Introduction: Bicycle Handle Bar Mount for IPhone 3gs/4/4S

I took up riding again after a long hiatus this past summer. I owned an iPhone 3GS and wanted to be able to secure it to bike to allow me to listen to music and run a GPS App (Cyclemeter or RunKeeper) to track my progress.  I looked everywhere and could not find a mount and case combo that would adequately protect my iPhone.  I wanted a Case that was waterproof and I wanted the phone to be also protected if I took a nose dive.  So I settled on a simple mount that is sturdy and a Pelican Case that should protect the phone from a nuclear blast.  The total cost of the mount was about $8-$10, most of that for the Lexan.  The case runs about $25 on Amazon.  

The case is bulky, but that is good as the bulk protects the phone.  It has a pass through iPhone compatible Headphone adaptor, allowing you to plug your headphones in to the box, then a wire in the box is plugged into the phone.  Headphones with buttons can control the phone.  

This is not a difficult project and skill level is pretty low.  The tools I used included a Chop Saw to cut Lexan (but there are cutting tools for that), a Dremel tool to cut slots, and a drill.  

Please be aware that all I do is ride a hybrid bike (Trek 7.3) on streets and a Rails to Trails system near my home.  So I do not want to suggest that this mount could handle the stresses of a Mountain Bike Ride.  

Step 1: The Parts

The Bicycle Mount is made of a Conduit Clamp and the sheet of lexan.

Parts: 

         Sheet of Lexan - I bought an 8x10 piece from Lowes that was 0.093inch thick.  I cut to 3" x 7" (approx)
         One 1.5" Conduit Clamp found at Lowes. This is used to hold electrical conduit to a wall or joist. Measure your Handle bars or        
                  Stem to determine the correct size clamp.
         One Pelican i1015 iPod Case from Amazon. 
         Velcro Strap (1/2" wide) from Lowes
         Sugru from http://www.sugru.com  This a silicone based product that molds like clay, cures at room temp in 24 hours.  
         One 10-32 Bolt 3/4" Length, Nut, 2 Washers, and 1 Lock Washer

Tools:

         Chop Saw to cut the Lexan.  But anything can be used.  THere are special knives.  I would use a steel straight edge with a knife.  
         Hand Sander or Sandpaper - used to smooth the rough edges of the lexan after cutting
         Dremel Tool with Cutting Disk.  Used to make clots for the Velcro
         Drill for hole

Step 2: Cut the Lexan

Take the case that you are going to use for your phone and lay it on the sheet of Lexan.  Measure a piece just slightly smaller than your case. I eyeballed mine and it was about 3" x 7" (maybe 6").  Cut the Lexan with a chop saw or other tool.  

Use sanding paper (150grit) with a power sander or sanding block to sand the edges of the Lexan.  

One could use a Jig Saw, Coping Saw, or Scroll Saw to round off each corner, to make it slightly nicer. 

After preparing the Lexan, take a Dremel tool with a cutting Disk.  Make marks at either end of the Lexan, about 1/2" wide.  Wide enough for the Velcro straps.  I cut the slots (you might want to practice on a scrap piece) and then used a box cutter to clean up the slots.  The slots are located about 1/2" from the outside of the Lexan.  

Take the Drill and Drill bit and drill a hole in the Lexan to accept the 10-32 screw.  I offset my hole to allow the Case to be mounted slightly forward on the Handle Bar.  I suggest holding up the Lexan to the Bike to figure out where to drill.  

Step 3: Mount the Bracket to the Bike and Case

I wanted my case mounted on the Stem, some would prefer the Handle Bars.  The Conduit Clamp can be rotated to suit either method.   I also took a piece of Velcro strap and put a piece around the stem, so it would rest under the Conduit Clamp.  That way it would protect the Stem's finish.  

The Case attaches with two pieces of Velcro Strap cut to length.  Keeps it secure for the type of biking that I do.  

Make certain that you use the lock washers.  When I did not use lock washers the case loosened on the clamp and rotated 90 degrees.  Due to the length of the 10-32 bolt, the nut could not fall off, but it was a pain.  The lock washer works like a charm.  

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