Replacement headlight mount for Trek Allant+ e-bike

The Trek Allant+ ebike comes with a headlight that is on a plastic bracket that is pretty delicate. This replaces it and looks way cooler.

Should fit any bike that uses the Herrmans MR8 180 lumen headlight.

I was building an Allant and the original headlight bracket was broken, so I replicated the mount in a design that is both more solid and easily printable. Used it as a stopgap so the original mount could be sumitted for warranty so the customer's bike was 100% OEM, but I believe it would be more durable than the stock version.

This was also designed in 2020 so the stock mount may have varied since then.

Print instructions

As with all things, if you choose to ignore the print instructions, failures of your print are not failures of the design.

Print in any higher temp filament, such as PETG - just don't use PLA if you're going to leave it on in the summer time. PLA would be fine for short term use as long as it's not subject to high temperatures.

Layer height can be anything you choose, but up the shells for strength. You can print at 100% infill but this is completely unnecessary and with 4 or 5 shells it will be more than strong enough.

Supports should be unnecessary, but because there are fillets starting at the print bed, those might turn out a little rough unless you at least start with a lower layer height. A Height Range Modifier in PrusaSlicer from 0-2mm setting layer height to 0.1mm would likely address this but isn't completely necessary for overall part strength.