Bicycle Turn & Stop Signals
3D Printed Parts for Bicycle Turn and Stop Signals with Front and Rear Lights 1.2 (2019-09-06)  


3D Printed Bicycle Turn and Stop Signals. JocysCom-Bicycle.zip file size: ~10MB

Below you will find parts and tools, which will help you to add turn and stop signals to your bicycle. Not all tools, like multimeter or label printer, are necessary. If you noticed mistakes, have questions or suggestions, know better component (available in EU and US), please write or send link to info@jocys.com • Bicylce on Thingiverse.com

This project is based on 12 Volts. Bicycle dynamos and lights are, usually, 6 Volts. USB is 5 Volts. Be careful and don't mix wires.

Parts were printed from PETG with Prusa3D i3 MK3 Printer.

The owner of this website is a participant in the Amazon EU Associates and Amazon Services LLC Associates Program...

Jocys.com

Updates
Updates

1.2 (2019-09-06) • Indicator-mirror-button holders redesigned.

Jocys.com

Parts
Parts
Turn Signals Mounted on M-Wave Box

2016-05M-WaveAmsterdam Cargo Box€32

1 x M-Wave Amsterdam Hardbox

High quality re-enforced plastic
Lockable with 2 keys
Dust and Water resistant
Fits on rear carrier rack
17 liter capacity

M-Wave Amsterdam Cargo Box Holes PDF File

A4 (210 x 297mm) file will help you to drill holes in right places

1. Print
2. Cut
3. Puncture
4. Drill

Handlebar

2016-05NC-17254 Trekking Pro Handlebar€30

1 x NC-17 254 Trekking Pro Handlebar

Material: trekking aircraft aluminum T6
position marks
Identification Number
Sweep: 16 °
Backsweep: 32 °
Height: 60 mm
Width: 618 mm
Weight: 343 grams
Handlebar clamp: 25.4 mm
Handlebar: 22.2 mm
Color: Black

Handlebar Stem

2019-05BBBHighSix BHS-28 Adjustable Handlebar Stem€30

1 x Adjustable Handlebar Stem

Adjustable stem angle: -30 ... 40 °
Extension: 90/110/130 mm
Handlebar Diameter: 25.4 mm
Fork Pipe Diameter: 21.8 mm
Material: 3D forged 6061 T6 aluminum
Weight: 264 grams

Shifter

2019-05SRAMA3.0 COMP 7 Speed Twist Shifter€9

My bicycle is equipped with "SRAM 3.0 COMP 7 Speed Twist Shifter". You may not be able to fit 3D printed indicator-mirror holder perfectly between brake lever and different shifter model.

7 Speeds
1:1 Actuation Ratio
SRS technology for light and precise indexing
50mm moulded composite black finish

Push Button Switch

2016-05UlincosU19C2B Latching Push Button Switch€9

2 x Red color LED for left and right turn indicators
1 x White color LED for front and tail light
1 x Blue color LED for hand brake levers

Head diameter: 22mm
Mounting hole size: 19mm
Depth inc contacts: 38mm
Switch combination: 1NO1NC
Operation types: Latching
Switch rating: 5A/250VAC
LED voltage: 12V DC
LED color: Blue
Head shape: High flush
Enclosure material: Aluminium alloy
Protection level: IP67, IK10

Lights

PhilipsOsramTop 10 LED Companies (2011)

HellaLight Requirements (2016-06-01)

Legal Regulations: 673_Legal_Requirements_Brochure_HELLA_EN.pdf

Automotive Bulbs: HASA_Bulbs_Catalogue_2012_LRes.pdf

LED Comparison: http://www.saving-star.com/smd-led-comparison

Indicators

2016-05TDH (Jiaxing HongFa Motor Vehicle Fittings)Bike ItMini Amber Indicators€14

4 x Mini Amber Indicator

Pair of indicators
Lens - 55 x 40mm
Length (ex thread) - 100mm
Depth - 35mm
Width - 40mm
Thread - 20mm long 8mm / M8 screw thread
Fitted with a 12V 23W BA9S Amber bulb

You should change standard halogen or incandescent bulbs to LED bulbs.
Some LED bulbs are larger than standard halogen or incandescent bulbs and will not fit inside.
Some LED bulbs are not as bright as halogen or incandescent bulbs (check specifications).

Front/Rear (Turn) Light:

Bulb Shape: H21W
Base Shape: BA9s (⌀9.1mm)
Lumen: 440 lm

Power: 21 W
Voltage: 12 V
Visibility: 160° Horizontal, 30° Vertical
Luminous intensity: Amber, 250 - 1 200 cd

2019-05OsramLEDriving PREMIUM 3850WW€7

Not as bright as Bonlux LED bulb.

2019-05HSUNBA9S T4W 20 LED SMD 3014 12-24V LED Bulb€7

2019-05HSUNBA9S T4W 20 LED SMD 3014 12-24V LED Bulb€7

2019-05BonluxBA9S LED Bulb 12V€3

4 x Bonlux BA9S LED Bulb 12V

Dimension: 10x30mm
Base Shape: BA9s
Lumen: 300lm

Power: 3 Watts
LEDs: 30pcs 3014 SMD LEDs
Input Voltage: 12-24V DC
Light Color: Cool white 6000k
Beam angle: 360 degree

2016-05OrafolORACAL 8300 Transparent Cal (034 Orange)€14

White LED lamps can be covered with orange transparent film.

Transparent PVC film (80 micron) with UV stabilizers
32 glossy colours
For internally illuminated short- and medium-term designs on backlit glass surfaces
Solvent polyacrylate, permanent, transparent
Dry and wet application
Service life: 5 years
DIN EN 13501-1

LED Flasher Relay

2016-05PsmGoodsLED Flasher Relay€9

1 x LED flasher relay

E.L.B type 3-pin adjustable LED light bulb turn signal adjustable speed flasher relay.

Size: 5x3x3cm
Specifications: 12.8V, 0.1W-150W c/m
6.3mm connectors

Stop and Tail Light

2016-05Shin Yo255-700 Universal Stop and Taillight OVAL€23

1 x Shin Yo Oval Universal Stop and Tail Light (12v 21/5w bulb)

Dimensions W x D x H: 103mm x 72mm x 68mm
Includes number plate light
Road legal

You should change standard halogen or incandescent bulbs to LED bulbs.
Some LED bulbs are larger than standard halogen or incandescent bulbs and will not fit inside.
Some LED bulbs are not as bright as halogen or incandescent bulbs (check specifications).

Rear (Brake/Tail) Light:

Bulb Shape: P21/5W
Base Shape: BAY15d (⌀15mm)
Lumen: 440/35 lm

Power: 21/5 W (High/Low)
Voltage: 12 V
Tail Visibility: 160° Horizontal, 30° Vertical
Tail Luminous intensity: Red, 4 - 42 cd
Stop Visibility: 90° Horizontal, 30° Vertical
Stop Luminous intensity: Red, 60 - 730 cd

2019-05HSUN1157 BAY15D P21/5W SMD 3030 12-24V LED Bulb€11

2019-05Sylvania1157R€10

2019-05Osram1457R€12

Not as bright as LUYED LED bulb.

Base: BAY15d
ECE category: P21/5W
Nominal voltage: 12.0 V
Nominal wattage: 3.00 W
Power input tolerance: ±10 %
Luminous flux: 30/10 lm
Light color LED: Red
Diameter: 27.0 mm
Length: 52.5 mm
Lifespan B3: 1500 h
Lifespan Tc: 4000 h
Product type: Off-road

LUYED (China) 1157 3014 78-EX red LED bulb: Brighter than OSRAM LED bulb. All LED chips are shining in “tail only” mode. When you press brake lever (enable “stop” mode), all LED chips become slightly brighter. Difference between “tail only” and “stop” mode is minimal and not very distinguishable. You can increased difference between “tail only” and “stop” modes by dimming tail light slightly with 1 kΩ potentiometer.

OSRAM (Germany) 1457R red LED bulb: Only 6 LED chips are shining in “tail only” mode. When you press brake lever (enable “stop” mode), another 12 LED chips start to shine. Not as bright as LUYED bulb in both modes, but difference between “tail only” and “stop” modes is more distinguishable without dimming tail light with 1 kΩ potentiometer. Currently I prefer LUYED with 1 kΩ potentiometer setup.

Potentiometer

2016-05CTS Corporation026TB32R102B1A1 1 kΩ Potentiometer€3

1 x 1 kΩ potentiometer for tail light

Some LED bulbs have very small difference between “tail only” and “stop” modes. You can increase this difference by slightly dimming tail light with 1 kΩ potentiometer.

Series: 026
Potentiometer Type: Linear
Maximum Resistance: 1 kΩ
Power Rating: 5W
Electrical Taper: Linear
Mounting Type: Surface Mount
Termination Style: Solder Lug
Shaft Length: 25.4mm
Shaft Diameter: 6.35 mm
Tolerance: ±20%
Actuator Type: Round Shaft

Hand Brake Levers

2016-05Star Union (Wuxing)Brake Lever€12

2 x E-bike brake lever

If you know EU or US e-brake lever manufacturer, please send link to info@jocys.com.
I use "noname" brake levers closest to this model:

Model: 89PDD.BS68.A
Approvals: RoHS
Waterproof: IPX6
Size: L 170mm W 120mm H 38mm
Weight: 110g
Wiring: two core wiring
Materials: Aluminum Alloy

2014-08WASD • O-Ring Switch Dampeners€15

4 x Blue o-ring (optional)

Stop light didn't turn-off with my "noname" brake levers sometimes. I added 2 blue o-rings under each switch to fix it.

0.4mm Reduction - Blue
0.2mm Reduction - Red

Rechargeable Battery

2016-05DBPowerPortable Car Jump Starter Battery€38

1 x DBPower Portable Car Jump Starter Battery

1. Car Jump Starter: with heavy duty clamps and cables, it can jump start your vehicle (up to 2.5L gas engine) up to 15 times with 300A peak current.

2. Portable Battery Charger: with 8000mAh capacity, it can charge smartphones, tablets, and other devices at a speed up to 2.1A per port. Recharging process finishes in just 5 hours.

3. Safety Protection: the crocodile clamps have over current protection, short circuit protection, overload protection, over-voltage protection, over-charge protection.

4. What You Get: DBPOWER jump starter DJS40, jump cables, android USB cable, welcome guide, 3-year warranty and friendly customer services.

2016-05AmazonEC5 Female 10cm Adapter Wire€5

1 x EC5 Female 10cm Adapter Wire

New jump cable version has box at the end of the cable. You will need to buy additional cable with EC5 female connector and add 6.3mm / 2.5 - 6.0mm² non-insulated male and female blade crimp terminal connectors at the ends.

Solar Panel Charger

Voltaic Systems (USA) + ControllerArveySTINomadMSCEceenDFRobot

2016-05Glory SolarGS6.5-CC Solar Panel Charger€25

2016-05LetsolarSH51 6.5V/7W Solar Panel Charger€25

2016-05EceenSP-065W Solar Panel Charger€25

1 x Solar panel charger

Hole diameters are 10mm.

Solar panel: 6.5V / 7W
Cells: SunPower
Max USB output: 5V/5W
Size:290*160*20mm
Weight:230g

Blade Fuse

2016-0512voltplanetMTA UniVal Blade Fuse€0.21

All LED lights draw about 1A in my setup. I used 11A (0.5mm²) cables and 2A (Grey) fuse.

2016-05MTAUniVal 2A Blade Fuse€0.21

2 x 2A blade fuse

Amperage - Body Color

0.5A - Dark Blue
1A - Black
2A - Grey
3A - Violet
4A - Pink
5A - Beige
7.5A - Brown
10A - Red
15A - Blue
20A - Yellow
25A - Natural
30A - Green
40A - Orange

2016-05Blade Fuse Holder€2

2 x Blade fuse holder

Second version, I bought, was made from harder plastic. To open cap easily, you need to push it sideways first.

Cable

2016-0512voltplanetSingle 0.5mm² 11A€0.33

50m Reel of Single 0.5mm² 11A

Manufactured to: ISO 6722:2006 (Class B)
Voltage rating: suitable for 12V & 24V systems (60V max.)
Nominal current rating: 11A
Maximum loading: 132W@12V, 264W@24V
No./size of conductors: 16/0.20mm
Conductor cross section: 0.5mm2
Maximum overall cable diameter: 1.7mm
Resistance per m at 20oC: 0.0371 Ω
Conductor material: Plain copper
Insulation material: PVC (hard grade)
Working temperature range: -40oC to +105oC (with brief excursions up to +120oC)

Connectors



48 x 2.8mm / 0.5 - 1.5mm² female
32 x 2.8mm / 0.5 - 1.5mm² male
6 x   6.3mm / 0.5 - 1.5mm² female
3 x   6.3mm / 0.5 - 1.5mm² male
1 x 6.3mm / 2.5 - 6.0mm² female for DBPower battery jump cable
1 x 6.3mm / 2.5 - 6.0mm² male for DBPower battery jump cable

~2m ... 3.2mm / 1.6mm Heat Shrink Tubing (2:1 ratio)
~1m ... 6.4mm / 3.2mm Heat Shrink Tubing (2:1 ratio)

2016-0512voltplanetNon-Insulated Male Blade Crimp Terminal Connectors€0.9

2.8mm / 0.5 - 1.5mm²3.2mm / 1.6mm Heat Shrink Tubing (2:1 ratio)
6.3mm / 0.5 - 1.5mm²6.4mm / 3.2mm Heat Shrink Tubing (2:1 ratio)
6.3mm / 1.5 - 2.5mm² • 6.4mm / 3.2mm Heat Shrink Tubing (2:1 ratio)
6.3mm / 2.5 - 6.0mm²6.4mm / 3.2mm Heat Shrink Tubing (2:1 ratio)

2016-0512voltplanetNon-Insulated Female Blade Crimp Terminal Connectors€0.9

2.8mm / 0.5 - 1.5mm²3.2mm / 1.6mm Heat Shrink Tubing (2:1 ratio)
6.3mm / 0.5 - 1.5mm²6.4mm / 3.2mm Heat Shrink Tubing (2:1 ratio)
6.3mm / 1.5 - 2.5mm² • 6.4mm / 3.2mm Heat Shrink Tubing (2:1 ratio)
6.3mm / 2.5 - 6.0mm²6.4mm / 3.2mm Heat Shrink Tubing (2:1 ratio)

Heat Shrink Tubing

2016-0512voltplanetHeat Shrink Tubing€1-9

2016-05GoCableTiesHeat Shrink Tubing Mini Reels (7 Colours)€1-9

Heat shrink tubed packaged into a convenient mini reel box
Ratio size - 2:1
Material: Black Polyolefin - standard wall heat shrink tube
Internal diameters from: 1.2mm up to 25.4mm (Pre-shrinkage)
Colours: Black, Red, Green, Blue, Yellow, White, Clear

Mirrors

2016-06MagaziStark Mirrors MG-1850 €76

2 x Magazi Stark Mirrors MG-1850

• Package: a pair ( Left hand / Right hand )
• Aluminum housing and stem.
• Convex lens.
• Available colour: chrome, carbon, anodizing black satin…
• Available glass: blue lens, chrome lens, aluminum lens.
• Available stem: BON arm stem, MX arm stem, RING III arm stem, HB arm stem, TM arm stem.
• Available screw: M10, M8 regular or reverse and 5/16".

Washers and Bolts

2016-05Pro-BoltAluminium Washer M8 20mm O/D€1

4 x M8 20mm Outer Diameter Washer.
Mirrors can be screwed with M8 40mm screws, included with Magazi MG-1850 mirrors.

Material: High Tensile Anodised Aluminium.
Part No.: LWA8-20
Material: Aluminium
Product Type: Washer
Weight In Gms: 0.93
Bar Code: 5053573533418
Country Of Manufacture: United Kingdom
Thread Diameter: 8mm
Outside Diameter: 20mm
Thickness: 1.6mm

2016-05DBA HardwareWasher M5 15mm O/D€0.3

8 x M5 15mm Outer Diameter Washer.

Material: A2 Grade Stainless Steel
Thread Diameter: 5.3mm
Outside Diameter: 15mm
Thickness 1.2mm

2016-05DBA HardwareM5 20mm hexagonal stud connector nuts€7

4 x M5 20mm Hexagonal Stud Connector Nut.

Thread size: M5 20mm
Material: 304 stainless steel; weight: 23G
Package Content: 4Pcs x hex connector deep nut; main Color: Silver tone
Hex size: 8mm(Width)
Grade: 4.8

2016-05AccuPrecision Screws€0.6

2016-05Open Builds (US)Low Profile M5 Bolt 30mm€0.3

2016-05Ooznest (UK)Low Profile M5 Bolt 30mm€0.3

4 x M5 10mm Low Profile Screw.
4 x M5 25mm Low Profile Screw.
8 x M5 30mm Low Profile Screw.
2 x M5 35mm Low Profile Screw.
4 x M5 40mm Low Profile Screw.
4 x M5 45mm Low Profile Screw.
2 x M5 60mm Low Profile Screw.

Material: Alloy Steel
Lenght: 6-65mm
Thread Pitch: 0.8mm
Hex Head: 3mm
Thickness 1.5mm

2016-05Pro-BoltM5 Nyloc NutM8 Nyloc Nut€0.2

4 x M8 Nyloc Nut.
22 x M5 Nyloc Nut.

2016-05AccuM3 8mm Cup Point Grub Screw (DIN 916)€0.5

2 x M3 8mm Cup Point Grub Screw (DIN 916) for knob.

Cup Diameter: 1.15mm-1.4mm
Finish: Chemical Matte Black
Length: 8mmv Manufacturing Standard: DIN 916
Material: A4 Stainless Steel (Black)
Min Socket Head Depth: 1.2mm
Pitch: 0.5mm
Socket Head: 1.5mm (1.52mm-1.58mm)
Thread Size: M3 (3mm)

2016-05AccuM3 Square Nut (DIN 562)€0.5

2 x M3 Square Nut (DIN 562) for knob.

Finish: Chemical Matte Black
Manufacturing Standard: DIN 562
Material: A4 Stainless Steel (Black)
Pitch: 0.5mm
Thickness: 1.8mm
Thread Size: M3 (3mm)
Width: 5.5mm

2019-01HenkelLoctite 243€6

1 x Loctite 243 for few screws

General purpose medium bond strength threadlocker.
Secures and seal bolts, nuts and studs to prevent loosening due to vibration.
Prevents loosening on vibrating assemblies, e.g. pumps, gear boxes or presses.
Works on all metals, including passive substrates (e.g. stainless steel, aluminum, plated surfaces).
Proven to tolerate minor contamination by industrial oils, e.g. motor oils, corrosion prevention oils and cutting fluids.
Permits disassembly with hand tools for servicing.
P1 NSF Reg. No.: 123000

2019-01Hama00178113 Bicycle Bell€4

2 x Hama 00178113 Bicycle Bell

Bicycle bell for greater road safety with a plastic holder for all common bicycle handlebars.

Colour: Black
Material: Aluminium Alloy

Front Light for 12v DC Supply

2017-01Busch + MüllerLumotec AVY E€20

1 x Busch + Müller Lumotec AVY E

40 Lux
Suitable for 6-42V DC supply
Close range light
Clip-on reflector
Rear Light Contacts (RLC)
Without switch (always on or switchable through E-bike console)

Parts (Optional)
Front Light for 12v DC Supply

2017-01Busch + MüllerLumotec IQ-X E€95

150 Lux
Suitable for 6-60 V DC supply
Extensive beam pattern
Close range light
Daytime running light
Requires at least 7.5 W nominal output of the drive system's light connection

Dynamo Rear Light

2017-01Busch + MüllerTopLight Line Brake Plus€28

• 2 high power LEDs inside the 90 mm LineTec light strip (transparent glass, shines red).
• Super bright with 320° visibility.
• Standlight (powered by capacitor, no batteries required), deactivates automatically after 4 minutes (parking function) or manually.
• Only 53 g, very slim, 94 x 45 x 16.5 mm.
• Integrated large Z reflector.
• Mounting distance 50 or 80 mm.
• Mark of approval F.

Grips

2016-06ErgonGP1 Touring €34

The original ergonomic grip. The GP1 sets the Worldwide standard in ergonomic comfort, materials, and quality. The GP1 eliminates numb hands, aching fingers, and tired forearms. The uniquely shaped grip body is made from 100% German, TÜV-certified rubber compounds of the purest quality – with infused Medical-grade white mineral oil for improved flexibility and durability. A forged aluminum clamp allows the grip to be adjusted for perfect fit, can be easily readjusted, and eliminates twisting once installed. (Carbon bar compatible).

Shifter

2019-05SRAMA3.0 COMP 7 Speed Twist Shifter€9

My bicycle is equipped with "SRAM 3.0 COMP 7 Speed Twist Shifter". You may not be able to fit 3D printed indicator-mirror holder perfectly between brake lever and different shifter model.

7 Speeds
1:1 Actuation Ratio
SRS technology for light and precise indexing
50mm moulded composite black finish

Saddle

2019-05Evan CyclesFWE Super Comfort II Memory Foam Saddle€38

Water resistant cover material.
Memory foam padding.
Shock absorbing elastomer springs. Arctech Suspension: the saddle rails are suspended away from the base to allow for a small amount of flex for shock absorption.
Zone cut out: central relief cut out in plastic base for pressure relief.
Dual Density Base: softer plastic in the base placed under the sit bones to help absorb vibrations.
Reflective rear panel.
Steel rails
Size: 272 x 208 mm
Weight: 910g

Seatpost

2019-05SR SuntourSP12-NCX€60

Travel: 50mm
Design: dia. 31.6 or 27.2mm w/ 25mm setback
Note: Hard spring, soft spring, 350 or 400mm length
System: Parallelogram system
Suspension system: Internal Coil with preload adjust/steel bushing parallelogram

Pump

2019-05SpecializedAir Tool Switch Comp Pump€16

SwitchHitter head works on Schrader or Presta valves with no disassembly.
Shows pressure on a rotatable gauge.
Durable plastic barrel with aluminium shaft to reduce flex and improve efficiency.
Plunger locks to body chamber with a simple twist for secure storage.
Water bottle boss mount included.
Max pressure: 120 PSI (8.3bar).
Volume-per-stroke: 48cc

Adjustable DC/DC Converter

2017-01KemoM015N Adjustable DC/DC Converter€12

For converting 12V to 6V if you want to use 6V lights.

Input voltage: 6-28 V(DC)
Output voltage adjustable: 3-15 V(DC) (electronically stabilized)
Note: The input voltage must be at least 3V higher than the adjusted output voltage.
Max. output current: 1.5A
Max. dissipation: ~3W without heat sink, ~10W with heat sink (not enclosed).
Dimensions: ~60x45x20mm (without fastening straps).

Dynamo

NiceLite LED Cycle Dynamo Bulbs

2017-01Busch + MüllerDymotec 6 Dynamo€32

High output tyre dynamo (6 volt, 3 watt) with approx. 40 % efficiency. The position to the tyre as well as the contact pressure can be aligned perfectly with two easy adjustments. With easy touch trigger: a quick press of the finger suffices, and the dynamo pivots toward the tyre. Less expensive than Dymotec S12 (12V, 6.2W). Available for either right or left side mounting. Dymotec 6 can power Halogen or LED bulbs:

2.4W / 6V (headlight) + 0.6W / 6V (taillight) bulb. Total: 3W.

or

3W / 6V single (headlight) bub.

• 6 Volt / 3 Watt
• Unique efficiency: approx. 40%
• Position and contact pressure adjustable
• Separate versions for mounting to the left or right of the bicycle

A special separate roller with high alloyed steel brushes is available for temporary use under extreme conditions. During rain, slush, snow or ice it works with optimised contact pressure and maximal traction – gentle to the tyre and self-cleaning.

Dynamo Power

2017-01Busch + MüllerE-Werk €95

Power without mains
For all those that do not want to do without mobile phone, GPS, MP3 player or other electronic devices while cycling, Busch & Müller has developed the bike-mobile E-WERK. Connected to a hub dynamo; the energy is made useable to charge and/or power mobile devices.

• Voltage and current adjustable
• Universal connections (e.g. USB)
• Extensive accessories
• Splash- and rainwater-proof

Universally usable
With this dynamo-connected, universal powering device, voltage (up to 13.3 V) and current (up to 1.5 A) can be adjusted variably in small increments. It charges at velocities of approx. 8 km/h and faster. At only 15 km/h it charges as quickly as standard mains connected chargers. It can be fed with up to 50 V DC, so that operation with an e-bike or car battery is possible as well.

Connection options of the E-WERK
Universal connections for USB, Mini USB, Micro USB. 2 free cables for individual connections. With special plugs for SON and Shimano hub dynamos. Watertight cable screw joints.

Headlamp

You should change standard halogen or incandescent bulbs to LED bulbs.
Some LED bulbs are larger than standard halogen or incandescent bulbs and will not fit inside.
Some LED bulbs are not as bright as halogen or incandescent bulbs (check specifications).

Headlight (High/Low Beam) Light:

Bulb Shape: H4
Base Shape: P43t
Lumen: 2000 lm
Power: 60/55 W (High/Low)
Voltage: 12 V
Low Visibility: 90° Horizontal, 30° Vertical
Low Luminous intensity: White, 86 250 - 101 250 cd (
High Visibility: 10° Horizontal, 10° Vertical
Low Luminous intensity: White, 86 250 - 430,000 cd

2019-05Philips11342ULWX2€72

2019-05Osram9726CW€98

Base: P43t
ECE category: H4
Nominal voltage: 12 /24 V
Nominal wattage: 14.00 W
Luminous flux: 1517/1258 lm
Color temperature: 6000 K
Light color LED: Cool white
Length: 203.0 mm
Diameter: 18.0 mm
Lifespan B3:2500 h
Lifespan Tc: 5000 h
Product type: Off-road

You should change standard halogen or incandescent bulbs to LED bulbs.
Some LED bulbs are larger than standard halogen or incandescent bulbs and will not fit inside.
Some LED bulbs are not as bright as halogen or incandescent bulbs (check specifications).

Headlight (Daytime Running Lamp) Light:

Bulb Shape: W5W
Base Shape: W2.1x9.5d
Lumen: 35 lm
Power: 5 W
Voltage: 12 V
Visibility: 90° Horizontal, 30° Vertical
Luminous intensity: White, 400 - 1 200 cd

2019-05Osram2850WW€12

Base: W2.1x9.5d
ECE category: W5W
Nominal voltage: 12.0 V
Nominal wattage: 1.00 W
Luminous flux: 70 lm
Color temperature: 4000K (Warm white)
Diameter: 10.0 mm
Length: 26.8 mm
Lifespan B3: 2500 h
Lifespan Tc: 5000 h
Product type: Off-road

Jocys.com

Tools
Tools
3D Printer

2018-05Prusai3 MK3€750

• Print technology: Fused Filament Fabrication (FFF) / Fused Deposition Modeling (FDM).
• 0.4mm nozzle (easy changeable) for 1.75 mm filament.
• Build volume 11,025 cm3 (25 x 21 x 21 cm).
• Layer height (layer resolution) from 0.05 mm (50 microns).
• Accuracy: 0.01 x 0.01 x 0.005 mm (10 x 10 x 5 microns).
• Max extruder temperature: 280 °C.
• Max heated bed temperature: 120 °C.
• Supported materials: PLA, ABS, PET, HIPS, Flex PP, Ninjaflex, Laywood, Laybrick, Nylon, Bamboofill, Bronzefill, ASA, T-Glase, Carbon-fibers enhanced filaments, Polycarbonates...

• Integrated LCD and SD card controller (8GB included).
• Automatic mesh bed levelling.
• Heatbed with cold corners compensation (warpless 3D printing from any material).
• Automatic skew axes compensation.
• Hassle free PEI print surface (no glass, no glue, no ABS juice).
• Easy multicolor printing based on layer height.
• 1 kg silver PLA filament included.
• Removable magnetic spring steel sheet with PEI surface.
• EINSY RAMBo motherboard.
• Silent Trinamic drivers with 256 microstepping.
• Faster printing: 200+ mm/s.
• Sensorless homing for X and Y axes.
• Detection and recovery of shifted layers.
• Improved frame rigidity with aluminium extrusions.
• Power loss detection and recovery.
• Better cooling from both sides of the object.
• Optional WIFI with Octoprint interface included.
• Bondtech extruder drive - filament is driven from both sides.
• Optical filament flow sensor with filament presence and movement detection.
• Automatic loading of filament when filament is inserted.
• Detection of jammed extruder with pause print.
• Both extruder cooling fan and print cooling fan detect RPM. When extruder fan is blocked, the printer will stop to prevent damage of extruder. Same applies for the print cooling fan.
• Extra silent Noctua fan.
• New P.I.N.D.A. 2 probe with included thermistor - faster temperature calibration.
• Room ambient temperature sensor.

Uninterruptible Power Supply (UPS) (Optional)

2015-10APCBack-UPS Pro€120-300

You need to disconnect "PSU Power Panic" (black and white twisted) cable from Prusa3D i3 MK3 board. Otherwise, Prusa printer will restart after each power failure.

The Back-UPS Pro family offers guaranteed power protection for high performance computer systems, routers/modems, external storage devices, game consoles and other electronics in your home or business. These UPSs supply electronics with abundant battery backup during outages and stabilize unsafe voltage levels. They also provide power protection from damaging surges and spikes, and allow the use of management software so you get the most out of your UPS. Premium features of this family may include Automatic Voltage Regulation (AVR), an LCD display, Smart Outlets, energy saving functions that reduce electricity use, network manageability, Watchdog, or configurable outlets. Together with the rest of the Back-UPS Pro's standard features, they are the perfect choice to protect your data and keep your system available.

Wire Striping Tool

2016-05C.K Tools495001 Wire Stripper€19

Stripping: 0.2 - 6.0mm²;
Cutting: HRC 40 - 50;
Crimping: 0.5 - 6.0mm² insulated and non-insulated terminals

Non-Insulated Terminal Crimping Tool

Choosing a ToolPressmaster

2016-05Laser1913 Crimping Pliers€33

You can crimp terminals with “C.K 495001”, but with “Laser 1913” it is much easier and faster.

For use on non-insulated terminals, the ratchet motion assures complete crimping. Forged jaws (spare jaws Part No 2927).

For use with non-insulated terminals:
  0.5-1.0mm², 1.5-2.5mm², 4-6mm²
  20-18AWG, 16-14AWG, 12-10AWG

Rubber grip handle for comfortable use.
Spare jaws available - Part No. 2927.
Ratchet motion assures complete crimping.
For insulated terminals use Part No. 0884.

2016-05Klein ToolsVDV205-036 Die Set€16

Induction hardened high-carbon steel

For use with non-insulated terminals:
  0.5-1.0mm², 1.5-2.5mm², 4-6mm²
  20-18AWG, 16-14AWG, 12-10AWG

2016-05HozanP-707€72

2016-0512voltplanetP00456 (YTH-202B)€14

I used 0.5mm² / 20AWG / 1.7mm diameter cable. Laser 1913 Crimping Pliers (0.5-1.0mm² / 20-18AWG) did not crimp insulated part well. I used P00456 (YTH-202B) non-insulated terminal crimping tool (0.3-0.5mm² / 20-22AWG) to crimp insulation part better.

22-26, 26-28
14-18, 20-22
22-26
10-14 16-18 20-22

Drill

2016-05BoschPSB 18 LI-2 Ergonomic€160

Some holes must be drilled in plastic. I used wood drill bits for that.

Comes complete with: Battery pack PBA 18 V 2,5 Ah W-B (1 600 A00 5B0), Double screwdriver bit, Compact quick charger AL 1830 CV (1 600 A00 5B4), Plastic case.

Battery voltage: 18 V
Drill chuck: 13-mm keyless chuck
Drilling diameter in masonry: 11 mm
Drilling diameter in steel: 13 mm
Drilling diameter in wood: 38 mm
Machine weight with battery: 1,3 kg
Max. impact rate: 22.500 bpm
Max. torque: 32 Nm
Max. torque for soft/hard screwdriving applications: 28 / 32 Nm
No-load speed (1st gear / 2nd gear): 0 – 430 / 1.400 rpm
Screw diameter up to: 10 mm
Torque settings: 20 + 2

Accessory Set

2015-01BoschX103Ti€50

18 HSS-TiN metal drill bits, diameter 1-10 mm
7 TC masonry drill bits, diameter 3-8 mm
7 wood drill bits, diameter 3-10 mm
3 spade bits, Titanium, diameter 16/22/32 mm
4 depth stops, diameter 3/5/8/10 mm
40 screwdriver bits:
L = 25 mm
PH 0/0/1/1/2/2/2/3/3/3
PZ 0/0/1/1/2/2/2/3/3/3
S 4/4/6/6/7/7
HEX 3/4/5/6
T 10/10/15/15/20/20/25/25/30/40
8 nutsetters, diameter 5/6/7/8/9/10/11/13 mm
4 HCS holesaws, diameter 32/38/45/54 mm
1 diameter gauge
1 countersink
1 tape measure
1 spirit level
1 Allen key
1 universal holder, magnetic
1 adapter for nutsetters
1 adapter for holesaws
1 hammer
1 adjustable spanner
1 pair of long nose pliers
1 pair of combination pliers

2018-12TackLife (China)PDH06A Step Drill Kit€20

For drilling 19mm hole in cargo box.

TackLife drill bits are not very precise. For example 10mm part diameters: 9.84mm, 9.50mm, 9.94mm

#1: 4 6 8 10 12mm
#2: 3 5 7 9 11 13 15 17 19mm
#3: 5 7 10 12 14 16 18 20 22mm
#4: 3 4 5 5.5 6 7 8 9 10 11 12 13mm
#5: 8 11 14 17 20 22 25 27 30 32 35mm
Automatic center punch

Butane Torch

2016-05DremelVersaFlame Butane Torch€45

You can use gas lighter for heat shrink tubing, but it is much easier to work with Dremel VersaFlame.

VersaFlame™ Multi-function Butane Torch

Integrated ignition button for easy startup, no independent ignition tool required.
Variable temperature and flame control for versatile use in both torch and flame mode.
9-piece kit for wide array of versatile applications.
Detachable base for hands-free operation.
Premium quality for long life, durability.
Filling valve for quick recharge.
Two-year warranty

Accessories

VersaFlame™ Butane Torch
Blower
Deflector
Flame Diffuser
Soldering Tip
Solder, Sponge, Tin, and Wrench
Storage Case
Manual

2016-05NewportButane Gas€12

Newport zero butane is Extra Purified Near Zero Impurities Gas - Perfect to use with Turboflame Lighters,Refilling Butane Lighters, other Butane-Powered Products And other personal needs.

Digital Multimeter

Digital Multimeters • SpreadsheetFluke

2016-01HyelecMS8233D Multimeter€16

2016-01BrymenBM257S Multimeter€121

2016-01BrymenBM867S Multimeter€168

I used multimeter for some measurements and to find right cable ends in “Continuity Test” mode during cable labelling process.

BM869s & BM867s is the next generation high performance industrial multimeter designed to solve complex problems in electronics, plant automation, power distribution, and electro-mechanical equipment. Ultimate choice of resolution, performance, safety and features. New series delivers the accuracy and advanced troubleshooting capabilities you need to solve problems fast. List of features is long: Large 500,000 counts Dual Display, dBm, 12kV Transient Portection, two channels temperature measurement, nS Conductance, High Impedance Voltage, High Accuracy 0.02% DCV, Current & Hz with unique functions:.

Beep-Jack™ – beeps against improper terminal plug in (decreases risk of damage).
VFD V & Hz – Variable Frequency Drives – measures fundamental voltage and frequency of most variable frequency drives.
CREST 1ms – to capture instanteous peaks.
REC – 50ms recording MAX, MIN, MAX-MIN & AVG.
X-Speed Capacitance – measures up to 25mF only in few seconds, 1kV protection.
4-20mA – Process control loop current reading.
T1 , T2 – two channel temperature measurement.

Label Printer

2016-11DymoLabelManager 280€60

For marking cables with labels. D1 Standard Labels 12mm (S0720610) settings:

Font Size: 16pt
Length: Fixed 1.5" (38mm)
Align: Right

With a large graphical display, fast-formatting keys and a long-lasting rechargeable battery, the LabelManager® 280 is your ticket to fast, uninterrupted labeling. The computer-style keyboard is perfect for typing text quickly, comfortably and easily. Plus, PC or Mac®*connectivity enables you to customize labels with fonts and graphics of your choosing from your computer. The LabelManager® 280 prints DYMO D1 labels in 6mm (1/4”), 9mm (3/8”), 12mm (1/2”) widths in a variety of colors – perfect for labeling your files, shelving, equipment and more.

2016-11DymoD1 Standard Labels 12mm (S0720610)€12

Created specifically for your LabelManager® and LabelWriterr® Duo label makers, DYMO D1 labels offer the performance and variety you need for most labeling jobs. They adhere to most clean, flat surfaces – including plastic, paper, metal, wood and glass – and feature easy-peel backing for trouble-free application. Versatile, durable and available in a wide variety of widths and colors, D1 labels take the hassle out of home and office organization.

Black on White
Black on Clear
Black on Yellow
Black on Blue
Black on Green
Black on Red
White on Clear
White on Black
Blue on White
Blue on Clear
Red on White
Red on Clear

Soldering Iron

2016-01WellerBP865CEU€28

2016-01WellerPU 81€110

To solder wires to potentiometer.

Channels: 1
Voltage: 230 V
Heating output: 95 W
Fuse: T800mA
Temperature range (depends on tool) °C: 150 - 450
Temperature range (depends on tool) °F: 302 - 842
Temperature accuracy °F: ± 17
Adjustable temperature range: 50°C - 550°C
Equipotential balance: Yes
Dimensions W x D x H (mm): 170 x 118 x 102 mm

2016-01WellerTip-Activator€9

For regeneration of oxidized tips. Cleaning only possible in hot state of the soldering tip.

2016-01WellerWP 65 Set€152

Heating Element Technologies • PDF

WP 65 - Soldering iron 65 W, 24 V with Power-Response Heating Technology.

XNT A - Soldering tip chisel 1,6 x 0,4 mm.

WDH 10 - Safety rest with Stop+Go function and dry cleaner.

Voltage: 24 V
Heating output: 65 W
Heat-up time (ca) in seconds (50-350°C / 120-660°F): 7
Tip type: HS
Tip family: XNT
Temperature range °C: 50 - 450
Temperature range °F: 150 - 850
Power Response Heating element technology: Yes
Power unit: PU 81, PUD 81, PUD 81i, PUD 121, PUD 151, WD 1M, WR 2, WR 3M, WR 3ME
Safety rest: WDH 10 (T0051512199)
ESD-safe: Yes
WT compatible: Yes

2018-12WellerEL60/40-100€7

2018-12Kester44 Flux-Cored Wire€25

Kester 44 Rosin Flux is an activated rosin formula for use in flux-cored solder wire. 44 has virtually dominated the field of activated rosin core solders for well over four decades. An outstanding performance feature of this flux is the “instant-action” wetting behavior. The high mobility and fast-spreading action of this flux results in more reliable production line soldering. 44 is classified as ROM1 per J-STD-004.

Sn60Pb40 - 0.8mm - 3.3% Flux - melting range 183-190°C
Sn63Pb37 - 0.8mm - 3.3% Flux - melting point 183°C

Protractor

2019-05Android boy's LabSmart Tool App€0

To set 20° angle for holders and brake levers on handlebar.

Smart Tools® is the complete package of 6 individual apps. It has 6 sets below for a total of 15 tools. In a word, All-in-One.

Set 1. Length, Angle, Slope, Level, Thread : Smart Ruler Pro
Set 2. Distance, Height, Width, Area : Smart Measure Pro
Set 3. Compass, Metal detector, GPS : Smart Compass Pro
Set 4. Sound level meter, Vibrometer : Sound Meter Pro
Set 5. Flashlight, Magnifier, Mirror : Smart Light Pro
Set 6. Unit : Unit Converter

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PETG Filament
PETG Filament and Printing Settings

I would not recommend to print parts from ABS (shrinkage is too big) or PLA (low heat resistance).

2018-05Prusa3DBlack PETG 1.75€22

2018-05Filament PMBlack PETG 1.75€22

2018-053DPrintzBlack PETG 1.75€27

About 1.1 kg with 80% infill.

10/10 - Parts printed with 3DPrintz (United Kingdom) PETG black filament had very pleasant high quality look, deep black color and even glossiness on all surfaces (top, bottom, sides). All printing settings in screenshots below. I don't know, who is 3DPrintz PETG filament manufacturer. From design of the spools, this could be NorthBridge (China) sub-brand Kexcelled (China). They claim, that they are "The largest 3D filament manufacturer in East China".

8/10 - Parts printed with Prusa3D (Czechia) and Filament-PM (Czechia) filaments had differences in surface glossiness, especially noticeable on top of the parts. Color blackness was good. Prusa3D and Filament-PM filaments are made by the same manufacturer Plasty Mladeč (Czechia).

6/10 - Parts printed with Real-Filament (Netherlands) PETG filament did not look as good as with other three filaments. Pale-transparent black color, differences in surface glossiness, especially noticeable on top of the parts, warping problems and stringing.

3DPrintz
Prusa3D / Filament-PM
Real-Filament

3DPrintz

2018-05PC JohnsonWindex Original Glass Cleaner€8

For preparing-cleaning heated printer bed before printing with PETG filament.

Water: Water
2-Hexoxyethanol:Cleaning Agent
Isopropanolamine: Cleaning Agent
Ammonium Hydroxide: Cleaning Agent
Lauryl Dimethyl Amine Oxide: Wetting Agent
Sodium Dodecylbenzene Sulfonate: Wetting Agent
Fragrance: Fragrance
Liquitint® Sky Blue Dye: Dye

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Printing Settings
Printing Settings for 3DPrintz PETG Filament

2018-05Prusa3DPrusaSlicer

PrusaSlicer is available for Windows, Mac and Linux

• "Extruder: 220°C".
• "Bed: 80°C".

• "Fill density: 80%".

• "Ensure vertical shell thickness: disabled - I had problems with thin 45° hanging angles with this feature enabled.
• "Perimeters: 3" - infill pattern is less visible on surface.

• Below are modified "0.20mm QUALITY MK3" settings, oriented to reduce printing noise (slow printing speed). There are no violent vibrations with low speeds... this means lesser probability for corners of big parts to unstick from heated bed, because of shrinking.
• Exception is "Speed for non-print moves > travel: 180" - low speed, like 20, creates surface blobs after long travel distances.
• You can print (faster) with default-recommended speed settings. Slower speeds gives smoother and glossier surface without matte areas.

• I added few lines to G-code to solve problems with filament blob on nozzle and intro line wearing surface of steel sheet plate.

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STL Files
STL Files

For better quality and safety... I printed majority of parts separately. To split group and to remove some parts:

1. Open “*.STL” file in PrusaSlicer Edition.
2. Click on [ Split to objects ] button.
3. Select parts one by one, which you don't want to print.
4. Press [ Del ] key on keyboard.

Seam position exceptions: PrusaSlicer > Print Settings > Layers and perimeters > Seam position: [ Rear ]

You can edit STL files with free and open source 3D creation suite Blender.

Import “*.STL” file:

  1. Blender 2.8 > File > Import > Stl (.stl).

If imported STL object is not visible:

  1. Select imported object in “Scene Collection” list (top-right panel).
  2. In “Object Mode“ (top-left drop-down) > Object > Set Origin > Geometry to Origin.

Main_Holder_Left.STL

For NC-17 254 Trekking Bicycle Handlebar 25.4 mm • 22.2 mm

1 x Main Holder Left
1 x Main Holder Left Cover Top
1 x Main Holder Left Cover Bottom - Seam Position: [ Rear ]
1 x Turn Signal Light Spacer
1 x Screw Cover Square
2 x Screw Cover Circle

Main_Holder_Right.STL

For NC-17 254 Trekking Bicycle Handlebar 25.4 mm • 22.2 mm

1 x Main Holder Right
1 x Main Holder Right Cover Top
1 x Main Holder Right Cover Bottom - Seam Position: [ Rear ]
1 x Turn Signal Light Spacer
1 x Screw Cover Square
2 x Screw Cover Circle

Control_Box_Cover.STL

1 x Control Box Cover - Seam Position: [ Rear ]

Control_Box_Plate.STL

1 x Control Box Plate

Control_Box_Parts.STL

2 x Fuse Holder
1 x Indicator Relay Holder
4 x Control Box 1 cm Spacer
2 x Cable Holder
1 x 10mm to 7mm Spacer for Smaller (16mm) Potentiometer

For all knobs - Seam Position: [ Rear ]
2 x Knob for Indicator Relay (10x6mm Knurled Shaft) or 24mm Potentiometer (26x6.4mm Shaft)
1 x Alternative Knob for Indicator Relay (10x6mm Knurled Shaft)
1 x Alternative Knob for 16 mm Potentiomerer (20x6mm Knurled Shaft)

Rear_and_Front_Cable_Boxes.STL

Rear light parts are for Shin Yo 255-700 Universal Stop and Taillight OVAL

1 x Rear Cable Box Cover - Seam Position: [ Rear ]
1 x Rear Cable Box Plate
1 x Rear Light Spacer
1 x Rear Light Screw Nut Holder
1 x Rear Light Screw Nut Holder Cover
1 x Front Cable Box Cover - Seam Position: [ Rear ]
1 x Front Cable Box Plate

Front_Cable_Box_Holders.STL

For all parts - Seam Position: [ Rear ]
1 x Front Cable Box Holder A Left
1 x Front Cable Box Holder A Right

1 x Front Cable Box Holder B Left with 22.2mm Bar for Phone Holder
1 x Front Cable Box Holder B Right

Battery_Holder.STL

For DBPower B07CVF7L77 300A 800mAh Jump Starter

1 x Battery Holder - Seam Position: [ Rear ]
2 x Battery Holder Clip - Seam Position: [ Rear ]

Solar_Panel_Holders.STL

4 x Solar Panel Holder Top
4 x Solar Panel Holder Bottom Spacer - Seam position: [ Rear ]

Label_Helper.STL

For marking cables with labels. D1 Standard Labels 12mm (S0720610) settings:

Font Size: 16pt
Length: Fixed 1.5" (38mm)
Align: Right

You can use needle or punch tool to slide label into helper, to prevent it from sticking to your fingers.

1 x Label Helper Part A
1 x Label Helper Part B

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Assembly
Assembly
Screws and Washers

2 X INDICATOR-BUTTON-MIRROR HOLDER

Handlebar hole:

  • 2 x M5 10mm Low Profile Screw
  • 2 x M5 15mm Outer Diameter Washer
  • 1 x M5 20mm Hexagonal Stud Connector Nut

1. Screw together low profile screw, connector nut and washer (arrows).
2. Insert screwed set into holder's handlebar hole.

Cable box cover hole:

  • 1 x M5 60mm Low Profile Screw
  • 1 x M5 20mm Hexagonal Stud Connector Nut

3. Insert connector nut into holder's mirror hole.
4. Put cover on top of the holder
5. Put shrinking tube on pliers and screw buttons into holder. Be careful. You can scratch paint easily.

Mirror hole:

  • 1 x M8 40mm Magazi MG-1850 Screw
  • 2 x M8 20mm Outer Diameter Washer

Indicator hole:

  • 1 x M8 Nyloc Nut

FRONT CABLE BOX HOLDER

Front cable box holder:

  • 4 x M5 30mm Low Profile Screw
  • 4 x M5 Nyloc Nut

Front cable box holder with 22.2 mm x 42 mm bar:

  • 4 x M5 45mm Low Profile Screw
  • 4 x M5 Nyloc Nut

CONTROL BOX PLATE

Control box plate:

  • 4 x M5 25mm Low Profile Screw
  • 4 x M5 Nyloc Nut

CONTROL BOX COVER WITH BATTERY HOLDER

Control box battery holder:

  • 4 x M5 40mm Low Profile Screw
  • 4 x M5 Nyloc Nut

REAR CABLE BOX PLATE AND REAR LIGHT HOLDER

Rear light holder:

  • 2 x M5 30mm Low Profile Screw
  • 2 x M5 Nyloc Nut

SOLAR PANEL HOLDERS

Solar panel holder with cable clips:

  • 2 x M5 35mm Low Profile Screw
  • 2 x M5 15mm Outer Diameter Washer
  • 2 x M5 Nyloc Nut

Solar panel holder:

  • 2 x M5 30mm Low Profile Screw
  • 4 x M5 15mm Outer Diameter Washer
  • 2 x M5 Nyloc Nut
Cables

Cable lengths may differ for your bicycle.

Cable labeled with “Dymo LabelManager 280”:

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