I want to add more cage mounts to my Pugsley. I see two options for doing this: drilling holes and tapping threads, and clamps that go around the tubes. Brazing in new ones isn't ideal since it ruins the paint and I don't know how to weld. Plus you'd need bigger holes which would weaken the tube more.
I would like to add two cage mounts underneath the down tube, possibly something to the top tube to put stuff up there (since it has that low stand-over height), and also a cage on each of the fork tines (I have a Moonlander fork right now but want to get the offset Pugsley fork when it becomes available which based on my research doesn't have the cage mounts like the Moonlander fork). There was a brief discussion here.
I realize that drilling the frame will void the warranty, so I am more inclined to drill the forks only and use clamps on the frame.
This website has lots of info on different options.
- Drilling holes. I see two methods for this. One is to use Rivnuts. Some people say they are great while others say they frequently loosen. Plus it is recommended that you get it done by a shop which I would rather not do since I like doing things myself.
The other method is to drill and tap a hole so the screws thread in directly. I presume the tubing thickness would not be sufficient to allow for enough threading, so I would have to extend it. How I imagine doing this is drilling the hole and then squirting in some JB Weld to extend a little tube in behind the hole. I would then drill this out to the correct diameter and thread the whole thing, metal + JB weld. This would require a strong bond between the JB Weld and the inside surface of the tubing. I presume that frame saver would prevent a good bond. Does the Pugsley have frame saver? Is it in the fork?
- Clamps. I never really liked the clamps that have a single attachment point to the tube since this would cause lots of torque as you go over bumps. Also I don't want a clamp that's going to extend the cage mounts a ways away from the tube, I want it up tight. I found two clamps that should do the trick, here and here. Each bolt for the water bottle cage gets its own clamp, and they seem to have a low profile. I'd use these on the frame. For the Specialized one, the Pugsley top tube is 29 mm diameter so it would probably work there, but not on the down tube which is fatter.
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