Friday, November 13, 2009

Custom Taillight Holder (Design II)

Late in August 2009, I wrote about a custom taillight holder that I had co-invented with a buddy of mine. I was using it up until recently. Sadly, it bit the dust during the Babble Ride.

While I can mount my Dinotte 140R-AA on the seat post, that setup is only good as long as I do not carry my rear trunk, which I plan to use tomorrow.

Ta-da...time to create a new Custom Taillight Holder! I tried creating one tonight and that's what this post is all about :)

Below is what I am trying to replace.

Here is the current state of the functional one above :(

I have attempted to document how I created my Custom Taillight Holder below.

Step 1: I needed the right El Cheapo tube for mounting the light on. I chose an old metallic broom handle.

Step 2: I cut the tube down to the length you desire. I think it is a good idea to keep the tube short! I used a traditional hacksaw to cut the tube down to the desired length.
Step 3: It may be a good idea to file off the rough edges caused by the hacksaw. I need to :) For doing this you can use a traditional file or be lazy and use a grinder like I did!

Step 4:  Measured how far apart the two holes on the Tubus rack were. I need to mount the metal tube to the rear rack.

Step 5: Drilled two holes in the tube so it can be fastened to the rear rack. 

Here is the almost-finished product!

Step 6: Measure the darn holes in the rack before buying fasteners using a guesstimated diameter!

Luckily, I had some spare bolts at home (not Zinc coated) which I used for fastening the Custom Taillight Holder to the rear rack. I will be (most likely) replacing these with Zinc coated fasteners soon!
Step 7: Wrapped the ends of the Custom Taillight Holder with Green Duct Tape. That's how Green I am :)

 Step 8: Fastened the Custom Taillight Holder to the Tubus Logo Rear Carrier.

And, here is the finished Custom Taillight Holder!

In the picture above the looks cocked to one side but I fixed it after looking at this picture!

Lessons learned:
  1. Be precise like an engineer (SteveA, can probably give me some coaching in this area!) :)
  2. Measure everything at least twice before going out and buying stuff based on "measurements" and guesstimates.
  3. Aluminum tubes are not super strong but they do work.
  4. Old mop/broom handles play a very important role in creation of new devices*. 
Good help makes things so much easier!

*When I taught  my daughter how to ride her bike sans training wheels, I found it very difficult on me to have to bend down to hold on to her bike so she didn't fall. I thought very hard about the problem at hand and ...... I came up with a silly but workable idea. I shoved a mop handle under the saddle all the way down, along the down tube, of my daughter's little bike, when teaching her to ride it without training wheels. It worked great and I did not have to bend down to hold the back of the saddle to prevent her from falling.  

Peace :)


  1. All I can say is "measure twice and cut once and sometimes even that's not good enough."

    Also, have you considered PVC pipe for such projects?

  2. That's awesome! I bet this mount won't break like the last one.

  3. SteveA,
    I am not sure PVC will hold-up well. I have to check it out!
    Thanks for the good suggestion.
    Peace :)


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