Eartec Headset Saddles (BB-1) - ToughBuilt bar (one piece)
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What it holds: UltraLITE double, single and EVADE head-form saddles that drop onto the BB-1 bar back block on a ToughBuilt box.

PRINT SETTINGS
  Filament:  PETG
  Walls:     5
  Infill:    35% gyroid
  Orientation: the files are already oriented for printing. Put them on the plate as they load;
               don't rotate them.

FILES AND SUPPORTS
  - EA1_ultralite_double_saddle_TB_T2p5.stl  (supports: no (unless your slicer warns))
  - EA2_ultralite_single_saddle_TB_T2p5.stl  (supports: no (unless your slicer warns))
  - EA3_evade_double_saddle_TB_T2p5.stl  (supports: no (unless your slicer warns))
  - EA1_ultralite_double_saddle_TB_T7p65.stl  (supports: no (unless your slicer warns))
  - EA2_ultralite_single_saddle_TB_T7p65.stl  (supports: no (unless your slicer warns))
  - EA3_evade_double_saddle_TB_T7p65.stl  (supports: no (unless your slicer warns))
  - BB1_EA1_ultralite_double_saddle.stl  (supports: no)
      how it lies on the plate: standing on the y0 end face (STL already oriented), no supports
  - BB1_EA3_evade_double_saddle.stl  (supports: no)
      how it lies on the plate: standing on the y0 end face (STL already oriented), no supports
  - BB1_EA2_ultralite_single_saddle.stl  (supports: no)
      how it lies on the plate: standing on the y0 end face (STL already oriented), no supports

HOW IT MOUNTS
  TOUGHBUILT BAR (ONE PIECE)
    The ToughBuilt StackTech / ClipTech bar hook is printed into the holder (one piece).
    Files with _toughbuilt_T2p5 / _toughbuilt_T7p65 in the name are the same holder with two throat
    sizes: print ONE. T2p5 for a thin (about 2 mm) steel edge, T7p65 for a 7.3 mm edge. If unsure, print
    the ToughBuilt fit coupon from the Test pieces section first. An M5 heat-set insert and an M5
    cup-point set screw clamp it to the bar.

    Notes for this holder: One piece with the ToughBuilt StackTech / ClipTech bar back (BB-1 hook: rear leg behind the plate, bearing pad, Torx-screw pocket, V sight notch). Print the throat that fits your bar: T2p5 (thin ~2 mm steel edge) or T7p65 (7.3 mm edge), per the TB fit coupon. Clamp: M5 heat-set insert + M5 cup-point set screw, pressed in and tightened with a 2.5 hex key through the 8 mm tunnel from the holder's open side. Top level with the plate edge. Prints on its end face like the shipped part, no supports. One-piece versions of all three saddles (UltraLITE double, UltraLITE single, EVADE/PRO16): print the one(s) you need. The older two-piece BB1_* rail saddles remain as this card's direct downloads; to use one of those you also need the separate bar back from the ToughBuilt family: 20_toughbuilt/BB1_bar_back_T2p5.stl or 20_toughbuilt/BB1_bar_back_T7p65.stl (same throat choice). The one-piece files here need nothing else. Also included: the earlier ToughBuilt bar version (BB1_EA1_ultralite_double_saddle.stl, BB1_EA3_evade_double_saddle.stl, BB1_EA2_ultralite_single_saddle.stl).

HOW IT WORKS
  The three Eartec headset saddles for the steel bar on the front of a ToughBuilt box or cart. They hang on the BB-1 bar back block (ToughBuilt Bar Accessories set), with the Magliner slot block replaced by BB-1's segmented dovetail.
  How it holds

  - The band lies across a roof shaped like the inside of a headband, in a trough between an 8 mm back stop and a 5 mm front nub, so it cannot walk off toward or away from the cart.
  - Each ear pad nests in a cradle at the end of the part: a tall oval mouth with a 4 mm deep seat. The band's own spring presses the pads into the seats, so the cups cannot swing on a moving cart. The oval is tall, so the cradle works with the band at any length.
  - The top and front edges of each seat have a 45 deg lead-in, so lifting the headset up or pulling it toward you opens the band by itself. The back and bottom edges keep the full 4 mm, so bumps do not shake it out.
  - Mic boom: swing it UP before you hang the headset. Eartec booms auto-mute in the UP position, so a parked headset is silent on the channel. The boom pivots in the middle of the cup's outer face and stands straight up beside the part. Nothing on the holder touches it.
  - One hand: lower the headset straight down over the part. The pads ride down the trumpet sides and drop into the seats. To take it, lift it straight up.
  Fit: clamp BB-1 on the bar first. Hold the saddle 6 mm higher than its final position, with its teeth lined up with BB-1's gaps, push it in and let it drop 6.3 mm. Lock it with an M3 x 40 bolt and nyloc (or a 3 mm pin) through the cross hole. Its top sits level with the bar's top edge.
  The cups hang about 170 mm below the bar top (189 mm for the EVADE saddle), starting about 27 mm out from the plate face. Before you print, check that the latches and handles of the box under the bar clear the hung headset, and that a hung headset does not stop the box below from opening in a stack (not yet measured).
  Sizes are estimates. Eartec does not publish headset, ear-cup, band or boom sizes. This part is drawn from photos and the published weights, with generous tolerances. Before you print, measure your headset (see "Check your headset") and compare with the numbers here.

OTHER MOUNTS
  The same holder also comes Backstage cart lip (one piece, strongest), Dock (swap between mounts), Mountless (desk, shelf, case or screw to a panel). Pick the mount on the site: https://cart-tools.sdos-placeholder.workers.dev/#bb1-ea1-ultralite-double-saddle

TEST THE FIT FIRST
  Carts, bars and tape rolls vary a little. Before a long print, print the small fit test from the
  Test pieces section of the site (or this part at low infill) and check it on your own gear.

Not affiliated with or endorsed by Magliner, Backstage Equipment, ToughBuilt, Milwaukee, Hollyland, Eartec, Sekonic, Inovativ, Matthews or Manfrotto. Brand names only say what a holder fits.
