Al Bicycle Threaded Inserts

[carlyai]

(Thought I may have better luck here than the bike forum.)

When the battery is mounted one usually uses the water bottle screws and screw holes.

In my case, 1. I can't do this, as the screw head profile is too high when mounting the battery bracket. Need to source lower head profile screws, and 2.

need to drill and tap inserts into the Al frame to securely mount the battery holder.

Anyone know where to get the inserts and low head profile screws?

Local shops no good and nearest bike shop 100km. 

Am also contacting the bike shops to see if they can do it.

 

[carlyai]

1 minute ago, carlyai said:

(Thought I may have better luck here than the bike forum.)

When the battery is mounted one usually uses the water bottle screws and screw holes.

In my case, 1. I can't do this, as the screw head profile is too high when mounting the battery bracket. Need to source lower head profile screws, and 2.

need to drill and tap inserts into the Al frame to securely mount the battery holder.

Anyone know where to get the inserts and low head profile screws?

Local shops no good and nearest bike shop 100km. 

Am also contacting the bike shops to see if they can do it.

 

Sorry, don't know what happened to the formatting.

[HighPriority]

Match the thread to a similar length countersunk or mushroom head screw/bolt.

Take your bidon screw to a hardware/engineering/building supplies type place to match it.

[Ralf001]

Rivnuts/nutsert for the frame.

 

I use a lot of low head hardware in my hobbies, I buy from here.

 

Nuts and Bolts - Lazada

 

 

 

 

[sometimewoodworker]

The threads are not tapped into the frame and you would not be able to do that anyway as the tube wall thickness is far too thin. The original nuts (they aren’t nuts)are placed from outside the tube and riveted in (though that may sound rather confusing). This means that you can only fit new mounting points this way. To get these fitted you probably need a car body shop or small machine shop, but they must have the screw rivet tool for you to have any success or you can buy a screw rivet tool,

Your only other options are to use the already installed captive nuts or use Jubilee Clips in some way.

 

[carlyai]

12 minutes ago, sometimewoodworker said:

The threads are not tapped into the frame and you would not be able to do that anyway as the tube wall thickness is far too thin. The original nuts (they aren’t nuts)are placed from outside the tube and riveted in (though that may sound rather confusing). This means that you can only fit new mounting points this way. To get these fitted you probably need a car body shop or small machine shop, but they must have the screw rivet tool for you to have any success you can buy a screw rivet tool, but it’s probably rather expensive. 
 

Your only other options are to use the already installed captive nuts or use Jubilee Clips in some way.

 

Thank you. 

Pressed into the frame makes sense.

Trouble with the original pressed threaded holes is, the one nearest the cranks is right under the battery connector. 

I can buy the low profile screw as @Ralf001 suggests, but I think I would have to try and insulate the screw top so it had no chance in shorting the battery connector.

More thinks needed. :)

[VocalNeal]

They are called rivet nuts https://www.lazada.co.th/products/hifeson-hand-rivet-nut-tool-head-nuts-manual-riveter-rivnut-tool-with-20pcs-steel-nuts-for-m3-m4-m5-m6-m8-m10-for-furniture-renovation-bike-cup-installation-i4252201665-s16831196347.html?

 

 

[carlyai]

1 hour ago, VocalNeal said:

They are called rivet nuts https://www.lazada.co.th/products/hifeson-hand-rivet-nut-tool-head-nuts-manual-riveter-rivnut-tool-with-20pcs-steel-nuts-for-m3-m4-m5-m6-m8-m10-for-furniture-renovation-bike-cup-installation-i4252201665-s16831196347.html?

 

 

Thank you.

[carlyai]

Purchased all my goodies.

Low head profile (round head) M5 bolts. Tried them and the make a neat fit.

M5 Rivnuts steel and Al with installing jig.

Takes a while as Rivnuts come from China.

Could not find a drill bit with small clearance for the Rivnut holes, so bought a reamer to make the holes just big enough.

Found some old metal bits to practice on....now I have everything, time to finish my genset start delay and get the new Rivnuts project done.

[KhunLA]

@carlyai

You're over thinking it, and trying to use what the bike has.  Drilling holes may compromise tubing strength.

 

Just get some kind of tubing clamp with screw mount.  My battery isn't in a hard case, and I actually zip tied to the frame ????

 

Something this will make life easier:

[carlyai]

12 minutes ago, KhunLA said:

@carlyai

You're over thinking it, and trying to use what the bike has.  Drilling holes may compromise tubing strength.

 

Just get some kind of tubing clamp with screw mount.  My battery isn't in a hard case, and I actually zip tied to the frame ????

 

Something this will make life easier:

Thanks, but too late.

Just need 1 rivnut I think, that will make 3 holding the battery case.

The Samsung cells 48V battery is heavy. :)

[carlyai]

Rivnuts and battery in.

Battery Samsung cells, 48V 20Ah 940Wh.

 

[Muhendis]

2 hours ago, carlyai said:

48V 20Ah 940Wh

Somethings not quite right here...........48 x 20 = 960Wh

[HighPriority]

Just now, Muhendis said:

Somethings not quite right here...........48 x 20 = 960Wh

Chinese cells… ????

It looks nice and neat @carlyai????????

[Ralf001]

On 7/31/2023 at 9:09 AM, carlyai said:

Purchased all my goodies.

Low head profile (round head) M5 bolts. Tried them and the make a neat fit.

M5 Rivnuts steel and Al with installing jig.

Takes a while as Rivnuts come from China.

Could not find a drill bit with small clearance for the Rivnut holes, so bought a reamer to make the holes just big enough.

Found some old metal bits to practice on....now I have everything, time to finish my genset start delay and get the new Rivnuts project done.

I buy my rivnuts from this store on lazada.

Lestpro

Delivered within days.