200ES Toolbox Rack Hinge Bushings

[kb0nly]

I was getting sick of the center portion of the rack rattling and driving me nuts so it was time to make some bushings. After looking at pictures of really mint survivors or restorations i saw there was a plastic bushing. The parts diagrams don't seem to show it and its not available anymore anyway. So i designed a quick and easy replacement that anyone can make.

Get a length of standard 1" PVC pipe, PVC conduit will work also but note they are slighting different sizes. The rack tubing is roughly 7/8" or 22mm depending on coating or paint, etc. Mine measured 22.33mm with the calipers.

Cut two lengths of the 1" pipe to 1 - 3/16" long, 1 - 3/16" is the max width that will fit inside the guide on the rear hinge point, now cut part of the side out, i removed a roughly 3/8" wide strip of the side to make a C shaped piece. I used a ratcheting tubing cutter to make quick work of this.

Now remove the screws that hold the tabs on that center rack piece, mine were rusted in, once i got them out i had pretty well destroyed the phillips head of them so i bought two new metric bolts and lockwashers and flat washers and ran a tap in the threads to clean them up for the new bolts. Snap the PVC bushings on and align so that the cut down the side of the new bushings is going to be towards the center, i just sat that piece of the rack in place so that the guide on the back arm held it upright while i turned the bushings to match then put on the tabs and bolt them back down, it will compress the PVC bushings down to the tubing size. A little dry lube on the rack can be used so the bushings move freely.

The PVC is just the right thickness so that the guide over the back keeps it from moving front to back and getting hung up, it also still has enough room to move freely. Nice and snug but not too tight, it will actually swing up and stay and when strapped down no more rattle!!



Now can anyone tell me what the latch side of this center rack should have to stop it from rattling?? It has holes where they sit down on the bar of the rack so i assume it had maybe a rubber bumper of some kind? I don't see that on any of the pictures i have been going through, i found a few that had the bushings at least but it looked like they didn't have anything on the latch end.

[Flossyb20]

http://www.bikebandit.com/houseofmot.../m1890#sch6463

#12 and #14 in this diagram - both still available

[kb0nly]

Thats who i tried to order them from, after about a week i got an email saying they weren't available, then it took two more weeks for them to refund my credit card. I didn't try to order the rubbers for the latch side, i might have to give it a try.

$7.25 each for something i made for like $.25 seems a little steep anyway... LOL

So far i have had nothing but bad luck with that bikebandit site, they always let me place an order for stuff that isn't available!

Just placed an order for the rubbers for the latch side, will see if they come through on those! The bushings i am going to stick with mine that i made, lots cheaper, do the same job, and easy to make new ones as they wear out. I found a more detailed picture of the originals on a mint 200ES, they look a lot thinner plastic then the ones i made, they would still rattle unless i also bent the mounts to pinch it tighter.. Verdict... I will stay with my "engineered replacements".. LOL

Thanks for the heads up on the rubber parts though!

[tripledog]

Nice job, kb! But I think you chose an inappropriate user name; I believe "McGiver" suits you better. If you think I am not going to do this upgrade, you couldn't be more wrong. Thanks for another great tip!

[Worden18]

Great work. It's nice to see a little bit of homemade things to improve a trike. Looks great man

[kb0nly]

Thanks guys! I know it wasn't like the parts engineering some of the guys on here do, but hey its the little things, like a rack that rattles and drives you nuts.... LOL

McGiver... Hmm, as long as its not with a side of fries.... LOL!