Front light bracket for Racktime TopIt front rack

Motivation

• stock, the Aventon Level.2 front light mounts to the stem

• the handlebar area gets cluttered quickly

• I first tried moving it to the suspension fork arch, but it would get blocked by front panniers

• then I tried simply extending it below the stem

• however, this would still be blocked whenever I have my pogies installed

• I moved the mount backwards on the stem with my old extension bar, but it would simply pitch forward under its own weight, & it still would get blocked by my pogies

• I disregarded this solution for a while, thinking that I wanted to keep the ability to dismount the front rack when I didn't need it

  • but in practice, I never dismounted the front rack for months, so it might as well be considered a permanent fixture of the bike now

  • this position isn't occluded by luggage on the front or sides of the pannier & is independent of my pogies

  • this position may get soaked by rain & road debris from the tire, so I simply hot glue/potted a strain relief area around where the wires enter the case of the light

Commercial product

• sheet metal construction

• note the actual light mount itself projects only a small amount

  • this is problematic since your light, like mine, may have near 0 range to adjust nod angle

Rev 1

• I underestimated how much range I would need

• out of laziness, I didn't print R2 & instead made up the difference with printed M5 spacers & a longer screw to avoid interfering the light with the bracket

• without the spacers, the light points barely in front of the bike

  

Rev 2

• the front rack naturally pitches about 45 deg downward from horizontal, so we need to counteract this

• ASM to verify pitch angle adjustment range before interference with a mockup of the Aventon front light – it can nearly balance out to level

  

Hardware required for R1 & R2

• qty 3 M5 locknut

  • 8 mm across flats, 5 mm tall

• qty 2 M5 x 10-14 mm CBORE or button head

  • to attach bracket to rack

• qty 1 M5 x 20-40 mm

  • to attach light to bracket

Printing

• neither of R1, R2 require supports