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OpenSCAD source code: Tour Easy seat clamp mount for rear running light
// Rear running light clamp for Tour Easy seat strut
// Ed Nisley - KE4ZNU - 2021-09
Layout = "Show"; // [Show,Build,Block]
Section = true;
/* [Hidden] */
ThreadThick = 0.25;
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
// Light case along X axis, seat strut along Y, Z=0 at strut centerline
LightOD = 25.4 + HoleWindage;
StrutOD = 5/8 * inch + HoleWindage;
PlateThick = 1/16 * inch;
WallThick = 2.0;
Kerf = ThreadThick;
Screw = [3.0,6.8,4.0]; // M3 OD=washer, length=nut + washers
Insert = [3.0,5.4,8.0 + 1.0]; // splined brass insert
RoundRadius = IntegerMultiple(Screw[OD]/2,0.5); // corner rounding
ScrewOC = [IntegerMultiple(StrutOD + 2*WallThick + Screw[ID],1.0),
IntegerMultiple(LightOD + 2*WallThick + Screw[ID],1.0)];
echo(str("Screw OC: ",ScrewOC));
BlockSize = [ScrewOC.x + Insert[OD] + 2*WallThick,
ScrewOC.y + Insert[OD] + 2*WallThick,
LightOD + StrutOD + 3*WallThick];
echo(str("Block: ",BlockSize));
BaseOffset = -(WallThick + LightOD/2); // block bottom to centerline
StrutOffset = LightOD/2 + WallThick + StrutOD/2; // light centerline to strut centerline
echo(str("Strut screw min: ",IntegerMultiple(PlateThick + WallThick + StrutOD/2 + Insert[LENGTH]/2,1.0)));
echo(str("Light screw min: ",IntegerMultiple(PlateThick + WallThick + LightOD/2 + Insert[LENGTH]/2,1.0)));
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,
$fn=Sides);
}
// Block with light along X axis
module Block() {
difference() {
hull()
for (i=[-1,1], j=[-1,1])
translate([i*(BlockSize.x/2 - RoundRadius),j*(BlockSize.y/2 - RoundRadius),BaseOffset])
cylinder(r=RoundRadius,h=BlockSize.z,$fn=NumSides);
for (i=[-1,1], j=[-1,1])
translate([i*ScrewOC.x/2,j*ScrewOC.y/2,BaseOffset - Protrusion])
rotate(180/8)
PolyCyl(Screw[ID],BlockSize.z + 2*Protrusion,8);
for (i=[-1,1], j=[-1,1])
translate([i*ScrewOC.x/2,j*ScrewOC.y/2,0]) {
translate([0,0,-Protrusion])
rotate(180/8)
PolyCyl(Insert[OD],Insert[LENGTH] + 1*Protrusion,8);
translate([0,0,(StrutOffset - Insert[LENGTH] - Kerf/2 + Protrusion)])
rotate(180/8)
PolyCyl(Insert[OD],Insert[LENGTH] + 1*Protrusion,8);
}
translate([-BlockSize.x,0,0])
rotate([0,90,0])
cylinder(d=LightOD,h=2*BlockSize.x,$fn=NumSides);
translate([0,BlockSize.y,StrutOffset])
rotate([90,0,0])
cylinder(d=StrutOD,h=2*BlockSize.y,$fn=NumSides);
translate([0,0,StrutOffset])
cube([2*BlockSize.x,2*BlockSize.y,Kerf],center=true);
cube([2*BlockSize.x,2*BlockSize.y,Kerf],center=true);
}
}
//- Build it
if (Layout == "Block")
if (Section)
difference() {
Block();
rotate(atan(ScrewOC.y/ScrewOC.x))
translate([0,BlockSize.y,0])
cube(2*BlockSize,center=true);
}
else
Block();
if (Layout == "Show") {
Block();
color("Green",0.25)
translate([-BlockSize.x,0,0])
rotate([0,90,0])
cylinder(d=LightOD,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,-BaseOffset])
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 - Kerf/2])
rotate([180,0,0])
intersection() {
Block();
translate([0,0,StrutOffset/2])
cube([2*BlockSize.x,2*BlockSize.y,StrutOffset],center=true);
}
}
@ednisley

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@ednisley ednisley commented Sep 17, 2021

More details on my blog at https://wp.me/poZKh-ap7

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