Sofirn SP36 Pro Mount - Bike - 1/4-20 - GoPro

This is a mount for the popular 8000 lumen flashlight from Sofirn - the SP36 Pro. It consists of an internal gasket that engages with the two recesses in the handle and an external shell which uses a 4mm x 35mm screw to secure. The gasket should be TPU. The shell should be a fracture tough material which has moderate heat resistance and strength - PETg should be ideal. The shell should be printed with 100% concentric infill, or set so that you have 6 wall layers to ensure a solid mount. The inner sleeve (gasket) has has 6 dovetails which mate tot he sleeve and I recommend printing the entire assembly as a single print (AMS or XL/multihead) using PLA as the support material for relatively easy removal. The PLA may stick a bit where it comes in contact with the TPU, but it's easy to cut away. The PLA will allow the (relatively) easy separation of the clamshell sleeve - just pull to deflect the shell open and grab the single layer of support between the screw bosses.

This mount is designed for a ¼"-20 screw at the base. I've not offset the threads, so if you print as-is you'll probably want to chase the threads with a tap. That's still not ideal, as modeled threads in PETg may or may not hold up to a violent use like mountainbiking. I've included the Fusion3D model, which is a an utter modeling catastrophe. If you want to change the mount, Sketch 11, is the boss diameter and placement for the threaded mount. Extrusion 22 in the model history is the boss itself and the immediately following fillet and (threaded) hole are for the mount. A word of warning: turn off the gasket(s) before working on the boss thread or the Bodies will likely merge (I told you it was a dumpster fire of a model).  You can re-set that thread to be a hole for a heat set insert (not recommended), model a larger hole for a helicoil (better), or cut through the gasket and add a hole for a T-nut (best option for rough service).

Sketches 3, 4 and 5 are the boss/hole, hex recess, and head recess for the 4mm screw. It should fit both a pan head or socket head screw. The nut might require a little heat to seat fully.  I'd originally intended to use a #8x1.5" screw but the nuts I have are larger than the standard in my nut chart and wouldn't fit, but 4mm is near perfect. You could make the boss bigger to account for that, or even use a #6x1.5" and probably get it to work as modeled (maybe need a little heat to set the #6 nut). 

Again, this is not an elegant or parametric model, so altering it for another flashlight model is probably going to be an exercise in frustration. 

The mount interface in the photos is a (generic) GoPro ¼"-20 to GoPro mount to match the mount on my bike. The third photo shows a test print of the gasket (in PETg) and the shell printed separately to test fit prior to printing the multi-material assembly.