Deck rail mounting system for LED light strings

This is group of models that I printed to mount LED string lights to my upper deck.
4h 57m
4× print file
0.30 mm
0.40 mm
81.00 g
4
9
0
176
updated April 26, 2023

Description

PDF

I'm in the process of adding LED canopy lights to my upper deck.  Since this is my upper deck, I needed to design holders for electrical conduit pipe that I will string the lights from.  I created and printed several models to accomplish this.

A bracket for my vinyl railing with spacers to help keep in place.

A bottom mount to attach to my deck.

A pipe cap so water doesn't run into the top of the pipe.

The bracket, bottom mount and pipe cap models use PrusaSlicer's Negative Volume feature to create the hole in the cylinder for the conduit to slide through.  Open the model file and reslice in PrusaSlicer to generate your own GCODE.  I did not include STL files because they don't reflect the Negative Volume feature.

The bracket goes over the top rail of a vinyl deck rail made for holding electrical conduit pipe you would find at your hardware store.  I used the conduit to mount LED light strands between the deck rail and house on my deck.  This bracket works with the spacers and bottom mount to keep the conduit from sliding around.

I printed the bracket in PETG in 0.3mm draft mode with only 10% infill using the gyroid pattern in PrusaSlicer.  This gives flexibility when needed.  IMPORTANT - You need to install this bracket over the rail when it is warm, otherwise it will break.  I just took mine directly off the print bed and stretched it carefully over the top of the deck rail.  Failure to have the part warm will cause it to break.

I printed the spacers in PETG in .3mm draft mode as well with 40% infill and 4 Perimeters. This helps to keep the printed model from squashing too much.  Once you install the bracket, you need to print the spacers to put between the bracket and the lower rail.  Once you have this in place, secure each spacer with a screw to hold it in place.  Make sure the screw is long enough to go through the deck railing.  This will hold the bracket from sliding side to side in case of wind.  I used Teks Self-Drilling Screws Metal-To-Metal, #10 1 ½" length.  BE SURE TO DRILL A PILOT HOLE!!!  Even though these are self-drilling, you will want to drill a pilot hole and tighten these by hand.  If you do not, you will crush your print.  A simple 5/16 nut driver will allow you to control the amount of tension you put on your mount.

The bottom mount is also printed in PETG in .3mm draft mode with 20% infill and the grid infill pattern.  Attach this bottom mount to your deck using long screws.  I used 3 5/8" screws. The conduit should slide right into the hole in the mount.

The Pipe cap is printed in PETG in .3mm draft mode with 20% infill and the grid infill pattern. Slide this over the top of your conduit to keep the rain from collecting in the pipe.

This is a work in progress, so if you have any questions or suggestions, let me know.

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