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August 21, 2019 17:11
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OpenSCAD source code: Ruggedized handlebar mount for Zzipper fairing strut on Tour Easy handlebars
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// 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); | |
} | |
} |
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