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Thread: Hella Mix and Match 3D Print Light Brackets

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  1. #1 Hella Mix and Match 3D Print Light Brackets 
    frequent forum contributor Club Member Patrick's Avatar
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    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.
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  2. #2 Re: Hella Mix and Match 3D Print Light Brackets 
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    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.
    1275 Marina/Ital based LWB Roadster in the process of a ground up rebuild.
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  3. #3 Re: Hella Mix and Match 3D Print Light Brackets 
    frequent forum contributor Club Member Patrick's Avatar
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    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.





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  4. #4 Re: Hella Mix and Match 3D Print Light Brackets 
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    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.
    1275 Marina/Ital based LWB Roadster in the process of a ground up rebuild.
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  5. #5 Re: Hella Mix and Match 3D Print Light Brackets 
    frequent forum contributor Club Member Patrick's Avatar
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    Quote Originally Posted by meverett View Post
    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
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  6. #6 Re: Hella Mix and Match 3D Print Light Brackets 
    frequent forum contributor Club Member Patrick's Avatar
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    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.













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  7. #7 Re: Hella Mix and Match 3D Print Light Brackets 
    frequent forum contributor Club Member David's Avatar
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    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.
    - 9th Custodian of JRR 929D, the Triumph Vitesse based special Paul Moorehouse built prior to the Triumph based Roadster kits.
    - 8th owner of Roadster chassis number 2395. Kit manufactured 1983, first registered in 1987. Now owned by Barry!
    - Builder of chassis number 2325 (PKK 989M) in the mid 80's. Now owned by Eric & Lynne in the NE of England.
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  8. #8 Re: Hella Mix and Match 3D Print Light Brackets 
    frequent forum contributor Club Member Patrick's Avatar
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    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.
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  9. #9 Re: Hella Mix and Match 3D Print Light Brackets 
    frequent forum contributor Club Member Patrick's Avatar
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    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

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  10. #10 Re: Hella Mix and Match 3D Print Light Brackets 
    frequent forum contributor Club Member Patrick's Avatar
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    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.
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