Starlink 2 inch pole mount <-> J-Pole adapter

prusaprinters

I was recently tasked with installing a Starlink 2.0.The intended deployment location was on an existing J-Pole mount. The J-Pole had an outer diameter of 39 mm. I don't know if this is standard or not, but the STEP file is included should you need to modify.The pole mount that Starlink sent was intended for poles UP TO 2 inches in OD. With all 6 of the longest grub screws included with the Starlink adapter, the pole mount could have been connected to the J-Pole... but just barely. All forces from the pole mount would be telegraphed to the J-Pole through the small amount of surface area where the grub screws contacted the J-Pole.Furthermore, the open cavity would have certainly guaranteed bug/pest ingress.I set about designing an insert/shim that would effectively reduce the inner diameter of the pole mount adapter down to just fit the J pole.I printed this in ABS as that's the only material I had handy that a) matched the color of the star link pole mount and b) would not melt in the sun.The pole mount adapter ships with M6 grub screws; the holes for the grub screws on this part are intentionally undersized so the threads have some plastic to 'bite' into as they're inserted.Dimensional accuracy is important as this part is intended to be a press/friction fit into the pole mount adapter. Print as fast or as slow as needed to achieve accurate dimensions. There is a ~2 degree taper angle so print the text facing down as that's the (slightly) broader side. No supports needed. Infill is your discretion but if you anticipate high winds or similar loads, more is probably better. I printed at 25% infill and the attachment feels solid.