Over-engineered Omnium Cargo Mini Max front light mount for Supernova E3 Pro 2

The initial goal of this project was to create a mount to attach a Supernova E3 Pro 2 light to the main tube of my Titanium Mini Max. However in doing so with a simple mount placing the light parallel to the horizon I noticed the light would spray in a vertical direction and blind people riding towards me.

I noticed the diffuser of the light is setup in a way to spray light laterally when mounted 'correctly'. So I needed to rotate the diffuser to account for my mounting, however I found the diffuser is mounted on 3 posts that form a triangle and can only be changed by 60 degrees. Therefore I needed a mount that held the light at 30 degrees so I can rotate the diffuser 60 degrees for a total of 90 degree correction. 

I also wanted the light to go underneath the post and not get blocked by it to get the full range of light spray, but also not hit the front tire when turning. This then put the light in clear view of passersby and vulnerable to opportunist thieves.

So in the end I came up with the solution where you can rotate the light out of the way when not in use and rotate it down 30 degrees to the correct position while in use. Remix to suit your needs.

This print is composed of 2 main parts along with a knob for an M6 bolt. I printed in Prusament PC blend natural white with 100% infill.

You will need the following:

3x M3 x 25mm button head screws

3x M3 nuts (nylock strongly recommended)

1x M6 bolt with 10m hex head for knob (total length including head ~25mm)

1x M6 nut (foor knob, nylock not recommended)

1x M6x32-25mm bolt (to attach light, comes with light)

1x M6 nylock nut (to attach light)

Optional:

1x M5x8 grub

Initial Print Prep:

Force a M5 nut into the back (interior) of the FL_OverOut piece where the knob will fit. Adding glue may help to secure. If the nut is protruding from the interior of the printed frame, shave it down with a file until it is flush with the print.

The M5x8 grub is used as a reference locator when rotating the light 30 degrees. Insert the grub into the FL_OverOut hole near where the light attaches, do not screw past the inner right for now.

Initial Light Prep:

This is optional but for me necessary cause I'm a perfectionist and cant sleep at night thinking about these little things.

If using a Supernova E3 Pro 2, the mirrors used to diffuse the light will have to be rotated for optimal light spray. The E3 Pro 2 is meant to mount vertically with the light pointed either upwards or downwards from the mounting point. In this position the diffuser sprays the light further in the lateral direction and restricts it vertically (to not blind people). We want to mount the light sideways therefore the diffuser will need to be arranged to account for this.

To do this unscrew the front of the E3 and remove the plastic diffuser. Use gloves when doing this or else thoroughly clean the diffuser before re-inserting. You may need to press the diffuser quite hard to get it to unscrew, it is thick plastic and there's a heavy spring behind it. 

You'll then find the LED mounted (with thermal paste, so be careful and don't wipe clean) to a metal plate. You'll see the diffuser has 3 pegs that insert into 3 slots forming a triangle. There's only 3 positions it can be mounted each at 60 degrees from one another. 

We want to rotate the diffuser so that the light sprays laterally when fixed at 30 degrees. Hover the light and imagine it attached to your bike at 30 degrees. Now find what angle the diffuser should be re-inserted, we want large sections at the side to be lateral and the slimmer section to be vertical (see image). You may need to rotate the LED mounting plate to get it in the correct position. By rotating the diffuser 60 degrees and then another 30 degrees from the final mount, we can effectively rotate the spray by 90 degrees.

If you don't do this step, the light spray will be wonky and at an angle.

To attach mount:

1. Wrap section of bike frame in electrical tape, no more than two layers thick, to add some grip. (Tip: remove front rack completely for easy access)
2. Fit the FL_OverInn print around the front tube and over the tape. Loosely secure it using 2x M3 screws and nylock nuts. Allow for movement. For this exact bike, there's a notch cutout that will fit into the notch on the cargo tray mounting plate, align to this.
3. Fit FL_OverOut around the FL_OverInn piece. Loosley secure it using 1x M3 screw and nut. Check to see if movement of outer piece over inner is smooth, otherwise remove and sand rough sections.
4. Preliminarily mount the light to help with alignment later, no need to fully tighten yet.
5. Align the outer and inner pieces. The outer has an arrow marker, the inner has a cutout section where the arrow references. Rotate the outer piece until the arrow is within the inner cutout, then tighten the M5 gub screw until it touches and rotate out a half to full turn. Now when you rotate the outer, the grub screw should block full rotation (arrow will remain in cutout reference).
6. Now rotate outer until the arrow is along the right side of the cutout area. This is when the light will be in the lower rotate position.
7. Once aligned, insert the M6 bolt to lightly lock the out to the inner. Rotate full assembly until the light is in the correct position, roughly 30 degrees from horizon.
8. Tighten the 2 M3 screws on the inner ring until mount is secure and doesn't move. You don't need to over-tighten, especially with tape, just tighten until it doesn't move with some force.
9. Tighten the 1 M3 screw on the outer ring until the right slides but with some friction. Re-tighten the grub screw and make sure out right slides with grub screw limiting movement to 30 degree range marked by arrow.
10. Finally align light and tighten securely with nylock nut.