A sketch and a caliper
The goal was simple: aim a pair of auxiliary lights slightly down at the road, with a bracket strong enough for an adventure bike, low-profile, fully adjustable — and printable on a desktop 3D printer. Everything below grew from that one photo.
From a sketch to a mounted prototype
A dozen iterations, a handful of gotchas. The interesting bits:
Tall discs → flat half-moon
The first idea — two stacked serrated discs — stood too tall. A flat serrated "half-moon" trough that the light nests into brought it low and compact.
Pitch, not heading
Getting the rotation axis right so the light tilts down toward the road — never sideways. Locking, indexed teeth set the angle.
The fastener that didn't fit gotcha
An M6 nut was physically wider than the gap between the light's mounting posts — no orientation worked. Dropped the clamp to M5, which fits exactly.
A bolt head jammed the tilt gotcha
On the first print the M4 screw head stuck out past the teeth and hit the other part, blocking the adjustment. Fix: recess the head deep into the body, well clear of the mesh.
The clamp head moves on an arc gotcha
As you tilt the light, the clamp bolt head slides along an arc — so the three bike-mounting holes had to be moved off to the sides to stay out of that sweep.
It hangs upside-down
On this bike the light mounts pendant, below the bracket. So the clamp arc was made symmetric (works either way up) and the captive nuts got retention clips so they don't drop out.
Then the unglamorous part gotcha
A non-manifold export, slicer support warnings, a g-code path conflict — each verified and ironed out before it ever hit the printer.
Mounted
First real prototype on a KTM 890 Adventure R. Now the fun part: ride and test.
The two parts in 3D
Part A clamps to the light, Part B bolts to the bike; the serrated teeth between them set the angle. Drag to orbit, scroll to zoom.
Print it yourself
Free to download and print. The main file holds both parts of one mount, laid out and oriented to slice.
Mounted on the bike
Printed in ASA, assembled, and bolted to a KTM 890 Adventure R.
Built by the FastGIS Mobile team
This mount is open hardware from the people building FastGIS Mobile — the adventure-riding navigator that finds the curves, follows the TET and captures every ride. Launching soon on iOS & Android.
See the app →