 0.2mm... to 0.1mm. Modified settings: PrusaSlicer ► Print Settings ► 0.20 QUALITY MK3 ► Advanced ► Slicing...Isopropanol 99.9% / Isopropyl Alcohol / IPAManufacturer Part Number: 1000-ISO-TRIGGERTrigger spray cap for bottles with a 28mm neck (OFF, Spray, Stream)1 LitreKleenex • Ultra Soft Pocket TissuesFor preparing-cleaning heated printer bed.PRINTING SETTINGSPrinting Settings for MCPP BasicFil or AmazonBasics PETG Filament on PrusaSlicer...for Spring Steel Sheet with Smooth Double-sided PEIFor BIG parts to stick on TEXTURED PEI Powder-coated Spring Steel Sheet sheet, I increased recommended bed temperature from 60-80°C (for AmazonBasic and MCPP BasicFill PETG filaments) to 85°C (First layer) and 90°C (Other layers). I printed BIG parts in my own Temperature Controlled Enclosure. Temperature inside enclosure was about 35°C with these bed settings. E3D V6 HotEnd is rated to 40°C ambient operating temperature. As you approach that temperature, cooling efficiency is reduced, allowing more heat up past the heatbreak. This can cause low temperature filament to soften in the mechanism to cause feed problems.Prusa3D • PrusaSlicer Modified settings: PrusaSlicer ► Filament Settings ► Prusament PETG ► Filament• "Extruder: 240°C".• "Bed: 85°C / 90°C". Modified settings: PrusaSlicer ► Print Settings ► 0.20 QUALITY MK3 ► Layers and perimeters• "Ensure vertical shell thickness: disabled" - I had problems with thin 45° hanging angles when it was enabled.• "Perimeters: 3" - infill pattern is less visible on surface. Modified settings: PrusaSlicer ► Print Settings ► 0.20 QUALITY MK3 ► Inflill• "Fill density: 80%." Modified settings: PrusaSlicer ► Print Settings ► 0.20 QUALITY MK3 ► Speed• Reduced printing speeds (10-20-180-400). Slower speeds results in smoother and glossier surfaces without matte areas, reduces printing noise with vibrations... lesser probability for corners of big parts to unstick from heated bed, because of shrinking.• "Travel: 180" - low speeds (like 20) creates surface blobs after long travel distances.• "First layer speed: 10" - for better adhesion. Modified settings: PrusaSlicer ► Printer Settings ► Original Prusa i3 MK3S ► Custom G-code• I added few lines to G-code to remove filament blob on nozzle right before printing starts and raised intro line to reduce wearing of steel sheet plate surface.G0 Z50 ; ADDED LINE - NOZZLE BLOB - Z up 50 mm to clean filament blob from nozzle before printing.G4 S5 ; ADDED LINE - NOZZLE BLOB - Pause 5 seconds to clean the nozzle.G0 Z-50 ; ADDED LINE - NOZZLE BLOB - Z down 50 mm to initial position.G0 Z0.5 ; ADDED LINE - INTRO LINE - Z up 0.5 mm for less intro line adhesion to prevent steel sheet plate surface from wearing.G0 Y-1 ; ADDED LINE - INTRO LINE - Y shift 2 mm intro line default start position to prevent steel sheet plate surface from wearing.STL FILESFor better quality and safety... I printed majority of parts separately.To split group and to remove some parts:1. Open “*.STL” file in PrusaSlicer Edition.2. Click on [ Split to objects ] button.3. Select parts one by one, which you don't want to print.4. Press [ Del ] key on keyboard.You can edit STL files with free and open source 3D creation suite Blender.Import “*.STL” file:1. Blender 2.8 ► File ► Import ► Stl (.stl).If imported STL object is not visible:1. Select imported object in “Scene Collection” list (top-right panel).2. In “Object Mode“ (top-left drop-down) ► Object ► Set Origin ► Geometry to Origin.Main_Holder_Left.STLFor NC-17 254 Trekking Bicycle Handlebar 25.4 mm • 22.2 mm1 x Main Holder Left1 x Main Holder Left Cover Top1 x Main Holder Left Cover Bottom1 x Turn Signal Light Spacer1 x Screw Cover Square2 x Screw Cover CircleMain_Holder_Right.STLFor NC-17 254 Trekking Bicycle Handlebar 25.4 mm • 22.2 mm1 x Main Holder Right1 x Main Holder Right Cover Top1 x Main Holder Right Cover Bottom1 x Turn Signal Light Spacer1 x Screw Cover Square2 x Screw Cover CircleControl_Box.STL1 x Control Box - Seam position: [ Rear ]Control_Box_Cover.STL1 x Control Box Civer - Seam position: [ Rear ]Control_Box_Parts.STL1 x Indicator Relay Holder2 x Cable Holder2 x Control Box 1 cm Spacer A4 x Control Box 1 cm Spacer B1 x 10mm to 7mm Spacer for Smaller (16mm) PotentiometerFor all knobs - Seam Position: [ Rear ]2 x Knob for Smooth 6.4mm Shaft1 x Extended Knob for Knurled 6mm Shaft1 x Knob for Knurled 6mm Shaft (with square dent)1 x Knob for Knurled 6.1mm Shaft (with circle dent)Battery_Holder.STLFor DBPower B07CVF7L77 300A 800mAh Jump Starter1 x Battery Holder2 x Battery Holder ClipRear_Light_Holder_and_Cable_Box.STLRear light parts are for Shin Yo 255-700 Universal Stop and Taillight OVAL1 x Rear Light Cable Box Cover - Seam Position: [ Rear ]1 x Rear Light Cable Box - Seam Position: [ Rear ]1 x Rear Light Cable Box Spacer1 x Rear Light Spacer1 x Rear Light Screw Nut Holder1 x Rear Light Screw Nut Holder CoverFront_Box_Holders.STLFor all parts - Seam Position: [ Rear ]1 x Front Cable Box Holder A Left1 x Front Cable Box Holder A Right1 x Front Cable Box Holder B Left with 22.2mm Bar for Phone Holder1 x Front Cable Box Holder B RightFront_Cable_Box.STL1 x Front Cable Box Cover - Seam Position: [ Rear ]1 x Front Cable Box PlateFront_Handlebar_Box.STLCan fit anti-theft alarms, like King Serry KS-SF22R1 x Front Handlebar Box Cover - Seam Position: [ Rear ]1 x Front Handlebar Box Plate1 x Front Handlebar Box InsertSolar_Panel_Holders.STL4 x Solar Panel Holder Top4 x Solar Panel Holder Bottom Spacer - Seam position exception:PrusaSlicer ► Print Settings ► Layers and perimeters ► Seam position: [ Rear ]Label_Helper.STLFor marking cables with labels. D1 Standard Labels 12mm (S0720610) settings:Font Size: 16ptLength: Fixed 1.5" (38mm)Align: RightYou can use needle or punch tool to slide label into helper, to prevent it from sticking to your fingers.1 x Label Helper Part A1 x Label Helper Part BCables