Скачать или смотреть Brompton G line adjustable handelbar catch installation

The Eerder metaal adjustable handlebar catch for G line to bring the handlebar closer to the fork. Especially the S and M size handlebar stems are pretty far out of the folded bike. And this adjusable handlebar catch will solve that.

Make yourself a fresh pot of Yogi tea cause this is going to be a long read! This might very well be the craziest part I've ever designed. Not because it's not usefull, the opposite, it's a nice solution to the handlebar projecting far out of the folded package of the G line. It's crazy timewise, for the amount of design work, the shear endless CAD revisions and lot's of time spent on proto typing and test fitting. And on top of this, when all work was done and the first batch of 14 kits was made, I had to make an instructional video and write the instructions below as an explanation to what you see in the video. Otherwise only a few people would be succesful in installing it on their G line Brompton. I will add €10 to the price of the catch 'just' for the instructions. I hope you understand, it's all low volume here. Super low most of the time. Exclusive shit man :))

Before you can install the Eerder adjustable handlebar catch for Brompton G line you have to make a few modifications. The instructions below are supposed to be read before and after you've watched the assembly instructions video.

First remove the catch by unscrewing the hex screw. Now you can modify the hole in your stem slightly. This hole, or cutout if you like, is milled in such a way that the sides (left and right, not top and bottom) are radial. So both sides line up with the center of the tube. Both have to be either machined with a Dremel like tool or filed (or a combination of both if you like) parallel to each other. The width should only increase marginally, it's mostly the angular sides which you file parallel. When done the width should be around 22.9 - 23.0 mm. The corners are rounded and should be a little sharper (smaller radius) to make room for the original (but modified) handlebar catch which will be comletely inside the stem, rather than half outside. You can end up with making the now shiny aluminium black again with a sharpy or some touch up paint if you like.

Next chamfer the sharp edge of the section below the cutout, in between the two hinge eyes. The hinge body will foul on itself before the handlebar comes flush with the fork leg. It's not made to hinge far enough to make the handlebar (almost) touch the fork leg. But it only takes a tiny chamfer to solve that. You need a Dremel like rotary tool or be very patient with a file as you can't make proper strokes. Scrape some material away with a sturdy and sharp knife (or deburring tool) will probably also work as aluminium is fairly soft. You can end up with making the now shiny aluminium black again with a sharpy or some touch up paint if you like.

Modify the catch by first taking it apart with a small screw driver, pry out the spring at the closed end of the plastic catch. Now you need to grind or file the spring to approximately 19.15 mm wide, the thin sections of the wire at the ground spot should be around 1.9 mm thick. The original diamter of the spring wire is 3 mm. The spring is made of hard stainless steel wire (probably 301) but still can be filed with a good sharp file. A bench grinder or a belt grinder can also be used, but be carefull to not remove to much.

Now that you've modified the spring you can reinstall it onto the plastic catch and file or grind the plactic to the same width, flush with the modified spring sides. But be carefull to not remove more than right up to the spring or you weaken the spring and the plastic part.

Next is the actuall installation of the adjustable handlebar catch

Start with removing the top plate (the one with the curved slot) by undoing the two M5x12 hex socket cap screws.

Now also remove a long aluminium nut, the one that's only finger tight. Not the other one! Leave the 3 washers on there. And install the M5x45 cap screw to the other long nut and lock it with the nut. Doesn't need to be very tight. It's just something to hold on to while installing the bottom part.

Insert the bottom section into the top side of the folded stem while holding the end of the long M5 screw. There's only one way to get it below the M6 threaded eye in the hinge body which can be seen in the video. The M6 retaining screw in the center of the bottom part should be half way, having an equal amount of thread on both sides of the part. When you can see the hex hole of the retaining screw though the hole of the eye you can start screwing it upwards (3mm allen key) into the threaded hole counter clockwise. Be carefull not to cross threads. It's good practise to apply a small amount of thread locking fluid.

Continue reading (only 5000 characters allowed by Youtube):
https://www.eerdermetaal.nl/brompton_...