Tour Easy Rear Fender Bracket: More Cable Clearance

Most likely due to the fiddling around the larger rear brake noodle, the 3D printed bracket holding the fender to the frame failed:

Tour Easy Rear Fender Bracket - failed joint
Tour Easy Rear Fender Bracket – failed joint

Hey, it lasted for six years.

Making another one just like the other one, but with a little more clearance for the brake cable fittings, required a few tweaks to the solid model:

Rear Fender Bracket - more clearance
Rear Fender Bracket – more clearance

It’s slightly less chunky and holds the fender a bit closer to the tire:

Tour Easy Rear Fender Bracket - new vs old clearance
Tour Easy Rear Fender Bracket – new vs old clearance

The piece over on the left cupping the fender wasn’t broken, so I scuffed up the mating surfaces, applied a layer of JB Plastic Bonder (my new go-to adhesive for printed stuff), clamped it overnight, and it looked OK.

While that was curing, I shortened the screw holding the clamp to the bike frame:

Tour Easy Rear Fender Bracket - cutoff wheel dust collection
Tour Easy Rear Fender Bracket – cutoff wheel dust collection

The shop vac nozzle does a great job of collecting all the abrasive dust; highly recommended.

Because I had a dollop of adhesive left over, I applied a 1.8 mm drill (from a set of metric bits I’d been meaning to buy for far too long) to the screw:

Tour Easy Rear Fender Bracket - screw drilling
Tour Easy Rear Fender Bracket – screw drilling

And glued a snippet of pretty blue PETG filament in the hole:

Tour Easy Rear Fender Bracket - frame screw PETG insert
Tour Easy Rear Fender Bracket – frame screw PETG insert

As far as I can tell, this will have no effect on the screw’s goodness, but it makes me feel better about crunching it onto the frame.

Installation goes like you’d expect and there’s now enough clearance to keep the brake hardware off the bracket:

Tour Easy Rear Fender Bracket - installed
Tour Easy Rear Fender Bracket – installed

I replaced the boot while installing the larger noodle; perhaps I should have trimmed most of it away.

The riding season is upon us!

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