Anyone removed the Trek Rail Battery Lock?

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Dave_B said:
I fitted the bracket today to my 750wh Rail.

Took a while to get it lined up, had to drill one more hole into the bracket to align it to the 750 mounting holes.

There is a lot of stuff to remove. A bit of a faff getting the rail plate off, but not too difficult.

Weights and measures below.

I also used some P rubber to fill the top and bottom gap.

The bad news…. My intermittent electrical issue has returned but I’ll post separately about that.

View attachment 102070View attachment 102071View attachment 102072View attachment 102073View attachment 102074View attachment 102075View attachment 102076View attachment 102077View attachment 102078View attachment 102079View attachment 102080View attachment 102081View attachment 102082
Click to expand...
Bro, can you advise me how you get this Block to attach the key hole ?

2839CE01-0AE7-415D-8C3E-33BAF28D583D.jpeg.jpg
 
Request for Testers
Inspired by this post, I created a 3D Print Version including the bracket and a keyhole closer. Weight goes from 331gr down to 23gr. So far tested on Rail 9.9 and 9.8, Model Year 2021.
Out for testing on: 2020 Rail 9 - 625Wh, 2022 Rail 9 GX - 625Wh, 2023 Rail 9.8 GX - 750Wh

Drop me a PM, if you would like to test it.
Rules would be:
- I would need your Rail Model, Year, Battery Capacity, as well as your delivery Address.
- Testing audience is limited to the first requester per Model / Year.
- You cover the shipping plus production cost. Total would be for Switzerland CHF 11.0, Europe: 8€ and rest of the World 12$.
- You need a TORX T10, T20, T25H and 2mm allen key as well as some loctite screw lock.
- You will provide helpful feedback. Either a good to go or what would need to be changed to make it work on your bike.

Happy Rail Riding !

IMG_0348.jpeg IMG_0343.jpegIMG_0342.jpegIMG_0349.jpegIMG_0335.jpeg
 
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RolfRapRap said:
Request for Testers
Inspired by this post, I created a 3D Print Version including the bracket and a keyhole closer. Weight goes from 331gr down to 23gr. So far tested on Rail 9.9 and 9.8, Model Year 2021.

Drop me a PM, if you would like to test it.
Rules would be:
- I would need your Rail Model and Year, as well as your delivery Address.
- Testing audience is limited to the first requester per Model / Year.
- You cover the shipping cost: Switzerland CHF 8.0, Europe: 5€, rest of the World 9$
- You need a TORX T10, T20, T25H and 2mm allen key as well as some loctite screw lock
- You will provide helpful feedback. Either a good to go or what would need to be changed to make it work on your bike.

Happy Rail Riding

View attachment 110406 View attachment 110407View attachment 110408View attachment 110409View attachment 110410
Click to expand...
I cant seem to message you. Would be interested 22 trek rail 9 GX
 
I can tell you from experience, the 750 battery has different mounting hole positions that the 625 battery. So you will need a different bracket design.
 
The two central holes are in very different positions. I had to drill the bracket to get just one of them to fit.
 
I didn’t make them. Read the thread mate. The guy who made them is in NZ.
 
RolfRapRap said:
Thanks for the Feedback @Dave_B !
I found your measurement earlier in this thread and created a second design for the 750 Battery. View attachment 110633
Click to expand...
Hi @RolfRapRap , I’m interested in trying this for my 2023 rail 7 625wh smart system and also on my 2023 rail 9.9 CXR 750wh smart system. The 9.9 has the new
Bosch race motor and it will be my race bike this year. I will be trying out to run a 625wh battery for some of the races and some races I’ll be running a 500wh battery. Can we talk possible about making an adapter to make up for the gap from 500 to 750 spacer and 625 to 750?
 
I am just designing a 3D printed bracket, going to print it in Carbon F so will likely be stronger than the bike itself, i will have two designs one for 500Wh and one for 625Wh battery. For me it's about saving the weight on the smaller battery/lock removal etc. I tend to come back from most rides with at least 50% of battery left so the weight saving is going to be more important for me with no issue on range. I was considering a lighter bike but this will be an ideal solution for me.

I am also looking how to save some weight from the battery cover, it's a massive chunk of weight, pretty sure it's the slotted bars on the back of the cover rather than the alloy cover itself. That's probably a more tricky problem to solve than the battery change/lock removal.
 
Last edited:
FastFreddyV said:
Hi @RolfRapRap , I’m interested in trying this for my 2023 rail 7 625wh smart system and also on my 2023 rail 9.9 CXR 750wh smart system. The 9.9 has the new
Bosch race motor and it will be my race bike this year. I will be trying out to run a 625wh battery for some of the races and some races I’ll be running a 500wh battery. Can we talk possible about making an adapter to make up for the gap from 500 to 750 spacer and 625 to 750?
Click to expand...
@FastFreddyV -
Bosch-Performance-Line-CX-Smart-System-E-MTB-Motor-2022-Review-Test-0.jpg
While the spacer could be done - how would you deal with the different connectors at the bottom of the 750is? Source:Der neue Bosch Performance Line CX Smart System-Motor 2022 im exklusiven ersten Test
 
Link said:
I am also looking how to save some weight from the battery cover, it's a massive chunk of weight, pretty sure it's the slotted bars on the back of the cover rather than the alloy cover itself. That's probably a more tricky problem to solve than the battery change/lock removal.
Click to expand...

Did you see post #66 and #68 ?
 
they changed between non-smart and smart... but if you have a Gen3 (or Gen4) Trek you can use only smart ones...
 
RolfRapRap said:
Request for Testers
Inspired by this post, I created a 3D Print Version including the bracket and a keyhole closer. Weight goes from 331gr down to 23gr. So far tested on Rail 9.9 and 9.8, Model Year 2021.
Out for testing on: 2020 Rail 9 - 625Wh, 2022 Rail 9 GX - 625Wh, 2023 Rail 9.8 GX - 750Wh

Drop me a PM, if you would like to test it.
Rules would be:
- I would need your Rail Model, Year, Battery Capacity, as well as your delivery Address.
- Testing audience is limited to the first requester per Model / Year.
- You cover the shipping plus production cost. Total would be for Switzerland CHF 11.0, Europe: 8€ and rest of the World 12$.
- You need a TORX T10, T20, T25H and 2mm allen key as well as some loctite screw lock.
- You will provide helpful feedback. Either a good to go or what would need to be changed to make it work on your bike.

Happy Rail Riding !

View attachment 110406 View attachment 110407View attachment 110408View attachment 110409View attachment 110410
Click to expand...
I also am having a hard time PMing you. I sent a message but it looked off. It didn't look like a PM but said posting a message to your profile and when I look in my messages it isn't there.
2022 Trek Rail 9.7 gen 2 625wh battery. Interested in trying a 500wh battery too. Thanks
PS: if anyone can tell me where I am supposed to click to send PM, I would really appreciate it.
 
Link said:
I am just designing a 3D printed bracket, going to print it in Carbon F so will likely be stronger than the bike itself, i will have two designs one for 500Wh and one for 625Wh battery. For me it's about saving the weight on the smaller battery/lock removal etc. I tend to come back from most rides with at least 50% of battery left so the weight saving is going to be more important for me with no issue on range. I was considering a lighter bike but this will be an ideal solution for me.

I am also looking how to save some weight from the battery cover, it's a massive chunk of weight, pretty sure it's the slotted bars on the back of the cover rather than the alloy cover itself. That's probably a more tricky problem to solve than the battery change/lock removal.
Click to expand...
Hi, interested in the bracket if it is reasonable cost, also interested in the cover if you get to that.
 
Link said:
I am just designing a 3D printed bracket, going to print it in Carbon F so will likely be stronger than the bike itself, i will have two designs one for 500Wh and one for 625Wh battery. For me it's about saving the weight on the smaller battery/lock removal etc. I tend to come back from most rides with at least 50% of battery left so the weight saving is going to be more important for me with no issue on range. I was considering a lighter bike but this will be an ideal solution for me.

I am also looking how to save some weight from the battery cover, it's a massive chunk of weight, pretty sure it's the slotted bars on the back of the cover rather than the alloy cover itself. That's probably a more tricky problem to solve than the battery change/lock removal.
Click to expand...
Can you print a cover?? I would really like one of those. I have an idea how to do it. I got the idea from a guy on YouTube. His Rail is 19.11 Kg! He made a carbon cover and just used Velcro. To me the best solution would be to add a little step at the front edge that would go inside the frame in the front only. At the bottom edge or just near the bottom a flat area that would set adjacent to the battery surface and just add a small piece of Velcro. Just need a small nylon strap hanging out at the bottom to grab onto to pull it off or a small slot at the bottom to pry it off.
 
Does anyone want to sell me the extra plastic piece that you removed from the end of the battery, the big piece with the handle on it. The piece that you removed to install the bolt on mount?
 
When removing the Battery Lock at the top - is there a specific reason for not also removing the lower docking bracket and Connector Plate? To directly attach the Battery Connection Plug to the battery und use the same Bracket to screw it to the frame?
 
The lower docking bracket and connector plate(bulkhead )helps secure and position the battery and frame cover in place. Some of the alignment procedure for the battery happens at this point.

I don’t think I would want the battery permanently secured in place since the battery area occasionally needs cleaning, or the battery can easily be removed for various reasons. I do like the idea of removing the locking mechanism and replacing it with a modified and lighter system.

Other than keeping the battery and plate alignment, and securing some cables, I don’t think there’s any structural value to the bulkhead.
 
Last edited:
RolfRapRap said:
When removing the Battery Lock at the top - is there a specific reason for not also removing the lower docking bracket and Connector Plate? To directly attach the Battery Connection Plug to the battery und use the same Bracket to screw it to the frame?
Click to expand...
I wouldn't want to remove the bottom bracket. These batteries are really heavy and some of us ride over some really rough terrain which puts a ton of force at the top and bottom of the battery. I really want to remove the heavy lock mechanism at the top but I really want a strong carbon printed mount for the replacement.
 
There is also the cover issue. That bottom mount holds the cover in position. That cover is pretty heavy too. I really wish someone would make a carbon replacement or a printed replacement.
 

I am trying to build my Rail similar to this one. Please see video. 19kg full power Rail. He removed the lock and also made a carbon battery cover and uses Velcro to hold it in place.
 
Scott76308 said:
There is also the cover issue. That bottom mount holds the cover in position. That cover is pretty heavy too. I really wish someone would make a carbon replacement or a printed replacement.
Click to expand...
I haven’t seen a printed version of the battery cover but I’m assuming mine is already carbon. (I hope). You might be able to order just a replacement carbon cover??
 
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