Zapf "Impulse" remote bike handlebar mount

This mount allows you to temporarily attach your Zapf Impulse garage door remote to your bikes handlebar. This way you can open your garage door while biking towards it, and close it after you drove out, without having to fumble for the remote in your pockets.

Right now, there is only one Ring diameter available, that only fits handlebars with a diameter of 32mm. I might make other diameters though if there is a need for it.

Materials

Filaments

For the “gasket” part you'll need some FLEX material like TPU. The gasket is deliberately made a tiny bit too large and will get squished, so a solid material gasket will just not fit.

For the other parts I recommend PETG or ASA, because the part is going to be used outside and has to withstand the sun (UV radiation and heat). The “Spring” part needs to be made of a sufficiently bendy material (at a relevant thickness of 1.8mm). 

I made my part from Carbon Fiber filled PETG (for the nice matte finish and because it is a bit stiffer), except for the “Spring” where I used normal PETG.

Parts to buy

You will need:

• Screws:
  • 1 M2x12
  • 2 M3x8
• Nuts:
  • 1 M2
  • 1 M3
• Heat inserts:
  • 1 M3 (at most 7mm long)

How to make

Printing instructions

• Put the “ring” pieces flat on the bed, so that the hinge halves will not need any support
• The “spring” and “gasket” should be printed on its side
• The mount can be printed standing up. But I achieved a more homogeneous look by tilting it backwards 45° and adding just a tiny support column to where it is connected to the ring, so it wouldn't topple over during printing (see picture in gallery). This yields diagonal layer lines which should also increase stability. 
• I designed the pieces for printing with a 0.6mm nozzle, but there should be no issues using a smaller nozzle (e.g. 0.4). 

Assembly

1. Remove the very thin material inside the hinge screwholes using a hobby knife.
2. Insert the heat insert into the hole in the receptacle for the mount on the ring using a soldering iron. 
3. Combine the two parts of the ring with the M2 screw and nut. Do not screw too tight. The hinge should be operable.
4. Cut the gasket open using a hobby knife (if you dont want to push it all the way over your handlebar and unmount everything else from it in the process).
5. Insert the gasket into the ring and use one M3 screw and the nut to close the ring at the “flap”.
6. Put the “spring” into the receptacle on the ring.
7. Put the “mount” on top of the spring, so that the spring ends up in the cutout of the mount.
8. Put the remaining screw into the hole of the mount and through the spring into the heat insert of the ring.

Feel free to reach out if there are any problems.