My ebike water bottle mount inserts stripped out (easy alternative)

silverback

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Mostly only kit bikes apply but there are always exceptions. It was more of a question of when the threads would strip not if. The two threaded protrusions in the frame aren't ideal for supporting a full size battery like mine. Even when the screws were cinched down firmly the battery had some wobble in it. The worst part was when it loosened off causing the battery poles to disengage and cut all power. Every time it would happen (about once a week) I'd think to myself I'm going to fix that d*m thing tonight for sure. Obviously I didn't and the screw threads finally blew out. I'm only surprised it didn't happen sooner, it was like that for daily riding.

You can see how I mounted the battery. And how I mounted it better. As soon as they upload.

Its a inexpensive fix and some personal peace of mind. All you need is two long carriage bolts. I always use stainless steel because there's nothing worse then rusty screws.


Long enough to pass through the frame bar, the battery mount, rubber and metal washers , and a polymer retaining nut. Polymer coated thread it won't back off at all. Pretty sure that's how they got the name "poly'locs". Or you can use a drop of red lock tite. I prefer to use polymer nuts every time I use bolts when they suit the mechanics. And there tensile strength is adequate.

I wouldn't use them inside of an engine of course, but almost everywhere else. I trust them unless there frequently turned manually. The plastic does eventually wear out to a point you can easily turn them with just your fingers. It takes turning them dozens and dozens of times but it eventually does happen. For a battery mount there's no reason to doubt them at all.
 

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I'm performing the surgery with love and surgical care , thanks for all concern.

If and when I add metal bracket with thick pliable rubber bushing, cinched down not over tightened, with double carriage bolts. In theory it should be stronger in that area.

Maybe you can see why I like that version so much, its the only year with that frame shape and the thick ass down tube . Its nice and flat underneith, and egg shaped around the other side. Oval. thats the one. The down tube is SO fat along with the high quality aluminum S used. 4 small holes shouldn't jeopardize it at all. Its not my first rodeo ppl have questioned rigidity of the frame since people have modifiide things. A lot of people imply it could snap. True it has happened before. But not all curcumstances are equal. Pretty soon the general idea is bad. I don't believe that. Not that its always a good idea either.

You can twist this kind of metal, severely and it doesn't want to break Its tough and light. I wouldn't attempt this with other material like CF or different metals.

Carriage bolts are great. when something is obstructing a side. I couldn't find 6" bolts with smaller thread. Two sizes to be exact, I tried 3 different stores. In the end I drilled out one of the inserts, left the hole the same sized. A new thred rivet can be tapped in place if someone prefers it. I might ride then retire this one when I'm ready for something else to play with.

Its an E bike now and some things you cant get around. This is better than a frame bag or back rack. I try to keep parts low key and work them in discreetly as possible. I like that frame, and yes I am cutting on it HAHA. A battery just doesn't hide that well.

When I built the bike I intended to drill to bury the derailleur cable. I figured it clutters up the frame under the down bar. I was aiming to keep that area minimal to just the bar, nothing stuck to it at all.

In the end this is a way better trade off. Epower is great, these bikes sizzle.

Tomorrow I can put them in my vice and shave off some material in order to set them low enough. I also countersunk the aluminum piece on the battery bracket to sink it down another hair or two. The battery won't lock in place if there's a 1/16" obstruction.
 

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you can see how flat the bar is down there. Key feature I liked anout that frame. and the sloping tail. Better than that is how comfortable it feels. Unless you are pedaling it for 10 minutes, its a horror show, get a hybrid instead if your pedaling ft.
 

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I may have one more. Oh, just the insert where I reamed it out. I took slow steps using 3 progressive bit sizes instead of hogging out one consistant hole. Bad idea because bits are more likely to grab that way. Its also not the cleanest way to work. Those holes mustn't of weakened the frame. I beat on that bike and my luck hasn't been the greatest lately. It would of snapped by now if it was going to.

The hole count is actually lower, some those already existed. But who's counting.
 

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I thinned the entire carriage bolt good and thin so it laid almost flat. It would be a nightmare if the battery wouldn't slide out from getting hung up at that point. To access the controller the battery has to come off.

Its strong and straight and safer now'. I could put a stainless crown nut over the stub or a fancy wing not or camouflage it to won't stand out.

I wouldn't recommend cutting in to frames unless you know a bit more than a little about structure and materials and such. Truthfully how/where what I did is no big deal. It can also be easily filled in with more aluminum later. But it will always be lectrified.

I like to keep bikes custum and clean, and dirty. I love bikes and fixing them and building them. No washers were needed the rivet humps out and makes a perfect seat for the polyloc. And the nylon letter L was unharmed for this story.
 

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Just keep an eye on things, ya don't want any surprise crack appearing on trail/street..make asense? :)
 
Now I just have to do something about that fender. Its a front but it looks even worse up there :ROFLMAO:
 

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