We had a test bike with a really fat bottle crack at the bottle boss from the fatigue of getting the bottle in and out of the cage. We reinforce all the DT bosses now. We were not happy with the available “star” shaped ones (IMO, they look dated), so I designed our own.
Wow thanks for the info and the dxf, the star ones definitely aren’t my style either. I’m guessing on your nice printed seat tube bottle mount the bosses get brazed in as well rather than printing it or tapping the thread? Tube blocks were the best money I ever spent
I really like this boss reinforcement idea, thanks for sharing how you’re doing it! I’ve been thinking about how to install bosses and might do something similar. Do you think it would be possible to have the pieces lasered from a tube so that you wouldn’t have to bend them? Maybe it would be more expensive but could save the step of having to squish them in tube blocks.
Haven’t looked into lasered tube suppliers. In my experience send cut send does a lot of online sales, allowing them to offer good value and fast turnaround. The lasered approach could be cool if you wanted to do really intricate designs
I need to get around to 3D printing the forming die for this:
Ah yeah that’s looking nice! It would definitely be an easy step to just squash them in an arbor press or something with a due set like that. Have you tried oshcut at all yet? I was pretty impressed with their pricing and quoting interface, but have yet to order anything from them.