bike_sm.jpg (13051 bytes) Cutting the opening for the switch

Making the opening for the toggle switch and drilling the 8mm power connector hole will take about 5 minutes.  You will need a 50 mm end cap from Marley (HTM DN50).

 endcap_holes.GIF (3651 bytes)

 

 

 

 

 

 

 

cap1.jpg (6626 bytes)

Draw a right anlge to pass underneath the "B" (on the second row of printing on the cap) and down through the "U" in the exact position shown here.

 

 

 

 

 

 

 

cap2.jpg (7381 bytes)

Complete the square by drawing another set of lines throught the "B" in the number DIN-4102-B1.

The horozontal line will pass through the middle of the "B". 

The verticle line will be drawin even with the left hand side of the "B".

This gives the proper size for the Conrad toggle switch catalog number 70000-62.

 

 

 

 

cap3.jpg (6390 bytes)Drill a hole 9-12 mm in diamter in the square.  I have found drilling two 8 mm holes makes it easier to carve out the square.

 

 

 

 

 

 

 

cap4.jpg (6817 bytes) Wtih a hobby knife (exacto knife) cut lines to the corners of the box.

 

 

 

 

 

 

 

 

cap5.jpg (6991 bytes)Make multiple cuts to carve out the square form.

 

Finish the edges flat and fit in the switch by carving away what is stopping the switch from going in.

 

 

 

 

 

cap6.jpg (6962 bytes)cap7.jpg (7338 bytes)