The very first problem I spotted on my new bike was the stupid design of the XT bumper end caps. They are just waiting to get ripped off by a tree.
On my very first ride I managed to remove one of them and I was trying to avoid doing that.
Anyway, I've come up with a possible way of still keeping the cap but hopefully stopping them from getting ripped off so easily.
I took some measurements and cut out four plates on my CNC router. They took a couple of goes till I managed to match the profile of the end cap. The plate is made of 10mm HDPE and once it's bolted in place, it is extremely ridgid.
Here's what I came up with.
As you can see, the plate has a 5mm deep trench for the end cap's edge to sit in. That way nothing can get in behind the cap to rip it off.
The centre hole has to be drilled through the bumpers end plate. Once all the holes lined up, the bolts are tightened and extra long screws are fixed into the end cap.
Unfortunatly the XT bars have to be removed for this to happen, but all up it took me approx 40mins to fit all four and that was taking it easy.
See what you think. Any comments welcome.
There is about 10mm gap between the guard and the back of the plate once the bumper is adjusted properly.
Edited by ozymax, 30 March 2013 - 01:36 AM.