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I made a handlebar! This style of bar is called a bullmoose bar, and is sort of neat because it is integrated into the stem. I missed pics of a couple steps. The bar material is 7/8" x 0.049" 4130 from McMaster-Carr. It ended up being cheaper to buy from mcmaster even with shipping then it was...

It just got really hot. It's a cheap contactor and its probably 20 years old so it probably didn't like the 30 minutes of continuous use. This is actually my work's lathe so I got the ok to buy a name brand contactor locally so I was able to replace it this afternoon. I ran it for an additional...

So funnily enough I completed the first step of this procedure - run for 30 minutes and then adjust preload to eliminate and play - and now my contactor is cooked LOL.

I've got the gear installed and have reinstalled the spindle and am now at the point to adjust the headstock bearing preload. The CT089 manual does not have any instructions on how to gauge if you have enough preload or not. Some other discussions I found on the interwebs say that the lathe...

It's probably 8" long :p

I'm pretty happy with this! The mini hole-saw worked perfectly, although I did have to zip the pilot bit off with a dremel as it didn't quite line up. I'm going to leave the back side hole as is until I remove the brakeline in a few weeks and I'll braze it closed then. Fits like a glove ;)

I am using the handlebar junction box already, but that junction box only has 2 ports, so essentially it is just connects the shifter to the rest of the system and acts as a convenient charging port. I still need a 3+ port junction b box elsewhere because the battery and derailleur need their...

I'm banking on being able to set it up in the mill so I'm not too worried about the pilot

I found these “thin wall” hole saws that I think will do the trick. In addition to them being shallow, it looks like the holesaw is fastened to the shank with a set screw, so I should I be able to drill a hole just big enough for the shank, position the holesaw inside the shell, and then insert...

Fortunately I am not a strong-as-an-ox kinda guy ;)