Rear rack and fender installation
Rear Rack and Fender installation
I wanted the fenders to match the matte black bicycle frame, so I used some 1500 grit sand paper and scuffed the fenders and painted them. (this is optional, just my preference)
However, I did notice that not all the screws supplied with the fenders were stainless steel. You can test this with a magnet. If they stick to the magnet, then they have some carbon steel in them and could possibly rust at a later date. You can protect them from this by painting them. (or replace with stainless hardware from the hardware store)
Nonetheless, here’s my painted fenders and screw hardware.
Next make sure all the threaded holes are cleaned out of paint and ready to accept new screws. Use a M5x0.8 tap to chase out the threads.
and these…both sides
and lastly these, both sides.
Find a screw that is proper length and install a large area washer on it. Add some Loc-tite to the screw threads.
Insert the screw through the bottom of the fender and thread it into the short tube between the chain stays. Go ahead and tighten this screw.
I used a clamp to prop up the rest of the fender on the seat stays while I moved onto the next step.
Use a clamp to prop up the rest of the fender on the seat stays while you move onto the next step.
Prepare the metal clip for installation. You can bend it by hand a little bit open so it doesn’t scratch the fender when you clip it over it.
Also, you’ll need to bend the little ears up under the fender once it is installed. I took a pair of pliers and wrapped the jaws with electrical tape so I wouldn’t scratch the fender when squeezing on it.
The metal clip can be installed on either side of the tube between the seat stays. Careful not to scratch the fender.
Once installed insert a screw, washer into the threaded hole and tighten (Loc-tite this connection).
Next, move onto the fender wire supports. There are two different types supplied. The ones with the black plastic tips are safety break-away fittings for the front wheel in case something gets stuck in between your wheel and fender. So we will be installing the bare metal wire supports for the rear.
Reinstall the rear wheel for this next step.
Temporarily secure the two wire supports to the bike frame using screws and washers (no Loc-tite at this time)
Note which holes are being used in the photos below.
Bend (open or closed) the wire supports where they line up with the tabs on the fender.
It should look like this.
Insert the plastic receiver pieces onto the metals tabs that are on the fenders like this.
This step requires you to mark the wire supports for cutting. In order to mark the wire supports you need to get the fender in it’s proper position. I use a folded rag sandwiched between the tire and the fender to hold the correct spacing (around 3/8″ all the way around).
The next step is to hold both left and right wire supports together (next to fender) and mark the wire supports with a marker. Mark halfway the height of the black plastic insert. This is your cut line. Mark all four ends of the wire supports.
Remove wire supports and cut with a hacksaw. Pay close attention to which way the wire support faces. (meaning which wire support is forward and which is aft)
The cut wire supports should look like this.
Next, install the wire support through the stainless retainer bolt and into the plastic fitting on the fender tab. Do this for all four connections. Take your time, this takes a little patience.
Confirm the fender is in the proper position. Aligned with the wheel and somewhat equally spaced around the wheel.
Apply a little Loc-tite to the bolt threads and install the nuts.
Position the rounded edge of the nut facing out as shown.
Next, remove and apply Loc-tite to the screw that hold the wire supports to the bike frame and tighten.
Rear Rack installation
Locate the spacers and proper length screws for securing the rear rack to the frame. There should be enough threads on the screw to match the thickness of the frame.
Carefully place the rear rack over the bike frame and align the fasteners with the holes. Temporarily tighten the screws.
Note: It’s best to dry-fit all the fasteners and when complete go back and remove each fastener and install Loc-tite and apply final tightening.
Confirm the bike is sitting level on the ground and then place a level on the rear rack to level it’s position.
Install the top rack supports as shown. While maintaining level, mark the aluminum supports where they can be trimmed of excess material.
Remove supports and cut excess material with a hacksaw.
When complete, remove and apply Loc-tite to each fastener (one by one) and perform final tightening of the screws.