Wednesday, July 18, 2007

Lawyer tabs

I spent some time preparing the front fork for the motor. The motor shaft and corresponding mounting bolts are much larger than a typical bike wheel. Modern bicycle forks have tabs at bottom of the fork that must be dealt with.

There is some debate as to why these "lawyer tabs" exist at all. I decided that the best solution was to file them off.

Disclaimer: I am not liable for what happens if you decided to modify your fork -- do this at your own risk.

First, I clamped a small piece of metal to the dropout to act as a guide. Then I used a metal file to remove the tab a little at a time, making sure that I didn't remove too much material. This method worked great -- I ended up with a flat mounting surface for the motor hardware.

After I removed the tabs I also removed excess material from the slot on the dropout. Electric bike motors in general require a 10mm slot and my fork had excess paint and metal at the opening that needed to be removed. This part is tricky so I used a digital caliper to periodically check the slot making sure that I didn't remove too much material.

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