I came across a project to build a hand crank generator that I thought might be useful to build. It sourced every part except the crank handle!
I scoured e-bay and the local resale shops for a suitable donor handle, and finally, I got my own 3D Printer! Time for my very first self designed project!
Following is the original project I needed this handle for. Not my project and not my video!
The Generator project is here: http://laserhacker.com/?p=642
YouTube build video here: https://www.youtube.com/watch?v=9y4pwcFyLOE
Printed with 5 walls in Cura instead of the default 3 for strength.
Also, I printed it with the shorter, fatter spindle end down and the crank handle up.
This does leave a fair bit of support material under the crank arm, but it prints nice and seems oriented to be sturdy.
The Mad, Mad, Mad World of CAD
After deciding that the CAD software industry was designed by Terry Gilliam as a way to torture people with logical minds, I settled on using SketchUp and whipped this up in 5 minutes. I know it's not a great design, and it was really meant to be a prototype just to see if the dimensions worked etc and it turned out to be stronger than I imagined.
Note that the hole for the generator shaft is intentionally too small so that I could drill it out with a drill bit for a smooth, round, snug fit. The shear pin hole is hand drilled since it looks like the hole location varies on these generators.