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I have been using similar truss clamps for decades, but for their intended use. :) If the tube matches their design diameter (typically 50 mm) I think using them like this looks great!

Real neat, those custom clamps! Can you estimate their strength other than by just trial? I mean, is there data for the material to do calculations? Hose clamps is not my top preference either, by far, but in this case more for looks than performance. It is an easy way to secure a rail to the...

Yes, seems similar. Mine is slightly thicker (1 mm vs 1/32" = 0,8 mm) but that should be of no importance. Partly to protect the frame, partly to even out any remaining rough parts on the rail, partly (mainly) to get higher friction. And not thicker sheet than that, to prevent wiggle. Got a...

Look into plastic fenders. That's is what I have on this bike. They are easy to keep clean, inexpensive, and can never dent. Here it is in the conversion process. Plastic for certain. 👍 I will want them to cover a little more though, and there is not a lot if space on my bike. I will likely...

I wish I had a full day's work to spend on my project, then it would be up and running already. :rolleyes: Battery needs to get in place, battery leads to motor soldered in, brake cut switches fit, new chain on, then test run. After successful test it gets new tires and handles and then I'm...

That bike has already, after lengthy consideration, got a BBSHD on it. ;)

I am jealous of the 3D printer. :) We have a small workshop at work that I can use, with small manual machines but still. I imagine 3D printing a similar rail would work too. If the tube profile can be replicated close enough and follow all the way over the width of the rail (as opposed to the...

Yes, I wanted a little extra width. The existing rivet nuts would have been of little use; the tube is so thin that lateral/bending force in the nuts may damage it. The slanted portion of the "outriggers" will fit a tube between 50-55 mm. It is a super easy piece to make, but because the...

Quick and dirty, a Quad Bob HD. :rolleyes: 1 mm rubber sheet on the tube and this should stay in place. (Normally wouldn't use slotted screws but they were the only countersunk I had with the right length.)

I like that rail! That has to be the way, thanks for the eye opener. :) I will attempt something like a Quad Bob (my battery is 15 lbs), either thick enough to cut threads in the rail itself or rather just inverting the battery screws.

Box fan, got it! 👍 As for repairing appliances in Europe, there has to be some misunderstanding. There are manufacturers that are most unwilling to supply parts or documentation, sure. That is mainly a matter of commercial decisions though, and not by regulation. People have their...

Language barrier here, sorry - what is box fan shell? The tube is >2" diameter and thin walled, so I want any type of fixture to squeeze as uniformly around the tube as possible. Today's idea is fixing a mounting rail using 4-5 regular hose clamps, I imagine that will be pretty gentle to the...

Yes, something along those lines, but I am thinking thicker and wider (longer) clamps machined to the profile of the not circular tube. And possibly three or four; my battery is maybe double the size of that on the pic.

Well written article, and certainly a way. But I have a handful of alternatives to try, and fail, before going there. The bike has racks both front and rear, and the front rack seems more and more tempting. We'll see. :)

Too heavy for the two rivets nuts in the frame tube, or for any number of rivet nuts really. Thinking of making a couple of Delrin clamps around the tube(s) to fit the battery base plate on.

Motor arrived, on the bike. Battery arrived, huge, not on the bike yet. Need to decide on the least bad place and mounting for it...

There are worse places for a maiden voyage. :) Upside with the BBSHD instead of DD hub is that with a different chain ring I hope to use the same bike to pull a trailer with kids (at a whole different speed). :)

Short update, I have let go of my initial idea for DD rear wheel drive. Not that I don't think it would be the best option for my use, but I have not been able to find a suitable supplier in Europe that sells just what I am looking for. So now a BBSHD is heading my way from pswpower German...

No steel here. Maybe not necessarily, on the shop's photos it has cassette hub. Could be that there are both versions. I am double checking with them that cassette is the case.

There. New discs and new organic pads made all the difference in the world. Also bedding in gave a most unflattering reminder of my present [lack of] stamina. 😅