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My bike frame CAD model is incomplete but I have the new housing set up to straddle the top shock mount. It fasten using the existinging shock stud with custom spacers. The highest point of the housing is about 1/4 above the top of the shock body mounting yoke. The width is about the same as the shock and it protrudes out the back about 3" behind the shock mount.
Overall, it's slightly more compact or tucked in than the Bates setup it will replace. I never had any issues bumping the old one when mounting or dismounting so I wouldn't expect any with the new one.
As far as durability, I'm making the cooling system and other upgrades to the printer so that I will be able to use some of the strongest printable plastics available. The plan is to use carbon fiber reinforced polycarbonate. I may try to build a mold and make the housing out of actual carbon. I want it as stout as I can possibly make it.
Only concern I really see is when getting the upper shock bolt tightened to spec that any shock movement could cause your mounting bracket to crack around the bolt.
The housing doesn't bear any of the clamping forces of the shock mount. There are two steel hexagonal spacers that take up the clamp load. The spacers slip fit into hexagonal cavities in the light housing and are unconstrained in the axial direction but once clamped by the shock mounting nut, they will prevent the light from rotating.
Don't mind the wall thickness of the light housing. I haven't started on the internals yet. Wanted to get the overall shape right first. I'm still not sure I like it. May shorten it up a bit more and try to slim up the "waist".
Black is the housing.
Dark Gray is the shock body and molded-in sleeve
Yellow is the shock stud
Red is the shock nut
Light grey is the spacers
What about slits/multiple small circle openings for the light to show on the side of the housing.
Originally Posted by cggorman
I actually want to do something like that. Haven't modeled it yet but I think I can squeeze more in there.
Sounds like a great idea. I always think really visible turn signals are a pretty key bit of safety gear, and allowing people next to you to know your intentions sounds like a great idea. Especially when it can be done in a way that stays attractive and unique!
The current plan is have a horizontal "stripe" on the outboard side of the signal housing with both amber and red LEDs. Reds would be traditional corner markers and would be on whenever the bike is running but would get brighter with braking or switch to amber and flash for turning.
Also plan to add a new amber led to the ***** at the ends of the hand levers (pointing sideways) to act as corner markers and flashers.
Been tweaking printer setting for a material that is supposed to be decent for "clear" parts. In reality, this printing process is FAR from ideal for transparency but I'm hoping it will allow me to evaluate different lens designs before commiting to the more involved casting process.
These are simple little test parts. 9 in total. None where I really want them but getting closer as I progressed.
Initial lens design and continued printer tweaking.
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