3D Printed Parts for Bicycle Turn and Stop Signals with Front and Rear Lights

DOWNLOAD Version 1.3.2 (2021-06-17) ZIP ~8MB

• Intro • Updates • Parts • Tools • PETG Filament • Printing Settings • STL Files • Cables

Detailed HELP with images on how to assemble parts (external link)...

INTRO

Below you will find parts and tools, which will help you to add turn and stop signals to your bicycle. Not all tools, like multimeter or label printer, are necessary. If you noticed mistakes, have questions or suggestions, know better components (available in EU and US), please write to info@jocys.com • Project page: Jocys.com/bicycle

Parts were printed from PETG with Prusa3D i3 MK3 Printer. If your printer is not precise enough, printed parts may not fit into each other.

If you made your own updates or (file) changes, related to this project, please send me a link. I will add this link to your work on this page.

This project is based on 12 Volts. Bicycle dynamos and lights are, usually, 6 Volts. USB is 5 Volts. Be careful and don't mix wires.

UPDATES

1.3.3 (2021-10-06) • Screw cover for Touratech folding mirror added.
1.3.2 (2021-06-17) • Cargo box parts (control box and rear light box) redesigned.
1.3.1 (2020-10-02) • Added knob for 6.1mm knurled shaft... to fit easier on 6mm plastic shaft.
1.3 (2019-10-28) • Handlebar center parts updated and handlebar box added.
1.2 (2019-09-06) • Indicator-mirror-button holders redesigned.

PARTS

	M-Wave • Amsterdam Cargo Box 1 x The M-Wave Amsterdam Hardbox
	M-Wave Amsterdam Cargo Box Holes PDF File A4 (210 x 297mm) file will help you to drill holes in right places: 1. Print 2. Cut 3. Puncture 4. Drill

NC-17 • 254 Trekking Pro Handlebar
1 x NC-17 254 Trekking Pro Handlebar

BBB • HighSix BHS-28 Adjustable Handlebar Stem
1 x Adjustable Handlebar Stem

SRAM • A3.0 COMP 7 Speed Twist Shifter
My bicycle is equipped with "SRAM 3.0 COMP 7 Speed Twist Shifter". You may not be able to fit 3D printed indicator-mirror holder perfectly between brake lever and different shifter model.

Ningbo Jietong Electronics • E751 (MIRS-201)
2 x Amber color LED for left and right turn indicators.

These switches are more intuitive than Ulincos push buttons, especially, during cycling with gloves.

Operation type: ON/OFF
Pole/way: 1 pole / 1 way
Rating: 16A@12V
Lever type: Illuminated paddle
Terminals: 4.8mm blade
Illumination: Bulb
Panel hole size: 20mm dia.
Overall dims (inc. terminals): 23 (Dia) x 40 (D) mm

Ulincos • U19C2B Latching Push Button Switch
1 x White color LED for front and tail light
1 x Blue color LED for hand brake levers

	TDH (Jiaxing HongFa Motor Vehicle Fittings) • Bike It • Mini Amber Indicators 4 x Mini Amber Indicator
	You should change standard halogen or incandescent bulbs to LED bulbs. Some LED bulbs are larger than standard halogen or incandescent bulbs and will not fit inside.
	Osram • LEDriving PREMIUM 3850WW Not as bright as Bonlux LED bulb. Bonlux • BA9S LED Bulb 12V 4 x Bonlux BA9S LED Bulb 12V Dimension: 10x30mm Base Shape: BA9s Lumen: 300lm

Orafol • ORACAL 8300 Transparent Cal (034 Orange)
White LED lamps can be covered with orange transparent film.

PsmGoods • LED Flasher Relay
1 x LED flasher relay

		Shin Yo • 255-700 Universal Stop and Taillight OVAL 1 x Shin Yo Oval Universal Stop and Tail Light (12v 21/5w bulb)
		You should change standard halogen or incandescent bulbs to LED bulbs. Some LED bulbs are larger than standard halogen or incandescent bulbs and will not fit inside.
		LUYED (China) 1157 3014 78-EX red LED bulb: Brighter than OSRAM LED bulb. All LEDs are lit in “tail only” mode. On pressing brake lever (“stop” mode), all LEDs become brighter. Difference between “tail only” and “stop” mode is minimal and not very distinguishable. You can increased difference between “tail only” and “stop” modes by dimming tail light slightly with 1 kΩ potentiometer.
		Osram (Germany) • 1457R red LED bulb: Not as bright as LUYED LED bulb. Only 6 LEDs are lit in “tail only” mode. On pressing brake lever (“stop” mode), another 12 LEDs light up. Not as bright as LUYED bulb in both modes, but difference between “tail only” and “stop” modes is more distinguishable without dimming tail light with 1 kΩ potentiometer. Currently I prefer LUYED with 1 kΩ potentiometer setup.

CTS Corporation • 026TB32R102B1A1 1 kΩ Potentiometer
1 x 1 kΩ potentiometer for tail light
Some LED bulbs have very small difference between “tail only” and “stop” modes. You can increase this difference by slightly dimming tail light with 1 kΩ potentiometer.

	Star Union (Wuxing) • Brake Lever 2 x E-bike brake lever If you know EU or US e-brake lever manufacturer, please send link to info@jocys.com. I use "noname" brake levers closest to this model: 89PDD.BS68.A
	WASD • O-Ring Switch Dampeners 4 x Blue o-ring (optional) Stop light didn't turn-off with my "noname" brake levers sometimes. I added 2 blue o-rings (2 x 0.4mm = 0.8mm Reduction) under each switch to fix it.

	DBPower • Portable Car Jump Starter Battery 1 x DBPower Portable Car Jump Starter Battery
	Amazon • EC5 Female 10cm Adapter Wire 1 x EC5 Female 10cm Adapter Wire New jump cable version has box at the end of the cable. You will need to buy additional cable with EC5 female connector and add 6.3mm / 2.5 - 6.0mm² non-insulated male and female blade crimp terminal connectors at the ends.

Voltaic Systems (USA) • Solar Panel Kits
Glory Solar • GS6.5-CC Solar Panel Charger
Letsolar • SH51 6.5V/7W Solar Panel Charger
1 x Solar panel charger
Hole diameters are 10mm.

	12voltplanet • MTA UniVal Blade Fuse All LED lights draw about 1A in my setup. I used 11A (0.5mm²) cables and 2A (Grey) fuse. MTA • UniVal 2A Blade Fuse 2 x 2A blade fuse
	Blade Fuse Holder 2 x Blade fuse holder Second version, I bought, was made from harder plastic. To open cap easily, you need to push it sideways first.

12voltplanet • Single 0.5mm² 11A
50m Reel of Single 0.5mm² 11A

48 x 2.8mm / 0.5 - 1.5mm² female
32 x 2.8mm / 0.5 - 1.5mm² male
6 x 6.3mm / 0.5 - 1.5mm² female
3 x 6.3mm / 0.5 - 1.5mm² male
1 x 6.3mm / 2.5 - 6.0mm² female for DBPower battery jump cable
1 x 6.3mm / 2.5 - 6.0mm² male for DBPower battery jump cable
~2m ... 3.2mm / 1.6mm Heat Shrink Tubing (2:1 ratio)
~1m ... 6.4mm / 3.2mm Heat Shrink Tubing (2:1 ratio)
12voltplanet • Non-Insulated Male Blade Crimp Terminal Connectors
2.8mm / 0.5 - 1.5mm² • 3.2mm / 1.6mm Heat Shrink Tubing (2:1 ratio)
6.3mm / 0.5 - 1.5mm² • 6.4mm / 3.2mm Heat Shrink Tubing (2:1 ratio)
6.3mm / 1.5 - 2.5mm² • 6.4mm / 3.2mm Heat Shrink Tubing (2:1 ratio)
6.3mm / 2.5 - 6.0mm² • 6.4mm / 3.2mm Heat Shrink Tubing (2:1 ratio)
12voltplanet • Non-Insulated Female Blade Crimp Terminal Connectors
2.8mm / 0.5 - 1.5mm² • 3.2mm / 1.6mm Heat Shrink Tubing (2:1 ratio)
6.3mm / 0.5 - 1.5mm² • 6.4mm / 3.2mm Heat Shrink Tubing (2:1 ratio)
6.3mm / 1.5 - 2.5mm² • 6.4mm / 3.2mm Heat Shrink Tubing (2:1 ratio)
6.3mm / 2.5 - 6.0mm² • 6.4mm / 3.2mm Heat Shrink Tubing (2:1 ratio)

12voltplanet • Heat Shrink Tubing
GoCableTies • Heat Shrink Tubing Mini Reels (7 Colours)

Magazi • Stark Mirrors MG-1850
2 x Magazi Stark Mirrors MG-1850

Pro-Bolt • Aluminium Washer M8 20mm O/D
4 x M8 20mm Outer Diameter Washer.
Mirrors can be screwed with M8 40mm screws, included with Magazi MG-1850 mirrors.

Accu • Washer M5 15mm O/D
8 x M5 15mm Outer Diameter Washer.

DBA Hardware • M5 20mm hexagonal stud connector nuts
12 x M5 20mm Hexagonal Stud Connector Nut (main holders, handlebar box, control box).

	Open Builds (US) • Low Profile M5 Bolt 30mm Ooznest (UK) • Low Profile M5 Bolt 30mm 4 x M5 10mm (main holders). 8 x M5 15mm (handlebar box). 4 x M5 30mm (control box). 6 x M5 30mm (rear light holder, solar panel holders). 2 x M5 35mm (solar panel holders). 4 x M5 40mm (battery holder). 4 x M5 55mm (or 50mm) (front box). 2 x M5 60mm (main holder).
	Draper • 3.0 mm Hexagon and Ball End Hexagon Key (33602) Tip allows the hexagon key to be used up to 30 degree angle from the screw head recess.

Pro-Bolt • M5 Nyloc Nut • M8 Nyloc Nut
4 x M8 Nyloc Nut.
22 x M5 Nyloc Nut.

Accu • M3 8mm Cup Point Grub Screw (DIN 916)
2 x M3 8mm Cup Point Grub Screw (DIN 916) for knob.

Accu • M3 Square Nut (DIN 562)
2 x M3 Square Nut (DIN 562) for knob.

Henkel • Loctite 243
NOTE: Do not apply too much - I could not unscrew one bolt and broke plastic.
General purpose medium bond strength threadlocker.
Secures and seal bolts, nuts and studs to prevent loosening due to vibration.

Hama • 00178113 Bicycle Bell
2 x Hama 00178113 Bicycle Bell
Bicycle bell for greater road safety with a plastic holder for all common bicycle handlebars.

Busch + Müller • Lumotec AVY E
1 x Busch + Müller Lumotec AVY E

King Serry • KS-SF22R Alarm
Alarm Volume: 113dB
Adjustable Sensitivity Level: 7
Waterproof: IP55 Loudspeaker
Bell Sound Types: 6
Batteries: 3 x 1.5V AAA (included)
Remote Controller: 1 (included)

TOOLS

Prusa • i3 MK3 3D Printer
Print technology: Fused Filament Fabrication / Fused Deposition Modeling.
0.4mm nozzle (easy changeable) for 1.75 mm filament.
Build volume 11,025 cm3 (25 x 21 x 21 cm).
Layer height (layer resolution) from 0.05 mm (50 microns).
Accuracy: 0.01 x 0.01 x 0.005 mm (10 x 10 x 5 microns).
Max extruder temperature: 280 °C.
Max heated bed temperature: 120 °C.
Supported materials: PLA, ABS, PET, HIPS, Flex PP, Ninjaflex, Laywood, Laybrick, Nylon, Bamboofill, Bronzefill, ASA, T-Glase, Carbon-fibers enhanced filaments, Polycarbonates...

C.K Tools • 495001 Wire Stripper
Stripping: 0.2 - 6.0mm²;
Cutting: HRC 40 - 50;
Crimping: 0.5 - 6.0mm² insulated and non-insulated terminals

Choosing a Tool • Pressmaster
Laser • 1913 Crimping Pliers
You can crimp terminals with “C.K 495001”, but with “Laser 1913” it is much easier and faster.
For use on non-insulated terminals, the ratchet motion assures complete crimping. Forged jaws (spare jaws Part No 2927).
For use with non-insulated terminals:
0.5-1.0mm², 1.5-2.5mm², 4-6mm²
20-18AWG, 16-14AWG, 12-10AWG
Klein Tools • VDV205-036 Die Set

Hozan • P-707
12voltplanet • P00456 (YTH-202B)
I used 0.5mm² / 20AWG / 1.7mm diameter cable. Laser 1913 Crimping Pliers (0.5-1.0mm² / 20-18AWG) did not crimp insulated part well. I used P00456 (YTH-202B) non-insulated terminal crimping tool (0.3-0.5mm² / 20-22AWG) to crimp insulation part better.

Bosch • PSB 18 LI-2 Ergonomic
Some holes must be drilled in plastic. I used wood drill bits for that.

Bosch • X103Ti

TackLife (China) • PDH06A Step Drill Kit
For drilling 19mm hole in cargo box with 3-5-7-9-11-13-15-17-19mm drill bit.
TackLife drill bits are not very precise. For example 10mm part diameters: 9.84mm, 9.50mm, 9.94mm

Dremel • VersaFlame Butane Torch
You can use gas lighter for heat shrink tubing, but it is much easier to work with Dremel VersaFlame.
Newport • Butane Gas
Extra Purified Near Zero Impurities Gas to use with Turboflame Lighters, Refilling Butane Lighters, other Butane-Powered Products And other personal needs.

Spreadsheet • Fluke
Brymen • BM235 Multimeter
Brymen • BM867S Multimeter
I used multimeter for some measurements and to find right cable ends in “Continuity Test” mode during cable labelling process.

Dymo • LabelManager 280
For marking cables with labels. D1 Standard Labels 12mm (S0720610) settings:
Font Size: 16pt
Length: Fixed 1.5" (38mm)
Align: Right

Dymo • D1 Standard Labels 12mm (S0720610)
Black on White, Clear, Yellow, Blue, Green, Red
White on Clear, Black
Blue on White, Clear
Red on White, Clear

Weller • BP865CEU
Weller • PU 81
For soldering wires to potentiometer.

Weller • Tip-Activator
For regeneration of oxidized tips. Cleaning only possible in hot state of the soldering tip.
Weller • WP 65 Set
WP 65 - Soldering iron 65 W, 24 V with Power-Response Heating Technology.
XNT A - Soldering tip chisel 1,6 x 0,4 mm.
WDH 10 - Safety rest with Stop+Go function and dry cleaner.

Weller • EL60/40-100
Kester • 44 Flux-Cored Wire
Sn60Pb40 - 0.8mm - 3.3% Flux - melting range 183-190°C
Sn63Pb37 - 0.8mm - 3.3% Flux - melting point 183°C

Android boy's Lab • Smart Tool App
To set precise 0° angle for indicator-mirror-button holders.

PETG FILAMENT

You will need about 1.1 kg with 80% infill
I would not recommend to print parts from ABS (shrinkage is too big) or PLA (low heat resistance).

I had no problems with these filaments:
Prusa3D • Jet Black Prusament PETG 1.75
MCPP • BasicFil Black PETG 1.75
Amazon • AmazonBasics Black PETG 1.75
3DPrintz • Black PETG 1.75

Brand	3DPrintz	Prusa3D (Prusament)	Amazon (MCPP)	Prusa3D (Filament PM)	Real Filament
Region	UK	Czechia	EU	Czechia	Netherlands
Overall (out of 10)	9.9	9.8	9.6	8.6	6.5
Color blackness-darnkness	9.4	9.6	10	9	6
Uniformity of surface glossiness: top (sides)	10	9 (10)	8 (9)	7 (8)	6
Stringing	10	10	10	8	6
Warping	10	10	10	10	8

PC Johnson • Windex Original Glass Cleaner
For preparing-cleaning heated printer bed... Spring Steel Sheet with Smooth Double-sided PEI before printing with PETG filament.

Water: Water
Cleaning Agent: 2-Hexoxyethanol, Isopropanolamine, Ammonium Hydroxide
Wetting Agent: Lauryl Dimethyl Amine Oxide, Sodium Dodecylbenzene Sulfonate
Fragrance: Fragrance
Dye: Liquitint® Sky Blue Dye

SHL • Isopropanol / Isopropyl Alcohol / IPA
NOTE: I didn't test-print parts for this project on Textured PEI Powder-coated Spring Steel Sheet.

For preparing-cleaning heated printer bed... Double-sided Textured PEI Powder-coated Spring Steel Sheet before printing with PETG filament.

For thin parts to stick correctly, you may need to adjust height of first layer perfectly and to reduce "Elephant foot compensation" from default value 0.2mm... to 0.1mm.

Modified settings: PrusaSlicer ► Print Settings ► 0.20 QUALITY MK3 ► Advanced ► Slicing...

Isopropanol 99.9% / Isopropyl Alcohol / IPA
Manufacturer Part Number: 1000-ISO-TRIGGER
Trigger spray cap for bottles with a 28mm neck (OFF, Spray, Stream)
1 Litre

Kleenex • Ultra Soft Pocket Tissues
For preparing-cleaning heated printer bed.

PRINTING SETTINGS

Printing Settings for 3DPrintz PETG Filament on PrusaSlicer
...for Spring Steel Sheet with Smooth Double-sided PEI

For BIG parts to stick on TEXTURED PEI Powder-coated Spring Steel Sheet sheet, I increased recommended bed temperature from 60-80°C (for AmazonBasic and MCPP BasicFill PETG filaments) to 85°C (First layer) and 90°C (Other layers). I printed BIG parts in my own Temperature Controlled Enclosure. Temperature inside enclosure was about +45°C with these bed settings.

Prusa3D • PrusaSlicer

Modified settings: PrusaSlicer ► Filament Settings ► Prusament PETG ► Filament
• "Extruder: 220°C".
• "Bed: 80°C".

Modified settings: PrusaSlicer ► Print Settings ► 0.20 QUALITY MK3 ► Layers and perimeters
• "Ensure vertical shell thickness: disabled" - I had problems with thin 45° hanging angles when it was enabled.
• "Perimeters: 3" - infill pattern is less visible on surface.

Modified settings: PrusaSlicer ► Print Settings ► 0.20 QUALITY MK3 ► Inflill
• "Fill density: 80%."

Modified settings: PrusaSlicer ► Print Settings ► 0.20 QUALITY MK3 ► Speed
• Reduced printing speeds (10-20-180-400). Slower speeds results in smoother and glossier surfaces without matte areas, reduces printing noise with vibrations... lesser probability for corners of big parts to unstick from heated bed, because of shrinking.
• "Travel: 180" - low speeds (like 20) creates surface blobs after long travel distances.
• "First layer speed: 10" - for better adhesion.

Modified settings: PrusaSlicer ► Printer Settings ► Original Prusa i3 MK3S ► Custom G-code
• I added few lines to G-code to remove filament blob on nozzle right before printing starts and raised intro line to reduce wearing of steel sheet plate surface.


G1 Z50 ; ADDED LINE --- Z Up to clean filament blob from nozzle

G1 Z-50 ; ADDED LINE --- Z Down

G1 Z0.50 ; ADDED LINE --- Z Up for less intro line adhesion to prevent surface of steel sheet plate from wearing

STL FILES

For better quality and safety... I printed majority of parts separately.

To split group and to remove some parts:
1. Open “*.STL” file in PrusaSlicer Edition.
2. Click on [ Split to objects ] button.
3. Select parts one by one, which you don't want to print.
4. Press [ Del ] key on keyboard.

	You can edit STL files with free and open source 3D creation suite Blender.
	Import “*.STL” file: 1. Blender 2.8 ► File ► Import ► Stl (.stl). If imported STL object is not visible: 1. Select imported object in “Scene Collection” list (top-right panel). 2. In “Object Mode“ (top-left drop-down) ► Object ► Set Origin ► Geometry to Origin.

Main_Holder_Left.STL
For NC-17 254 Trekking Bicycle Handlebar 25.4 mm • 22.2 mm
1 x Main Holder Left
1 x Main Holder Left Cover Top
1 x Main Holder Left Cover Bottom
1 x Turn Signal Light Spacer
1 x Screw Cover Square
2 x Screw Cover Circle

Main_Holder_Right.STL
For NC-17 254 Trekking Bicycle Handlebar 25.4 mm • 22.2 mm
1 x Main Holder Right
1 x Main Holder Right Cover Top
1 x Main Holder Right Cover Bottom
1 x Turn Signal Light Spacer
1 x Screw Cover Square
2 x Screw Cover Circle

Control_Box.STL
1 x Control Box - Seam position: [ Rear ]

Control_Box_Cover.STL
1 x Control Box Civer - Seam position: [ Rear ]

Control_Box_Parts.STL
1 x Indicator Relay Holder
2 x Cable Holder
2 x Control Box 1 cm Spacer A
4 x Control Box 1 cm Spacer B
1 x 10mm to 7mm Spacer for Smaller (16mm) Potentiometer

For all knobs - Seam Position: [ Rear ]

2 x Knob for Smooth 6.4mm Shaft
1 x Extended Knob for Knurled 6mm Shaft
1 x Knob for Knurled 6mm Shaft (with square dent)
1 x Knob for Knurled 6.1mm Shaft (with circle dent)

Battery_Holder.STL
For DBPower B07CVF7L77 300A 800mAh Jump Starter
1 x Battery Holder
2 x Battery Holder Clip

Rear_Light_Holder_and_Cable_Box.STL
Rear light parts are for Shin Yo 255-700 Universal Stop and Taillight OVAL
1 x Rear Light Cable Box Cover - Seam Position: [ Rear ]
1 x Rear Light Cable Box - Seam Position: [ Rear ]
1 x Rear Light Cable Box Spacer
1 x Rear Light Spacer
1 x Rear Light Screw Nut Holder
1 x Rear Light Screw Nut Holder Cover

Front_Box_Holders.STL

For all parts - Seam Position: [ Rear ]

1 x Front Cable Box Holder A Left
1 x Front Cable Box Holder A Right

1 x Front Cable Box Holder B Left with 22.2mm Bar for Phone Holder
1 x Front Cable Box Holder B Right

Front_Cable_Box.STL

1 x Front Cable Box Cover - Seam Position: [ Rear ]
1 x Front Cable Box Plate

Front_Handlebar_Box.STL
Can fit anti-theft alarms, like King Serry KS-SF22R
1 x Front Handlebar Box Cover - Seam Position: [ Rear ]
1 x Front Handlebar Box Plate
1 x Front Handlebar Box Insert

Solar_Panel_Holders.STL
4 x Solar Panel Holder Top
4 x Solar Panel Holder Bottom Spacer - Seam position exception:
PrusaSlicer ► Print Settings ► Layers and perimeters ► Seam position: [ Rear ]

Label_Helper.STL
For marking cables with labels. D1 Standard Labels 12mm (S0720610) settings:
Font Size: 16pt
Length: Fixed 1.5" (38mm)
Align: Right
You can use needle or punch tool to slide label into helper, to prevent it from sticking to your fingers.
1 x Label Helper Part A
1 x Label Helper Part B

Parts for Bicycle Turn and Stop Signals with Front and Rear

0.2mm layer, 2 walls, 15% infill