Bike Handlebar Mount
Overview
To provide a stable platform for mounting a bike headlight and an action camera to my bike, I wanted to build a very sturdy mount that could clamp to either side of where the stem connects to the handlebar.
This is my end product:
Material and Equipment
1" aluminum square stock
Stainless steel screens
1 1/4" endmill (matches diameter of my handlebars)
Steps
First, I cut two equal length pieces of aluminum stock.
I mounted these into the vice with a little over 1/2" exposed up top.
I milled off 1/2" of material, leaving a 1/4" tab at the left side on one piece, which is the mounting surface for the lights/camera.
For comparison, here are the 2 pieces below a completed mount:
I used the 1 1/4" end mill to bore out the curves for the handlebar. I offset it 0.1" so that there is a gap between the two pieces when they fit together over the handlebar -- this gives space to actually clamp down.
I drilled and tapped the smaller piece to accept #6-32 screws.
The finished product is seem at the top of the page!