Hella Mix and Match 3D Print Light Brackets

[Patrick]

When we first build the Sportster 3D printing wasn’t a thing for home users. This has changed in the last 13 years, so it seem like a good time to make some improvments.

Version one of the rear light brackets where aluminim, work fine don’t look so good:







CAD Designs in Fusion360 (free for home gamers!) so far, allows for 3mm body thinkness when mounted. It’ll need a gasket to keep the damp out, also the fibre glass is not a consisten thinkness:





Some rendered versions with clear models of the outter ring and inner light:











Now we need to print the first protoype and see how it fits:



After the first printed versions I can then test the part and see if it needs any modifications.

[meverett]

Re: Hella Mix and Match 3D Print Light Brackets

That’s Interesting. 3D printing seems to be the way to go.
What printer will you be using?
It’s something that I may have to try out and learn something new.

[Patrick]

Re: Hella Mix and Match 3D Print Light Brackets

Richard & I share an Ultimaker 2+. Test print in PLA, will be able to test fit in a day or two as Richard has the printer at his house. The final version will be printed in a copolyester for more heat resilience.

[meverett]

Re: Hella Mix and Match 3D Print Light Brackets

Ah, the ultimaker 2+ is out of my league. I could use the excuse ‘our son could learn a lot in 3D printing’ and go for a cheaper option.

[Patrick]

Re: Hella Mix and Match 3D Print Light Brackets

Ah, the ultimaker 2+ is out of my league. I could use the excuse ‘our son could learn a lot in 3D printing’ and go for a cheaper option.

Have a look at the Prusa i3 MK3 https://shop.prusa3d.com/en/3d-print...-mk3-kit.html# same quality as the UM2+ - it's the one I'd buy if I were getting one now. Back when we got the UM2+ there wasn't anything else that printed to the same precision and quality for less, the price is also why I share the printer rather than have my own

[Patrick]

Re: Hella Mix and Match 3D Print Light Brackets

Here the first test print test fit, some Dremel work needed due to minor measurements being out, mostly it’s Ok! Will need some clearance where the two units are close together.

[David]

Re: Hella Mix and Match 3D Print Light Brackets

Excellent work.

There are online services where you can upload your 3D design to an people will print it for you, not sure if it’s mainly USA based though, could be from memory.

[Patrick]

Re: Hella Mix and Match 3D Print Light Brackets

Thanks and yeah - https://www.shapeways.com/ - they list their HQ in NYC now. When I last ordered they were only in The Netherlands. They still have an office there and it looks like EU orders ship from there rather than the US, so no duty to pay! (for now :/ ) Lots of material choices there, but can get expensive as you pay for volume.

[Patrick]

Re: Hella Mix and Match 3D Print Light Brackets

Version 2 model, more compact, less print time and should have a good 1-2mm gap to place both lights next to each other.

Version 2



Version 1



Version 2



Version 1

[Patrick]

Re: Hella Mix and Match 3D Print Light Brackets

Version 2 on the left, much smaller than the inital version:




Some clearance to fit two next to each other on the Sporster



The part is still more than strong enough for to keep the light in



Test fitting on the wing



LED centre light test fit (yep, rusty screws need changing)



View from the outside


I need to make a few minor tweaks and it's ready to use.

[meverett]

Re: Hella Mix and Match 3D Print Light Brackets

Excellent job and looking neat.
I found a cheap 3D printer at £170 that has good reviews by Creality. I know it is not in the same league but may be worth a try.

7CAE58FC-9CD5-43BD-803E-5A2B16E0769F.jpeg

[Patrick]

Re: Hella Mix and Match 3D Print Light Brackets

Looks nice Does it have a heated bed? That's quite important for larger prints otherwise things can warp easily. Also for anything other than PLA it becomes more important.

If you've not already seen Tomas Sanladerer's channel it's worth a look: https://www.youtube.com/channel/UCb8...L1ohROUVg46h1A

[meverett]

Re: Hella Mix and Match 3D Print Light Brackets

Thanks I will tune in to that YouTube channel.
The Creality Ender 3 has a heated bed but looks like it will only take PLA filament.
May be worth a try as an entry level printer.

https://rover.ebay.com/rover/0/0/0?mpre=https%3A%2F%2Fwww.ebay.co.uk%2Fulk%2Fitm%2F263595617375

[Patrick]

Re: Hella Mix and Match 3D Print Light Brackets

Part evolution from initial concept to final co-polyester print, shown at the front the traditional bulb clear lens, LED amber indicator and LED ring light.


The final part:



Test fit with traditional bulb holder style clear lens indicator:



New LED centres, these don’t have the big tail and rubber seal out the back so it’s vulnerable to stone impacts and dirt inside the rear arches.



To solve the first/damage issue I’ve modelled up a dust cap, on the right version 1 printed in one part. The rough surface comes from removing supports. Version 2 on the left, printed in two parts, up the other way. That leaves a clean finish on the ourside from the print bed and clean surface without any overhang for the inside.



Version 2 split print in more detail, these parts are glued together using CA / Superglue



Wire clearance



Wire cap in place



The end is shaped so that shrink tube can easily be place over the cables to protect them

[meverett]

Re: Hella Mix and Match 3D Print Light Brackets

Wow, well done looking great. Suprising what can be done with an idea and printer, I can imagine knowing how to use it helps too :-)