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Handelbar mount for Samsung S5 with wireless Qi charging - weather proof

3D model description

2016-03-28: Update
Version 16 is now ready and tested! Better! Stronger! Smoother!

This is a handlebar mount for Samsung Galaxy S5. It will not only allow you to safely place the phone at a good position for you to see your GPS app, speedometer, music app or whatever, but it will actually allow you to charge the phone at the same time - wirelessly!
Put the phone in the mount, flip the self-locking top and start driving.

Made for a 1" handlebar, but can easily be used on smaller diameter handlebar by just placing a thin rubber sheet or a few layers of electrical tape between the handlebar and the mount.

I've done a LOT of revisions during the last year but were never quite happy with them until now. This is version 16, so a lot of tweaks and practical solutions has been added over time. The size may seem a bit large at first, but it has its reasons;

Stability. You don't want it breaking apart and dropping your precious phone when going 140km/h.
Safety; to add a safe distance for the wireless charger not to be affected by other metal objects, like handlebars.
Clearance. To get clear of any handlebar clamps that fixes the handlebar to the bike. Tested and verified on a Suzuki VL800 Volusia with risers.
Small tweaks:

Self-locking visor/lid. While the visor is closed, it is impossible to move the phone up more than a tiny bit, which in itself locks the visor using the sidebars inside of the visor. Additionally, the air pushes the lid down while riding.
Visor come in three different sizes, print the one you want.
Access to all buttons, including Volume up/down, Home and Power
( Power button requires you to first flip the lid open).
Access to headset jack.
Lower side walls, making it more easy to lift the phone from the mount.
Recess for the camera. Minimizes the risk of scratching the lens.
Immersed holes for nuts and bolts for a clean look and better stability.
Drain holes for rain water.
There are a bunch of Wireless Qi pucks on eBay for about 3€. I bought mine there and it has been working great mounted on my motorcycle since about 10'000 kilometers back (note: this was on an earlier version of the mount - new version is even stronger). Alternatively, disassemble any cheap Qi charger or get a DIY kit and hot glue it to the inside of the center cover - this allows you to line up the charger perfectly with your receiver pad in the phone.

Shopping list:

If your phone don't already have it, you need a Qi receiver for your phone. Search eBay or your favorite electronic store for "S5 Qi receiver".
1 x Qi charger, 69x9mm or DYI kit. Search eBay or your favorite electronic store for "Qi charger". This is often bundled with the S5 Qi receiver, so you can save a buck by buying them together.
5 x M6 bolts, stainless steel with round Allen head. Should be 40mm long (not including the head).
5 x M6 locking nuts, stainless steel.
Total price: less than 7€.
You also need to provide power to the charger. You can either use:

A battery pack with a USB outlet
A standard 12V jack with a cigarette plug to USB.
(these two can be found everywhere)
A 12V to MicroUSB adapter. This is what I use, through a relay to make sure that it's only charging when the bike is running.
For more information see http://www.frankjohansson.com/3d-printed-handlebar-phone-mount-with-wireless-charging-for-galaxy-s5/, where I describe in detail how to assemble it, including the electronics. Lots of photos!

Note: Photos are from version 15, but instructions are identical.

3D printing settings

I printed with PLA at 0.1 height, 75% infill to be on the safe side.

I've been using an earlier version in unpainted PLA for a couple of months and it's held up fine, riding about 50 km/day, but ABS, Nylon or PETG might be better.

USE SUPPORT.
If needed, slowly(!) drill out holes with a 6mm bit to make sure the bolts goes through smoothly.

Place the Qi charger in the main slot of the mount. You may have to remove the top and bottom rubber rings on the charger (they are just glued in place). The MicroUSB port on the charger should be facing down the bottom hole. Then place the the Qi cover over it. If it's not tight enough to stay there, use some silicon, hot glue or sugru on the edges of the cover to keep in place. (make sure the charger is actually working before that), this will keep rain out of your changer. The phone itself is already waterproof.
If the phone is not connecting with the charger, or keeps loosing connection, the charger and receiver are not lined up. Check exactly in what position the receiver is located in your phone, open up the charger case and place the charger coil so that it lines up with the receiver. Use hot glue or Sugru to fasten the charger guts inside the Qi cover.

Attach the whole mount with M6 bolts (from the clamp) to the body (M6 locking nuts). Once they are in position and the mount is at a good angle, tighten the bolts.

Next, place the Lock at the top, lining it up with the to hole in the body. Use an stainless or plastic M6 bolt as hinge center, make sure it's not magnetic (see if a magnet will stick to it). Otherwise, just use a zip tie and you're good to go.

Drive safely.

Creator

Hi! I'm a tinkerer, designer and maker from Sweden. If you like my designs, feel free to leave a comment. :)

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CC BY NC

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