Segway Minipro Control Bar

thingiverse

This handle replaces the knee control of the Segway Mini-Pro. I live in a rural environment with gravel and dirt roads, and need more control than the knee bar offers. I rode the original Segway, and liked it's handle bar control system. I believe the Mini-Pro has a more delicate control arm construction and this new control bar was constructed to not over stress the original control mechanism. This arm achieves 4 objectives: Better control than the original. Balances like the original. Built in stand. Built in MiniPro carry handle. It is also lighter, locks in place and is as easy to remove. Non-printing materials needed are 3' of 1/2" aluminum rod and 7" of 3/8" aluminum rod or similar. The top knob is small, meant for gripping with 2 fingers. It doesn't need much side to side force to steer. Forward and reverse are handled by balance as before. I think the paddle handle works best. The plastic fitting needs to be strong, so it is printed with no fill except for 30% on the bottom plate. The rest is 6 top, 6 bottom and 6 perimeter layers. I printed in ABS, then brushed it with acetone, then 2 hours in an acetone fume chamber to fully bond the layers and produce a glossy finish. There are 2 drain holes in the inside, fill up between the inner and outer wall, then drain. It will cure overnite. The lock is made with a bit of 1/8" thick or less flat bar bent 90 degrees, drilled and secured with a flat head 3mm bolt screwed from the inside, thru the lock, thru a small spring, secured with a nut and washer. See photo. Print a 1" test section to check for fit on the MiniPro. I printed at 90% extrusion rate, 2400 feet per minute, sitting on the bottom plate. Cooling was 10% fan after the bottom plate. The aluminum rods can be threaded or glued. I threaded mine, 1/2-13. The 7" rod is for the handle / stand. The control bar hole will need to be altered or drilled to 1/2" if glued. The little Tee handle is for the original control bar, as mine broke on first use and I needed something stronger. It is not needed otherwise.