/Bike/BoxClip.foocad

Clips onto my bike rack and permanently attached to a box (or anything else of my choosing).

Usage : Clip 2 or more clips onto the bike's rack, and apply hot-glue to the flat surface. Place the box onto the clips and wait for the glue to set. Take the box and clips off the bike, and make holes through the box and attach permanently with wood screws. The hot-glue is only to aid alignment (the rack isn't square, so calculating hole positions is tricky!).

Use washers inside the box to spread the load; otherwise the box may rip when removing from the bike.

FYI, the box I'm using is an old unwanted drill case.

Print using PETG or other semi-fleximble filament (PLA is too stiff).

FooCAD Source Code

import uk.co.nickthecoder.foocad.screws.v3.*
import uk.co.nickthecoder.foocad.threaded.v2.*
import uk.co.nickthecoder.foocad.smartextrusion.v1.*
import static uk.co.nickthecoder.foocad.smartextrusion.v1.SmartExtrusion.*

class PannierClip : AbstractModel() {
    
    @Custom
    var thickness = 24
    
    @Custom
    var screwPitch = 1.5

    @Custom
    var shimSize = Vector3( 24, 44, 2 )

    @Piece
    meth clip() : Shape3d {
        val angle = -90 + 13.5

        val doc = SVGParser().parseFile( "pannierClip.svg" )
        val fiveP = doc.shapes["fivecm"] // A 5cm rectangle. Used to scale to the correct size.
        val scale = 50.0 / fiveP.size.x

        val main = doc.shapes["main"].scale(scale).rotate(angle)
            .smartExtrude( thickness ).edges(Chamfer(0.6))
            .centerXY().translateX(3.5)

        val top = Square( 44, thickness ).roundAllCorners(2,1).center()
            .extrude( 3 )
            .rotateX(-90)
            .bottomTo(0)
            .frontTo( main.back -3 )

        val sides = Square(10, thickness).roundAllCorners(2,1)
            .smartExtrude( 10 )
                .bottom( Chamfer(2) )
            .rotateX(-90)
            .bottomTo(0).leftTo( top.left ).backTo( top.front )
            .mirrorX().also()

        val holes = Thread.woodScrew( screwPitch )
            .threadedHole( 16 )
            .rotateX(90)
            .centerZTo( sides.size.z/2 )
            .backTo( top.back )
            .centerXTo( -17 )
            .color("Red")
            .mirrorX().also()

        return main + top + sides - holes
    }


    @Piece
    meth washer() : Shape3d {
        val block = Circle(10).smartExtrude(4)
            .top( Chamfer(2) )
        val hole = Countersink().topTo( block.top )

        return block - hole
    }

    @Piece
    meth jig() : Shape3d {
        val real = clip().rotateX(-90).bottomTo(0).centerY() - Cube( 100 ).center().bottomTo( 1 )
        val main = Square( 44, thickness ).roundAllCorners(3).center().extrude(1)
        val holes = Cylinder( 3, 2 ).bottomTo(-1).translateX( -17 ).mirrorX().also()

        return main - holes + real.previewOnly()
    }

    @Piece( about="The box has an uneven surface which needs shims to make flat." )
    meth shim() = Square( shimSize.x, shimSize.y ).roundAllCorners(3).extrude( shimSize.z )

    override fun build() : Shape3d {
        return clip()
    }
}