Exactly what it says on the tin; I abused my Beamer 5 light and after a while, the case began to crack. When it no longer stayed together, I got out the calipers. Most of the dimensions (like the mount) were integer numbers of millimeters. I used a favorite trick to get positions for the battery terminals. I scanned the terminals along with a 5mm grid and imported it into Onshape. Then I scaled the image so that the grid was correct and traced.
It prints in the face-down orientation you see in the gallery; I was nervous about the bridging on the top, but it was no problem for the printer (A PrinterBot metal).
If I had it all to do over again:
1. I'd add a feature to the back end to retain the battery connector spring.
2. The first time I dropped it, the weight of the batteries popped the back of the housing right off. I covered the whole thing in epoxy; it looked horrid, but it's been sturdy since.
Details
Even if you don't have this particular model of light, the mounting bracket interface is pretty standard.
I've attached a drawing.
Files
Mounting bracket drawing.pdf
Dimensions for the interface between a bicycle light and one common handlebar clamp
Adobe Portable Document Format -
418.34 kB -
02/21/2018 at 04:02