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OpenSCAD source code: Tour Easy fairing mount for LED flashlights
// Tour Easy Fairing Flashlight Mount
// Ed Nisley KE4ZNU - July 2017
/* [Build Options] */
FlashName = "AnkerLC40"; // [AnkerLC40,AnkerLC90,J5TactV2,InnovaX5]
Component = "Mount"; // [Ball, BallClamp, Mount, Plates, Bracket]
Layout = "Show"; // [Build, Show]
Support = false;
MountSupport = true;
/* [Extrusion] */
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] */
ToeIn = 0; // inward from ahead
Tilt = 20; // upward from forward
Roll = 0; // outward from top
Shift = -5; // realign to plate center
//- Screws *c
/* [Hidden] */
ID = 0;
OD = 1;
LENGTH = 2;
/* [Screws and Inserts] */
BallInsert = [2.0,3.5,4.0];
BallScrew = [2.0,3.5,2.0];
ClampInsert = [3.0,4.2,8.0];
ClampScrew = [3.0,5.9,50.0]; // 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]
];
NumSides = 8*4;
echo(str("Flashlight: ",FlashName));
FlashIndex = search([FlashName],LightBodies,1,0)[F_NAME];
BallThick = IntegerMultiple(5.0,ThreadWidth); // thickness of ball wall
echo(str("Ball wall: ",BallThick));
BallOD = max(45,IntegerMultiple(LightBodies[FlashIndex][F_GRIPOD] + 2*(BallThick + BallInsert[OD]),2.0));
echo(str(" OD: ",BallOD));
BallScrewOC = BallOD - BallThick - BallInsert[OD]; // from OD to allow different body diameters
echo(str(" screw OC: ",BallScrewOC));
BallLength = min(sqrt(pow(BallOD,2) - pow(LightBodies[FlashIndex][F_GRIPOD],2)),
LightBodies[FlashIndex][F_GRIPLEN]);
echo(str(" hole len: ",BallLength));
ClampThick = 2*ClampInsert[OD];
echo(str("Clamp wall: ",ClampThick));
ClampOD = BallOD + 2*ClampThick;
echo(str(" OD: ",ClampOD));
ClampScrewOC = BallOD + 2*ClampInsert[OD];
echo(str(" screw OC: ",ClampScrewOC));
ClampLength = 0.70 * BallLength;
echo(str(" length: ",ClampLength));
//- 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,$fn=Sides);
}
//- Ball around flashlight
// Must print two!
module BodyBall() {
difference() {
intersection() {
sphere(d=BallOD,$fn=2*NumSides); // basic ball
cube([BallLength,2*BallOD,2*BallOD],center=true); // max of flashlight grip length
}
translate([-LightBodies[FlashIndex][F_GRIPOD],0,0])
rotate([0,90,0]) rotate(180/NumSides)
PolyCyl(LightBodies[FlashIndex][F_GRIPOD],2*BallOD,NumSides); // flashlight body
for (j=[-1,1])
translate([0,j*BallScrewOC/2,0]) // commmon screw offset
translate([0,0,-BallOD])
PolyCyl(BallInsert[ID],2*BallOD,6); // punch screw shaft through everything
translate([0,BallScrewOC/2,-Protrusion])
PolyCyl(BallInsert[OD],(BallInsert[LENGTH] + 3*ThreadThick + Protrusion),6); // threaded insert
translate([0,-BallScrewOC/2,BallThick])
PolyCyl(BallScrew[OD],BallOD,6); // screw head clearance
translate([0,0,-BallOD/2]) // remove bottom half
cube(BallOD,center=true);
translate([0,0,BallOD - BallThick/2]) // slice off top = bottom for E-Z build
cube(BallOD,center=true);
}
if (Support) {
NumRibs = 24;
RibHeight = (BallOD - LightBodies[FlashIndex][F_GRIPOD]/cos(180/NumSides) - BallThick) / 2;
ChordC = 2*sqrt(BallThick*BallOD/2 - pow(BallThick/2,2));
intersection() {
cube([BallLength,2*BallOD,2*BallOD],center=true); // max of flashlight grip length
translate([0,0,BallOD/2 - BallThick/2])
for (i=[0:NumRibs - 1])
rotate(i*360/NumRibs + 180/NumRibs) // avoid screw holes
translate([ChordC/2 + BallOD/8,0,-RibHeight/2])
cube([BallOD/4,2*ThreadWidth,RibHeight],center=true);
}
}
}
//- Fairing Bracket
// Magic numbers taken from the actual fairing mount
// Centered on screw hole
/* [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
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),$fn=8); // dead center at the origin
}
}
//- General plate shape
// Centered on the hole for the fairing bracket
Plate = [100.0,30.0,6*ThreadThick + Bracket[2]];
PlateRad = Plate[1]/4;
echo(str("Base plate thick: ",Plate[2]));
module PlateBlank() {
difference() {
translate([BracketHoleOC,0,0])
intersection() {
translate([0,0,Plate[2]/2]) // select upper half of spheres
cube(Plate,center=true);
hull()
for (i=[-1,1], j=[-1,1])
translate([i*(Plate[0]/2 - PlateRad),j*(Plate[1]/2 - PlateRad),0])
resize([2*PlateRad,2*PlateRad,2*Plate[2]])
sphere(r=PlateRad); // nice rounded corners!
}
translate([2*BracketHoleOC,0,-Protrusion]) // screw holes
PolyCyl(BracketHoleOD,2*Plate[2],8);
translate([0,0,-Protrusion])
PolyCyl(BracketHoleOD,2*Plate[2],8);
}
}
//- Inner plate
module InnerPlate() {
difference() {
PlateBlank();
translate([0,0,Plate[2] - Bracket[2] + Protrusion]) // punch out fairing bracket
Bracket();
}
}
//- Clamp around flashlight ball
module BallClamp() {
BossLength = ClampScrew[LENGTH] - ClampScrewNut[LENGTH] - 2*ClampScrewWasher[LENGTH] - 4*ThreadThick;
difference() {
union() {
intersection() {
sphere(d=ClampOD,$fn=NumSides); // exterior ball blamp
cube([ClampLength,2*ClampOD,2*ClampOD],center=true); // aiming allowance
}
for (i=[0])
hull() {
for (j=[-1,1])
translate([i*(ClampLength/2 - ClampScrew[OD]),j*ClampScrewOC/2,-BossLength/2])
rotate(180/8)
cylinder(d=(ClampScrewWasher[OD] + 2*ThreadWidth),h=BossLength,$fn=8);
}
}
sphere(d=(BallOD + 1*ThreadThick),$fn=NumSides); // interior ball
for (i=[0] , j=[-1,1]) {
translate([i*(ClampLength/2 - ClampScrew[OD]),j*ClampScrewOC/2,-ClampOD]) // screw clearance
rotate(180/8)
PolyCyl(ClampScrew[ID],2*ClampOD,8);
}
}
color("Yellow")
if (Support) { // ad-hoc supports for top half
NumRibs = 6;
RibLength = 0.5 * BallOD;
RibWidth = 1.9*ThreadWidth;
SupportOC = ClampLength / NumRibs;
cube([ClampLength,RibLength,4*ThreadThick],center=true); // base plate for adhesion
intersection() {
sphere(d=BallOD - 0*ThreadWidth); // cut at inner sphere OD
cube([ClampLength + 2*ThreadWidth,RibLength,BallOD],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 +1 to fill the far end
translate([i*SupportOC - ClampLength/2,0,0])
rotate([0,90,0])
cylinder(d=BallOD - 2*ThreadThick,
h=RibWidth,$fn=NumSides,center=true);
}
}
}
}
//- Mount between fairing plate and flashlight ball
module Mount() {
translate([-BracketHoleOC,0,0])
PlateBlank();
translate([Shift,0,ClampOD/2])
rotate([-Roll,ToeIn,Tilt])
intersection() {
translate([0,0,-ClampOD/2])
cube([2*ClampOD,2*ClampOD,ClampOD],center=true);
BallClamp();
}
if (MountSupport) { // anchor outer corners during worst overhang
RibWidth = 1.9*ThreadWidth;
SupportOC = 0.1 * ClampLength;
difference() {
rotate([0,0,Tilt])
translate([Shift + 0.3,0,0])
for (i=[-4.5,-2.5,0,2.0,4.5])
translate([i*SupportOC - 0.0,0,(ClampThick + Plate[2])/2])
cube([RibWidth,0.8*ClampOD,(ClampThick + Plate[2])],center=true);
# translate([Shift,0,ClampOD/2])
rotate([-Roll,ToeIn,Tilt])
sphere(d=ClampOD - 2*ThreadWidth,$fn=NumSides);
}
}
}
//- Build things
if (Component == "Ball")
if (Layout == "Show")
BodyBall();
else if (Layout == "Build") {
translate([0,+1*(BallOD/2 + BallThick/2),0])
translate([0,0,BallOD/2 - BallThick/2])
rotate([180,0,0])
BodyBall();
translate([0,-1*(BallOD/2 + BallThick/2),0])
translate([0,0,BallOD/2 - BallThick/2])
rotate([180,0,0])
BodyBall();
}
if (Component == "BallClamp")
if (Layout == "Show")
BallClamp();
else if (Layout == "Build") {
Both = false;
difference() {
union() {
translate([Both ? ClampLength : 0,0,0])
BallClamp();
if (Both)
translate([-ClampLength,0,0])
rotate([180,0,0])
BallClamp();
}
translate([0,0,-ClampOD/2])
cube([2*ClampOD,2*ClampOD,ClampOD],center=true);
}
}
if (Component == "Mount")
Mount();
if (Component == "Plates") {
translate([0,0.7*Plate[1],0])
InnerPlate();
translate([0,-0.7*Plate[1],0])
PlateBlank();
}
if (Component == "Bracket")
Bracket();
@ednisley

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Owner Author

commented Jul 21, 2017

More details on my blog at http://wp.me/poZKh-6VG

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