Rack failure!!!

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Joined: 07/25/2008
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Points: 64

I had a rack failure on the way home from the store yesterday. I heard an unusual sound about a mile from home, but didn't notice until I got home. I have 4 x 12v/12Ah SLAs on the stock rack for the BD36. The weight seemed to be no problem (supposed to be designed to hold 40#, pack is about 35#). The way that I had it strapped on with a ratchet strap seemed to be the problem. I had it strapped on just to the top part of the rack, but should have looped under the bottom brace at least once. I think that the bouncing caused the pack to bounce up in a way that caused the weld to break in an upward motion. I may have also had the strap so tight that inward force may have contributed to the weld break. I tried J-B Weld, no way would that work. To have it re-welded would be at least $20. I ordered a rack from ebay that is supposed to hold up to 55# for a little over $20, and I'll strap it on looping under the bottom braces, not as tightly next time.

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Joined: 04/06/2008
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Re: Rack failure!!!

Thats odd. I have the WE stock rack and at the time I had an MTX trunk bag to hold 5-SLA 12AH batteries and it held up like a champ even on offroading trails.

dogman's picture
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Joined: 04/29/2008
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Re: Rack failure!!!

Depends on the quality of the weld. You got the good ones.

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Joined: 07/25/2008
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Points: 64
Re: Rack failure!!!

The rack that was supposed to hold 55 pounds was not as good quality as the stock rack, so I just ordered another stock rack from Bernson EV. Also talked to a guy at my daughter's school who said that he would be willing to weld for free if I have another weld break. I resold the other rack on ebay, so wasn't out much on that.

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Joined: 07/22/2008
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Points: 98
Re: Rack failure!!!

I have a Delta brand rack. No problem with 36 v. I'll bet it could hold 50 lbs. The only thing you then have to worry about is whether screws/fittings are too tightly fastened.
What can happen is over-tightening strips the threading.
A seat post beam type rack is out of the question as they set weight limits to 20 or 25 lbs. Personally, I'd like to find a seat post beam rack that also has bars that are fastened to the rear bottom of the bike frame. Another cool idea would be to find a rack that has a little spring/suspension in the support bars.

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Joined: 06/29/2008
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Points: 21
Re: Rack failure!!!

"cool idea would be to find a rack that has a little spring/suspension in the support bars."

That is a very cool idea. Being able to support x number of pounds is one thing but withstanding the g-loads going over the potholes and railroad tracks is a different matter.

I've put an extra pad of styrofoam packing material under my SLAs and it does help absorb the shock on those bumpy rides. Bet it takes a lot of the load off the rack and bet the batteries like it too.

And happy new year!

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Joined: 07/22/2008
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Points: 98
Re: Rack failure!!!

I just bought a 2009 kit on Ebay. It's made by the same people who make Wilderness: Brushless, supposedly regenerative and compatible w/ 36 or 48 volts. Can put out up to 1200 watts. But it is not a wilderness
Anyways, the included bike rack attaches to the seat post and rear bottom of frame. This is a neat set up and makes it harder to steal the seat post.
Top speed is 25 mph or 30 mph. The battery bag will hold either 36 v 12 ah or 48 v 7 ah. I'm just worried about the 35 amp controller. Hopefully this kit will work out.
Happy new year

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