Anyone removed the Trek Rail Battery Lock?

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agreed a thicker angle bar would be better
 
Unlikely. They are very aware of the issue and have not said anything about an update. My LBS called them just a few days ago and all Trek said was look at the new fitment procedure etc, nothing about any potential fix.

the aftermarket solution appears to be the best.
 
Dave_B said:
The list so far….

myself
@Rob Rides EMTB
@Nautical Biker
@Fat Rat
@RustyMojo
@emtboulder
@Animal80
@raf
Click to expand...

So there are only 8 people interested so far.

I saw a post on FB, I think from the original designer, where the bracket had been thickened by adding another piece of aluminum and only using one bolt. The thicker section looked to be at least 20mm thicker, hence a longer bolt through the frame and a much stronger connection. ( I cant find the picture, I will keep trying to find it)
 
Found it!

8B7DD496-5E58-4BC0-9B5C-3D87B51E5483.jpeg
6C8C7AE5-A007-40BE-BAAB-1D683D838160.jpeg
 
Dave_B said:
So there are only 8 people interested so far.

I saw a post on FB, I think from the original designer, where the bracket had been thickened by adding another piece of aluminum and only using one bolt. The thicker section looked to be at least 20mm thicker, hence a longer bolt through the frame and a much stronger connection. ( I cant find the picture, I will keep trying to find it)
Click to expand...
will you be able to ship it into europe? (slovakia for me) and how much will it cost with all fees/postage-asking if it is revelant to do it on my own or wait dor cnc solution.
 
no idea mate. I'm simply getting a lit of interested parties to see if we can reach 20 people. if we can, it will then be for @Rob Rides EMTB to discuss with his contact about production / costs / shipping etc
 
I really should get off my arse and just make one. It looks super simple. Albeit I’d worry about the longevity of the thread in the alloy. So maybe a carbon fibre version with a glued nut maybe a better option. Either way if someone makes them I’m in
 
I like to be able to easily remove the battery (to knock four to five kg off the bike's weight when loading into the back of my car) but I do stress about not having the key to hand.

Is it possible to adapt/destroy the lock barrel so that it can be operated by a screw-driver or similar? Car thieves seem to find it quire easy.

Apologies if this idea is a nonsense or has already been discussed.
 
As I was whipping up a prototype today I noticed that none of the previously presented versions include a recess for the cables, the factory lock mechanism has a recess and I noticed a flat plate squashes the cables upon tightening, so if you’re going to have one cnc machined then I’d recommend this addition 👍

C0752D0F-90E4-4DF7-8EC4-090F84D87A1F.jpeg F632ACCD-77D4-4680-A6B7-099414DEC821.jpeg
 
Arron M said:
As I was whipping up a prototype today I noticed that none of the previously presented versions include a recess for the cables, the factory lock mechanism has a recess and I noticed a flat plate squashes the cables upon tightening, so if you’re going to have one cnc machined then I’d recommend this addition 👍

View attachment 99530 View attachment 99531
Click to expand...

Do you want to make 13 of them?
 
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Dave_B said:
Di you want to make 13 of them?
Click to expand...

Possibly, there would be a few things to hash out though:
firstly I’m in Australia so logistically it may mean sending over the entire batch and having someone distribute them locally.
Secondly I agree with Fox’s earlier point regarding the thickness of material where the threaded holes are, so we could use a 6mm angle, which may eat into some of the weight savings, or (what my final design will likely be) 3mm battery interface plate welded to 8mm plate where both versions would have a recess for cables.
My prototype is 11mm thick as I was just using scrap I had at hand, but I didn’t do this for weight saving, I’m about to start transporting my bike on the out side of my vehicle and don’t like these stories about battery’s falling out, even though it never has.
Thirdly is everyone happy that if it fits my ‘21 rail 7 that it will fit as well on your own bike?
 
Arron M said:
firstly I’m in Australia so logistically it may mean sending over the entire batch and having someone distribute them locally.
Click to expand...
not a problem, I can do this.
Arron M said:
Secondly I agree with Fox’s earlier point regarding the thickness of material where the threaded holes are, so we could use a 6mm angle, which may eat into some of the weight savings, or (what my final design will likely be) 3mm battery interface plate welded to 8mm plate where both versions would have a recess for cables.
Click to expand...
your prototype looks great, maybe 3mm battery plate and 6mm welded plate? I am sure the group would give their input on this.
Arron M said:
Thirdly is everyone happy that if it fits my ‘21 rail 7 that it will fit as well on your own bike?
Click to expand...
I could not say for sure, maybe @Rob Rides EMTB or others will know? I suppose if the bracket is for bikes with the 750 battery, then it would fit all Rails that have this battery?
 
But it would still fit even with the cable entry, so no need to make different versions?
 
I’m up for buying one still chaps. Anything to get rid of the crappy system that’s fitted factory. Presuming this would negate the need for the crappy alloy ‘rib’ that seems to force poor fitment of my battery into the frame
 
emtboulder said:
I've got a '21 rail 7 and I'm happy with that fitment. It's for a 625Wh battery, and not the 750Wh, correct?
Click to expand...

If the 750 uses identical part numbers for the lock mechanism I can’t see why it wouldn’t fit both. Though fitting the battery top first as you need to involves a little more faffing (bit of a wiggle and pushing the bottom in and down on an angle) it’d be nice to know the 750 drops in the same.
Obviously yes my ‘21 7 is a 625 and is a confirmed fit.
 
Anyone removing a battery lock mech to save 360 grams of weight is friggin looney tunes. You are saving 360 paper clips worth of weight. Better off shaving and taking a dump before you ride. The things people do to save this kind of weight is mind boggling. What exactly is the benefit of this amazing weight savings?
 
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