Battery Rack


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I have made a rack to mount the battery on. To do so I have sawn apart a rack like this one:

Click on any image to enlarge it. 

 Raleigh Rear Carrier Rack With Spring Clip (black or silver)
 £26.99 including delivery from:

http://www.discountbicycles.co.uk/biz/product.php?xProd=3313 

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First of all I removed the spring clip then sawed the side struts off from  the rack top retaining as much of the rectangular tags as possible.

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The underside now looks like this.

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The dissembled parts metamorphosing.

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I am adapting most of the bought rack parts to make the new rack.

 

Click on any image to enlarge it.

 

  Its starting to take shape now.

It is possible just to use M3.5 screws and nuts to fix the parts together but as I had a set of taps I thought that I would make use of them. I will probably use some instant glue on the threads to prevent the parts loosening. 

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Bend the forward fixing bracket around a screwdriver, providing a radius to reduce the chance of cracking.

         

Fix the bracket to join the fronts of the two racks together. Note that the surplus tubing is first removed from the new rack. The stubs can be seen on the photos.

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Now join the rear of the racks together. Note that the existing rear light has been replaced by a CatEye led unit.

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Click on any image to enlarge it.

 

     

  This bottom fixing bracket was fashioned from parts of the new rack and joins the bottom of the Giant rack to the bottom of the new frame.

The top left photo shows one bend removed from one of the brackets. This had a clinch nut fitted then inserted up into the bottom of the Giant rack.  The bottom of the new rack now rests on the bracket and is clamped in place using more parts from the new rack. The two rubber strips stop the rack from fretting the battery case.

The picture on the right shows the underside of the rack.

As I own a Nutsert Kit I used it to make up the bottom fixing  bracket. However M5 & M6 screws, nuts and washers will provide satisfactory fixing.

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Click on any image to enlarge it. 

  

Here is the battery clamped in place with flat bungees and the power plug inserted.

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The modification is now finished.  Note that the second battery now sits below the pannier bag.

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