OpenSCAD source code: Ruggedized handlebar mount for Zzipper fairing strut on Tour Easy handlebars

Zzipper Fairing - Strut Mount.scad

// Fairing strut mount for Tour Easy handlebars
// Ed Nisley - KE4ZNU - 2019-08

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

Support = false;

/* [Hidden] */

ThreadThick = 0.20;
ThreadWidth = 0.40;

HoleWindage = 0.2;

Protrusion = 0.1;			// make holes end cleanly

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

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

inch = 25.4;

//----------------------
// Dimensions
// Handlebar along X axis, strut along Y, Z=0 at handlebar centerline

HandlebarOD = 0.875 * inch + HoleWindage;

StrutOD = 0.375 * inch + HoleWindage;

PlateThick = 1.0 / 16.0 * inch;

WallThick = 2.0;

Screw = [3.0,6.8,4.0];                 // M3 OD=washer, length=nut + washers

RoundRadius = IntegerMultiple(Screw[OD]/2,0.5);             // corner rounding

ScrewOC = [IntegerMultiple(StrutOD + 2*WallThick + Screw[ID],0.5),
           IntegerMultiple(HandlebarOD + 2*WallThick + Screw[ID],0.5)];

echo(str("Screw OC: ",ScrewOC));

BlockSize = [ScrewOC.x + 2*RoundRadius,ScrewOC.y + 2*RoundRadius,HandlebarOD + StrutOD + 3*WallThick];

echo(str("Block: ",BlockSize));

HandleBarOffset = WallThick + HandlebarOD/2;                // block bottom to centerline
StrutOffset = HandlebarOD/2 + WallThick + StrutOD/2;        // handlebar centerline to strut centerline

echo(str("Screw length: ",BlockSize.z + 2*PlateThick + Screw[LENGTH]));

NumSides = 2*3*4;

//----------------------
// Useful routines

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);
}

// Basic shapes

// Block with handlebar along X axis

module Block() {

  difference() {
    hull()
      for (i=[-1,1], j=[-1,1])
        translate([i*ScrewOC.x/2,j*ScrewOC.y/2,-HandleBarOffset])
          cylinder(r=RoundRadius,h=BlockSize.z,$fn=NumSides);

    for (i=[-1,1], j=[-1,1])
      translate([i*ScrewOC.x/2,j*ScrewOC.y/2,-(HandleBarOffset + Protrusion)])
        PolyCyl(Screw[ID],BlockSize.z + 2*Protrusion,8);

    translate([-BlockSize.x,0,0])
      rotate([0,90,0])
        cylinder(d=HandlebarOD,h=2*BlockSize.x,$fn=NumSides);

   translate([0,BlockSize.y,StrutOffset])
      rotate([90,0,0])
        cylinder(d=StrutOD,h=2*BlockSize.y,$fn=NumSides);


  }

  if (Support) {                // totally ad-hoc
    color("Yellow")
    cube(1,center=true);
  }

}


//- Build it

if (Layout == "Block")
  Block();

if (Layout == "Show") {
  Block();

  color("Green",0.25)
    translate([-BlockSize.x,0,0])
      rotate([0,90,0])
        cylinder(d=HandlebarOD,h=2*BlockSize.x,$fn=NumSides);

  color("Green",0.25)
    translate([0,BlockSize.y,StrutOffset])
      rotate([90,0,0])
        cylinder(d=StrutOD,h=2*BlockSize.y,$fn=NumSides);
}

if (Layout == "Build") {
  translate([-1.2*BlockSize.x,0,HandleBarOffset])
    difference() {
      Block();
      translate([0,0,BlockSize.z])
        cube(2*BlockSize,center=true);
    }

  translate([1.2*BlockSize.x,0,StrutOD/2 + WallThick])
    difference() {
      rotate([180,0,0])
      translate([0,0,-StrutOffset])
        Block();
      translate([0,0,BlockSize.z])
        cube(2*BlockSize,center=true);
    }

  translate([0,0,StrutOffset])
    rotate([180,0,0])
      intersection() {
          Block();
        translate([0,0,StrutOffset/2])
          cube([2*BlockSize.x,2*BlockSize.y,StrutOffset],center=true);
      }
  }

More details on my blog at https://wp.me/poZKh-8nV