KLite dynamo headlight mount for Surly 8-Pack bike rack

This is a strong, low profile mount for KLite dynamo bicycle headlight and the Surly 8 pack rack. Nice and curvy to match the look of the Klite and rack tubing.

It will not get in the way of a basket or any gear you have attached to the top of the rack. There are no pivots, no moving parts, just a clean mount with a fixed tilt angle. The light itself sits inside a notch so that it can't rotate on it's mounting bolt, and there is a recess for an M5 nylock or nut.

This is designed around the version of the 8Pack Rack with two M5 bosses facing forward, spaced 90mm on centre. There is another (newer?) version of the rack without those bosses, which this part is NOT compatible with.

There are 2 versions included : a 0 degree tilt, and a -3 degree down-tilt. I run my rack ever so slightly tipped up and the down tilt brings the spot beam to where it should be. Pictured is the 3 degree variant.

Parts you will need:

- 1 - 10-12mm M5 bolt for the light. It can be no longer than 12mm because the bolt hole is lined up with the rack tubing.

- 1 - M5 nylock or nut

- 2 - 15mm-ish M5 bolt with flush washers to attach the bracket to the rack.

- Loctite blue or other threadlocker (optional)

Printing:

ASA or at least a PETG fiber composite highly recommended.

100% infill. This bracket will be subject to vibration, jolts, and possibly impact if used on a mountain bike.

The tolerances for the nut are tight but still drop-in so that it will grab as you tighten the bolt. Perhaps do a test print at low infill or in PLA and adjust scaling if needed.

Happy trails!