RadRover Handlebar Extender

thingiverse

This flashlight extender was designed specifically to work with my RadRover from Rad Power Bikes, allowing me to center-mount a light source. I made the extender extra wide in case I decide to install additional components in the future. The handlebar that came with my bike measured approximately 31.8 mm at the section where I wanted to attach this extender. To create the extender, I printed two separate rings first. Then, I printed the extender bar itself. Finally, I printed the flashlight holder. This design is intended to be paired with a clamp that I already possess; you can skip it or find an alternative if desired. The extender bar measures 25mm in diameter for reference. This custom-made part was created using Tinkercad, and you can edit it online at https://www.tinkercad.com/things/jZ5LD9XoIX1. UPDATE: The initial version of this design failed to meet expectations. The UltraFire flashlight that I mounted to it proved too heavy, causing the entire handlebar extender system to break when I encountered a significant bump. Version 2: I've revised the design to incorporate more plastic around the area where the first version failed. Fingers crossed that this updated design will perform better. Version 3: After multiple iterations, I've finally developed a working model that can safely carry a heavy flashlight without breaking. You can view this improved design at https://tinkercad.com/things/3D1g9xVLxtC. Print Settings: Printer Brand: Robo 3D Printer: R1 ABS + PLA Model Rafts: Yes Supports: Yes Resolution: .4 Infill: 15% Notes: When printing the extender bar on my Robo 3D R1+ Plus, I used a raft and supports to ensure a successful print. After two initial attempts resulted in the bar lifting off the bed, I chose to use Simplify3D's easy-to-remove raft to guarantee a good print. I also printed the arms horizontally for added strength, with the print lines running up and down the arms. For the rings, I printed them without a raft or supports. All pieces are meant to be printed in place without rotation to optimize their strength in the final product. Post-Printing Assembly: To connect the rings to the extender, I used 1 1/2 inch wood screws. To attach the rings to the handlebar, you'll need to drill holes and use nuts and bolts. I utilized 12mm M3 bolts and M3 nuts myself. I recommend using a shim or flattening a rubber band for the inside of the rings to achieve better grip once it's installed.