Bafang BBS02: Terry Symmetry Battery Mount Tee Nuts

The two middle mounting blocks under the Bafang battery plate have 5 mm holes for the screws going into the water bottle studs brazed to the frame. The outer blocks clamp around the frame and it seemed like a good idea to secure the plate to them, as well:

Terry Bafang battery mount - trial installation
Terry Bafang battery mount – trial installation

Those two blocks have a recess for an M5 tee nut:

Terry - Bafang battery - station 2 - bottom view - solid model
Terry – Bafang battery – station 2 – bottom view – solid model

I snipped off the prongs with hardened diagonal cutters and filed the stubs to a uniform height:

Modified M5 tee nuts
Modified M5 tee nuts

Applying a hot soldering gun to the plate melted the stubs into the block:

Terry Bafang battery mount - tee nut in place
Terry Bafang battery mount – tee nut in place

An M5 screw with a wingnut atop a big washer kept the tee nut properly aligned while pulling it into the melty plastic; I was pleasantly surprised at the lack of drama.

A ring of JB Plastic Bonder urethane adhesive glued the nut to the block:

Terry Bafang battery mount - tee nut gluing
Terry Bafang battery mount – tee nut gluing

The adhesive starts out runny and flows under the nut, so there’s more surface in play than meets the eye.

Clamping the partially cured goo to the frame atop a layer of waxed paper squashes any protruding adhesive lumps flat and prevents them from marring the tube’s paint:

Terry Bafang battery mount - tee nut adhesive molding
Terry Bafang battery mount – tee nut adhesive molding

Anchoring the battery to the bike at four spots makes it utterly immovable, which seems like a good way to ensure longevity:

Bafang BBS02 - Terry Symmetry full assembly
Bafang BBS02 – Terry Symmetry full assembly

That’s a test assembly predating the cable management cleanup …

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