OpenSCAD source code: running light mount for Tour Easy fairing

Fairing Flashlight Mount.scadd

// Tour Easy Fairing Flashlight Mount
// Ed Nisley KE4ZNU - July 2017
// August 2017 -
// August 2020 - add reinforcing columns under mount cradle
// August 2021 - 1 W Amber LED

/* [Build Options] */

FlashName = "1WLED";      // [AnkerLC40,AnkerLC90,J5TactV2,InnovaX5,Sidemarker,Clearance,Laser,1WLED]

Component = "BallClamp";       // [Ball, BallClamp, Mount, Plates, Bracket, Complete]

Layout = "Build";              // [Build, Show]

Support = true;

MountSupport = true;

/* [Hidden] */

ThreadThick = 0.25;       // [0.20, 0.25]
ThreadWidth = 0.40;       // [0.40]

function IntegerMultiple(Size,Unit) = Unit * ceil(Size / Unit);

Protrusion = 0.01;        // [0.01, 0.1]

HoleWindage = 0.2;

/* [Fairing Mount] */

Side = "Right";          // [Right,Left]

ToeIn = -10;            // inward from ahead
Tilt = 20;              // upward from forward (M=20 E=10)
Roll = 0;               // outward from top

//- Screws and inserts

/* [Hidden] */

ID = 0;
OD = 1;
LENGTH = 2;

/* [Hidden] */

ClampInsert = [3.0,4.2,8.0];

ClampScrew = [3.0,5.9,35.0];                // thread dia, head OD, screw length
ClampScrewWasher = [3.0,6.75,0.5];
ClampScrewNut = [3.0,6.1,4.0];              // nyloc nut

/* [Hidden] */

F_NAME = 0;
F_GRIPOD = 1;
F_GRIPLEN = 2;

LightBodies = [
  ["AnkerLC90",26.6,48.0],
  ["AnkerLC40",26.6,55.0],
  ["J5TactV2",25.0,30.0],
  ["InnovaX5",22.0,55.0],
  ["Sidemarker",15.0,20.0],
  ["Clearance",50.0,20.0],
  ["Laser",10.0,30.0],
  ["1WLED",25.4,40.0],
];

//- Fairing Bracket
// Magic numbers taken from the actual fairing mount

/* [Hidden] */

inch = 25.4;

BracketHoleOD = 0.25 * inch;          // 1/4-20 bolt holes

BracketHoleOC = 1.0 * inch;           // fairing hole spacing
                                      //  usually 1 inch, but 15/16 on one fairing

Bracket = [48.0,16.3,3.6 - 0.6];      // fairing bracket end plate overall size
BracketHoleOffset = (3/8) * inch;     //  end to hole center

BracketM = 3.0;                       // endcap arc height
BracketR = (pow(BracketM,2) + pow(Bracket[1],2)/4) / (2*BracketM);  // ... radius

//- Base plate dimensions

Plate = [100.0,30.0,6*ThreadThick + Bracket[2]];
PlateRad = Plate[1]/4;

RoundEnds = true;

echo(str("Base plate thick: ",Plate[2]));

//- Select flashlight data from table

echo(str("Flashlight: ",FlashName));
FlashIndex = search([FlashName],LightBodies,1,0)[F_NAME];

//- Set ball dimensions

BallWall = 5.0;                                      // max ball wall thickness
echo(str("Ball wall: ",BallWall));

BallOD = IntegerMultiple(LightBodies[FlashIndex][F_GRIPOD] + 2*BallWall,1.0);
echo(str(" OD: ",BallOD));

BallLength = IntegerMultiple(min(sqrt(pow(BallOD,2) - pow(LightBodies[FlashIndex][F_GRIPOD],2)) - 2*4*ThreadThick,
                 LightBodies[FlashIndex][F_GRIPLEN]),1.0);
echo(str(" length: ",BallLength));

BallSides = 8*4;

//- Set clamp ring dimensions

//ClampOD = 50;
ClampOD = BallOD + 2*5;
echo(str("Clamp OD: ",ClampOD));

ClampLength = min(20.0,0.75*BallLength);
echo(str(" length: ",ClampLength));

ClampScrewOC = IntegerMultiple((ClampOD + BallOD)/2,1);
echo(str(" screw OC: ",ClampScrewOC));

TiltMirror = (Side == "Right") ? [0,0,0] : [0,1,0];

//- Adjust hole diameter to make the size come out right

module PolyCyl(Dia,Height,ForceSides=0) {      // based on nophead's polyholes
  Sides = (ForceSides != 0) ? ForceSides : (ceil(Dia) + 2);
  FixDia = Dia / cos(180/Sides);
  cylinder(r=(FixDia + HoleWindage)/2,h=Height,$fn=Sides);
}

//- Fairing Bracket
//  This part of the fairing mount supports the whole flashlight mount
// Centered on screw hole

module Bracket() {

  linear_extrude(height=Bracket[2],convexity=2)
    difference() {
      translate([(Bracket[0]/2 - BracketHoleOffset),0,0])
        offset(delta=ThreadWidth)
          intersection() {
            square([Bracket[0],Bracket[1]],center=true);
            union() {
              for (i=[-1,0,1])                    // middle circle fills gap
                translate([i*(Bracket[0]/2 - BracketR),0])
                  circle(r=BracketR);
            }
          }
        circle(d=BracketHoleOD/cos(180/8),$fn=8);     // dead center at the origin
    }
}

//- General plate shape
// Centered in the middle of the plate

module PlateBlank() {

    difference() {
        intersection() {
            translate([0,0,Plate[2]/2])                           // select upper half of spheres
            cube(Plate,center=true);
            hull()
            if (RoundEnds)
                for (i=[-1,1])
                translate([i*(Plate[0]/2 - PlateRad),0,0])
                    resize([Plate[1]/2,Plate[1],2*Plate[2]])
                    sphere(r=PlateRad);                           // nice round ends!
            else
                for (i=[-1,1], j=[-1,1])
                translate([i*(Plate[0]/2 - PlateRad),j*(Plate[1]/2 - PlateRad),0])
                    resize([2*PlateRad,2*PlateRad,2*Plate[2]])
                    sphere(r=PlateRad);                           // nice round corners!
        }
        translate([BracketHoleOC,0,-Protrusion])                  // punch screw holes
            PolyCyl(BracketHoleOD,2*Plate[2],8);
        translate([-BracketHoleOC,0,-Protrusion])
            PolyCyl(BracketHoleOD,2*Plate[2],8);
    }
}

//- Inner plate

module InnerPlate() {

  difference() {
    PlateBlank();
    translate([-BracketHoleOC,0,Plate[2] - Bracket[2] + Protrusion])       // punch fairing bracket
      Bracket();
  }
}

//- Outer plate
// With optional legend for orientation and parameters

module OuterPlate(Legend = true) {

    TextRotate = (Side == "Left") ? 0 : 180;

    difference() {
        PlateBlank();
        if (Legend)
            mirror([0,1,0])
            translate([0,0,-Protrusion])
                linear_extrude(height=3*ThreadThick + Protrusion) {
                translate([BracketHoleOC + 15,0,0])
                    text(text=">>>",size=5,spacing=1.20,font="Arial",halign="center",valign="center");
                translate([-BracketHoleOC,8,0]) rotate(TextRotate)
                    text(text=str("Toe ",ToeIn),size=5,spacing=1.20,font="Arial",halign="center",valign="center");
                translate([-BracketHoleOC,-8,0]) rotate(TextRotate)
                    text(text=str("Tilt ",Tilt),size=5,spacing=1.20,font="Arial",halign="center",valign="center");
                translate([BracketHoleOC,-8,0]) rotate(TextRotate)
                    text(text=Side,size=5,spacing=1.20,font="Arial",halign="center",valign="center");
                translate([BracketHoleOC,8,0]) rotate(TextRotate)
                    text(text=str("Roll ",Roll),size=5,spacing=1.20,font="Arial",halign="center",valign="center");
                translate([0,0,0])
                    rotate(90)
                    text(text="KE4ZNU",size=4,spacing=1.20,font="Arial",halign="center",valign="center");
                }
    }
}

//- Slotted ball around flashlight
//  Print with brim to ensure adhesion!

module SlotBall() {

NumSlots = 8*2;                                             // must be even, half cut from each end
SlotWidth = 2*ThreadWidth;
SlotBaseThick = 10*ThreadThick;                             // enough to hold finger ends together
RibLength = (BallOD - LightBodies[FlashIndex][F_GRIPOD])/2;

  translate([0,0,(Layout == "Build") ? BallLength/2 : 0])
    rotate([0,(Layout == "Show") ? 90 : 0,0])
    difference() {
      intersection() {
        sphere(d=BallOD,$fn=2*BallSides);                                       // basic ball
        cube([2*BallOD,2*BallOD,BallLength],center=true);                       // trim to length
      }
      translate([0,0,-LightBodies[FlashIndex][F_GRIPOD]])
        rotate(180/BallSides)
          PolyCyl(LightBodies[FlashIndex][F_GRIPOD],2*BallOD,BallSides);        // remove flashlight body

      for (i=[0:NumSlots/2 - 1]) {                                              // cut slots
        a=i*(2*360/NumSlots);
        SlotCutterLength = LightBodies[FlashIndex][F_GRIPOD];
        rotate(a)
          translate([SlotCutterLength/2,0,SlotBaseThick])
            cube([SlotCutterLength,SlotWidth,BallLength],center=true);
        rotate(a + 360/NumSlots)
          translate([SlotCutterLength/2,0,-SlotBaseThick])
            cube([SlotCutterLength,SlotWidth,BallLength],center=true);
      }
    }

  color("Yellow")
  if (Support && (Layout == "Build")) {
    for (i=[0:NumSlots-1]) {
      a = i*360/NumSlots;
      rotate(a + 180/NumSlots)
        translate([(LightBodies[FlashIndex][F_GRIPOD] + RibLength)/2 + ThreadWidth,0,BallLength/(2*4)])
          cube([RibLength,2*ThreadWidth,BallLength/4],center=true);
    }
  }
}

//- Clamp around flashlight ball

BossLength = ClampScrew[LENGTH] - 1*ClampScrewWasher[LENGTH];
BossOD = ClampInsert[OD] + 2*(6*ThreadWidth);

module BallClamp(Section="All") {

  difference() {
    union() {
      intersection() {
        sphere(d=ClampOD,$fn=BallSides);                        // exterior ball clamp
        cube([ClampLength,2*ClampOD,2*ClampOD],center=true);    // aiming allowance
      }
      hull()
        for (j=[-1,1])
          translate([0,j*ClampScrewOC/2,-BossLength/2])
            cylinder(d=BossOD,h=BossLength,$fn=6);
    }

    sphere(d=(BallOD + 1*ThreadThick),$fn=BallSides);       // interior ball with minimal clearance

    for (j=[-1,1]) {
      translate([0,j*ClampScrewOC/2,-ClampOD])                              // screw clearance
        PolyCyl(ClampScrew[ID],2*ClampOD,6);
      translate([0,j*ClampScrewOC/2,                                        // insert clearance
                  -0*(BossLength/2 - ClampInsert[LENGTH] - 3*ThreadThick) + Protrusion])
        rotate([0,180,0])
          PolyCyl(ClampInsert[OD],2*ClampOD,6);
      translate([0,j*ClampScrewOC/2,                                        // insert transition
                  -(BossLength/2 - ClampInsert[LENGTH] - 3*ThreadThick)])
          cylinder(d1=ClampInsert[OD]/cos(180/6),d2=ClampScrew[ID],h=6*ThreadThick,$fn=6);
    }

    if (Section == "Top")
      translate([0,0,-ClampOD/2])
        cube([2*ClampOD,2*ClampOD,ClampOD],center=true);
    else if (Section == "Bottom")
      translate([0,0,ClampOD/2])
        cube([2*ClampOD,2*ClampOD,ClampOD],center=true);
  }

  color("Yellow")
  if (Support) {                                      // ad-hoc supports
    NumRibs = 6;
    RibLength = 0.5 * BallOD;
    RibWidth = 1.9*ThreadWidth;
    SupportOC = ClampLength / NumRibs;

    if (Section == "Top")                             // base plate for adhesion
      translate([0,0,ThreadThick])
        cube([ClampLength + 6*ThreadWidth,RibLength,2*ThreadThick],center=true);
    else if (Section == "Bottom")
      translate([0,0,-ThreadThick])
        cube([ClampLength + 6*ThreadWidth,RibLength,2*ThreadThick],center=true);

    render(convexity=2*NumRibs)
    intersection() {
      sphere(d=BallOD - 0*ThreadWidth);                         // cut at inner sphere OD

      cube([ClampLength + 2*ThreadWidth,RibLength,BallOD],center=true);

    if (Section == "Top")                                       // select only desired section
      translate([0,0,ClampOD/2])
        cube([2*ClampOD,2*ClampOD,ClampOD],center=true);
    else if (Section == "Bottom")
      translate([0,0,-ClampOD/2])
        cube([2*ClampOD,2*ClampOD,ClampOD],center=true);

      union() {                                                 // ribs for E-Z build
        for (j=[-1,0,1])
          translate([0,j*SupportOC,0])
            cube([ClampLength,RibWidth,1.0*BallOD],center=true);
        for (i=[0:NumRibs])                                     // allow NumRibs + 1 to fill the far end
          translate([i*SupportOC - ClampLength/2,0,0])
            rotate([0,90,0])
              cylinder(d=BallOD - 2*ThreadThick,
                      h=RibWidth,$fn=BallSides,center=true);
      }
    }
  }
}

//- Mount between fairing plate and flashlight ball
//  Build with support for bottom of clamp screws!

module Mount() {

MountShift = [ClampOD*sin(ToeIn/2),0,ClampOD/2];

  OuterPlate();

    mirror(TiltMirror) {
        intersection() {
            translate(MountShift)
                rotate([-Roll,ToeIn,Tilt])
                    BallClamp("Bottom");
            translate([0,0,Plate.x/2 + 3*ThreadThick])
                cube(Plate.x,center=true);
        }

        if (MountSupport)                                 // anchor outer corners at worst overhang
            color("Yellow") {
                RibWidth = 1.9*ThreadWidth;
                SupportOC = 0.1 * ClampLength;
                intersection() {
                    difference() {
                        rotate([0,0,Tilt])
                            translate([(ClampOD - BallOD)*sin(ToeIn/2),0,3*ThreadThick])        // Z = avoid legends
                            for (i=[-4.5,-2.5,0,2.0,4.5])
                                translate([i*SupportOC - 0.0,0,(5 + Plate[2])/2])
                                cube([RibWidth,0.7*ClampOD,(5 + Plate[2])],center=true);
                        translate(MountShift)
                            rotate([-Roll,ToeIn,Tilt])
                                sphere(d=ClampOD - 2*ThreadWidth,$fn=BallSides);
                    }
                    translate([0,0,ClampOD/2])
                        cube([Plate.x,Plate.y,ClampOD],center=true);
                }
            }
  }
}

//- Build things

if (Component == "Bracket")
  Bracket();

if (Component == "Ball")
  SlotBall();

if (Component == "BallClamp")
  if (Layout == "Show")
    BallClamp("All");
  else if (Layout == "Build")
    BallClamp("Top");

if (Component == "Mount")
  Mount();

if (Component == "Plates") {
  translate([0,0.7*Plate[1],0])
    InnerPlate();
  translate([0,-0.7*Plate[1],0])
    OuterPlate(Legend = false);
}

if (Component == "Complete") {
  OuterPlate();
  mirror(TiltMirror) {
    translate([0,0,ClampOD/2 + BossOD*abs(sin(ToeIn))]) {
      rotate([-Roll,ToeIn,Tilt])
        SlotBall();
      rotate([-Roll,ToeIn,Tilt])
        BallClamp();
    }
  }
}

More details on my blog at https://wp.me/poZKh-alB