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The slightly modified Shimano part...for what? If you look closely, you can see where the aluminum fractured in the mill vise — not important since the intention was to make a new part anyway...
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A small piece of 6000-series aluminum scrap was used for the new part. Dimensions were transferred from the original part and marked on the new piece.
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The sheet aluminum is mounted to an aluminum rod which is gripped in the mill vise during milling.
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The part is nearly complete: all holes are drilled, mounting points are counter-bored and relieved.
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The nearly finished part is sanded to 600-grit prior to polishing. The two small holes are tapped to receive the M3 socket-head bolts which attach to the battery cradle...
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The finished part, polished to a mirror-like shine. Two M5 socket-head cap screws were dimensioned on the lathe to fit flush with the top surface of the new part. The two brass pieces (braze-on stand-offs) were made from 12.7mm diameter rod on the lathe: shaped, drilled, tapped, and counter-bored.
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The custom-made mounting bracket parts for the Shimano Di2 EW-7970 battery and cradle, shown.
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Battery cradle attached to battery mounting bracket with braze-on stand-offs.
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Attaching the battery...
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Battery locked in place.
