Mounting a switch to handle bars?

[HovR]

I'm looking for a way to mount a momentary on/off switch (like this) to handle bars. I want it to be semi-permanent, so no tie wraps.

Anyone got any ideas? Thanks!

 

[MattHB]

Could they be mounted in the end of the bars like end caps? They look of a similar size? Obviously it would mean drilling the bars to pass wiring

 

[Night Train]

A small ABS box with a removable lid like this.

Drill the lid to take the switch and then make a cut out in the back that will fit over the profile of the bars.
Two zip ties that go around the bars and terminate inside the base of the box to secure it. Then use Sugru to make it weather proof around the bars.

 

[HovR]

I'd considered that, although I'm not sure how it would be secured in.

I also thought I could maybe mount them in the bar end caps, however have a screw in the center to lock the caps into the bars, so if I drilled out the center the caps would fall out - And (IME) I don't think push fit plugs would be secure enough.

Edit: The above was aimed at MattHB's post! NT managed to sneak a post in whilst I was writing. :P

 

[biggs682]

what will it br operating and how easy to find does it need to be in the dark

 

[HovR]

what will it br operating and how easy to find does it need to be in the dark

I wondered if anyone would ask. It will be operating this (or some variant thereof). Doesn't need to be illuminated or anything, but would obviously need to be accessible in the dark.

 

[HovR]

A small ABS box with a removable lid like this.

Drill the lid to take the switch and then make a cut out in the back that will fit over the profile of the bars.
Two zip ties that go around the bars and terminate inside the base of the box to secure it. Then use Sugru to make it weather proof around the bars.

Neat idea. Found some small 40x27x17mm boxes on eBay. Thinking of securing them to the bars with something like this (but smaller) for added security.

Still open to any new ideas, though.

 

[Night Train]

It will take a bit of testing to make sure that the box is big enough to keep the switch contacts away from the U bolt clamp.
Alternatively, if you have a motorbike horn and a battery to run it would it be worth getting a whole swtich block from a motorbike and switching your lights too?

 

[buddha]

Could you not wire-to/cannibalise the switch of something like a Knog bike light (or similar small bike light) . I don't know if the switch is a mechanical on/off type, but you could substitute that with something suitable from RS/maplin.
Also, try searching for motorbike handlebar switches.

 

[Night Train]

A microswitch set in Sugru might be a good option too.

 

[HovR]

The main problem with using the original switch, a switch off a bike light, or a micro switch, is that I was planning on using a high-current switch with low gauge (thick) wiring to remove the need for a relay. Notice the switch I linked to is rated at 10 amps, which should suffice, where smaller switches would burn out.

 

[slowmotion]

What kind of battery is going to power the horn? Any idea of its size? This is a nice little design problem.

 

[HovR]

What kind of battery is going to power the horn? Any idea of its size? This is a nice little design problem.

I was planning on using a 4000mAh 12 volt Lithium Polymer (Li-Po) battery - The kind used in serious RC equipment. I've already tested it on the same horn I linked earlier, and it works great.

It's also light, and small enough to fit in my saddle bag!

 

[buddha]

You could still use a low-power switch to trigger a relay/transistor (placed near the battery). Do you want 10A running on/near the handlebars!?

 

[HovR]

You could still use a low-power switch to trigger a relay/transistor (placed near the battery). Do you want 10A running on/near the handlebars!?

My wiring hasn't failed me yet, even in a salty marine environment - But I guess I could hit two birds with one stone and buy a fused relay.