Eerder metaal adjustable handlebar catch for G line to bring the handlebar closer to the fork. Especially the S and M size handlebar stems protrude quite far from the folded bike. And this adjusable handlebar catch will solve that.
Make yourself a fresh pot of Yogi tea cause this is going to be a long read! This might very well be the craziest part I've ever designed. Not because it's not usefull, the opposite, it's a nice solution to the handlebar projecting far out of the folded package of the G line. It's crazy timewise, for the amount of design work, the shear endless CAD revisions and lot's of time spent on proto typing and test fitting. And on top of this, when all work was done and the first batch of 14 kits was made, I had to make an instructional video and write the instructions below as an explanation to what you see in the video. Otherwise only a few people would be succesful in installing it on their G line Brompton. I will add €10 to the price of the catch 'just' for the instructions. I hope you understand, it's all low volume here. Super low most of the time. Exclusive shit... :)
Material: 304 stainless steel plates and hardware, aluminium studs / long nuts
Weight: 54 gr
Before you can install the Eerder adjustable handlebar catch for Brompton G line you have to make a couple ofmodifications. The instructions below are supposed to be read before and after you've watched the assembly instructions video.
- first remove the catch by unscrewing the hex screw. Now you can modify the hole in your stem slightly. This hole, or cutout if you like, is milled in such a way that the sides (left and right, not top and bottom) are radial. So both sides line up with the center of the tube. Both have to be either machined with a Dremel like tool or filed (or a combination of both if you like) parallel to each other. The width should only increase marginally, it's mostly the angular sides which you file parallel. When done the width should be around 22.9 - 23.0 mm. The rounded corners of the cutout should get a smaller radius to make room for the original (but modified) handlebar catch which will be comletely inside the stem, rather than half outside. You can end up with making the now shiny aluminium black again with a sharpy or some touch up paint if you like.
- next chamfer the sharp edge of the section below the cutout, in between the two hinge eyes. The hinge body will foul on itself before the handlebar comes flush with the fork leg. It's not made to hinge far enough to make the handlebar (almost) touch the fork leg. But it only takes a tiny chamfer to solve that. You need a Dremel like rotary tool or be very patient with a file as you can't make proper strokes. Scrape some material away with a sturdy and sharp knife (or deburring tool) will probably also work as aluminium is fairly soft. You can end up with making the now shiny aluminium black again with a sharpy or some touch up paint if you like.
- No need to modify the plastic catch anymore (as can be seen in the instructional video) as a modified catch is included from now on. Just for a slight upcharge.
- Next is the installation of the adjustable handlebar catch
- Start with removing the top plate (the one with the curved slot) by undoing the two M5x12 hex socket cap screws.
- Now also remove a long aluminium nut, the one that's only finger tight. Not the other one! Leave the 3 washers on there. And install the M5x45 cap screw to the other long nut and lock it with the nut. Doesn't need to be very tight. It's just something to hold on to while installing the bottom part.
- Insert the bottom section into the top side of the folded stem while holding the end of the long M5 screw. There's only one way to get it below the M6 threaded eye in the hinge body which can be seen in the video. The M6 retaining screw in the center of the bottom part should be half way, having an equal amount of thread on both sides of the part. When you can see the hex hole of the retaining screw though the hole of the eye you can start screwing it upwards (3mm allen key) into the threaded hole counter clockwise. Be carefull not to cross threads. It's good practise to apply a small amount of thread locking fluid.
- Now it's time to thread the long nut back on with a 8mm socket wrench of max 12 mm outside diameter.
- Slide the catch over the plastic ball while facing up so you can put it through the cutout in the stem. Now push the 6.5 mm pin of the top part in the hole of the catch. Line up the 5mm hole with the long nut under it. Install the M5x12 cap screw with the washer and the spring washer. Only finger tight for now. Insert the other M5x12 screw (don't forget the washers) through the curved slot.
- Now adjust the handlebar to about the desired position and tighten the screw at the slot and after that the other one. Test fold and make adjustments if necessary. The rougher you are with folding the stem the further the handebar should be away from the fork in order to compensate for the deflection. So be gentle and your Brompton will thank you, plus it will be more compact. Be moderate with tightening these two screws, no need to over tighten.
- and when you made it this far you are DONE!! Congratuations, I hope your Yogi isn't cold now...