First let me say that I did mention that it needs to be tweaked, now that I have some time, I see it needs a lot of tweaking. Maybe this is why no one else has done this yet!
Here is a render of what the mount would look like with a BOLT on it (angled so you can see the issues).
The BOLT requires a twist of approximately 68° from insertion to locking in place. You should be able to see that with 5 cm from center to center there simply isn't enough room even if the clamp were not in the way.
The clamp, I am not sure how good it works but I did build an out-front mount for another cyclist on these forums that uses the same mechanism, Try sending @nathanong87 a PM and ask him how the out-front mount works and if he had issues getting it around the bars. The Extension bar is smaller so I might need to thin them a bit. The nylon is flexible until you have around 4 mm of thickness then it is incredibly rigid.
I can't build in a hinge and the reason I don't initially make the clamps in two parts is that Shapeways (as with most print services) hates multi-part prints because it requires more human interaction. And if they lose a part they generally just reject the print instead of reprinting it. I can put the two parts together with a ring that will hold them during printing and polishing.
About the bottom cover, there are several reasons I don't include it and people like Raceware don't use it.
- It adds to the cost of the print, and is just another part that Shapeways has to keep track of.
- There is literally no way for me to tether it to the other parts, so it is treated as a separate piece with an increase in human handling and associated cost increase.
- Raceware doesn't use it because they build their mount out of solid nylon with the entire form modeled in place, it is heavier and more costly to do it this way, we are Weight Weenies after all.
- Until recently there was no way to match the smooth surface of the original mount, so in an effort to look more finished when the mount is on the bike, I resorted to reusing the bottom cover, Professional Plastic may solve that issue.