-
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Save eonist/a6d81682c50625c8b8f8b413c3562c49 to your computer and use it in GitHub Desktop.
| stem https://dosnoventabikes.com/components/dsnv103-stem/ | |
| wheel: https://dosnoventabikes.com/components/dsnv106-wheel-set/ and | |
| bar: https://dosnoventabikes.com/components/dsnv106-flat-bar/ | |
| seat post: https://dosnoventabikes.com/components/dsnv105-seatpost/ | |
| drop bar: https://dosnoventabikes.com/components/dsnv101-drop-bar/ |
also this is the omera build. its not called sparton
Got it, two corrections applied. Here's the updated list:
Omera — Full Parts List
🚲 Bike Parts
| Part | Product | Link | Price |
|---|---|---|---|
| Fork | Nologo 700C Disc Carbon, UD Gloss Black | AliExpress | $44 |
| Headset | 1-1/8" Integrated Threadless, alloy, black | AliExpress | $15 |
| Stem | No Logo 3K Carbon Stem, 31.8mm | AliExpress | $30 |
| Handlebar | NO LOGO 3K Full Carbon Flat Bar, 31.8mm | AliExpress | $25 |
| Brakes F+R + Levers | Shimano MT200 Hydraulic Set (incl. levers) | AliExpress | $38 |
| Rotors F+R | Shimano Deore SM-RT56 6-Bolt, 180mm F / 160mm R | AliExpress | $22 |
| Crankset | Fixed Gear 44T 170mm Alloy, black | AliExpress | $29 |
| Pedals | Ultra Light Alloy Flat, black | AliExpress | $9 |
| Gates CDX Belt | Gates Carbon Drive CDX | Bikeman | $60 |
| Gates CDX Front Sprocket | Gates CDX Chainring | Bikable | $55 |
| Gates CDX Rear Sprocket | Gates CDX Thread-On | Bike Components | $29 |
| Front Wheel | Pasak 27.5" Disc Hub, thru axle | AliExpress | $55 |
| Tires ×2 | Kenda Kwest 700x25c all-black slick | AliExpress | $30 |
| Tubes ×2 | 700c standard | AliExpress | $8 |
| Saddle | ULLICYC Ultralight Full Carbon, black | AliExpress | $35 |
| Seatpost | NO LOGO Carbon Seatpost 27.2mm, matte black | AliExpress | $22 |
| Seatpost Clamp | Standard 31.8mm, black | AliExpress | $6 |
| Bike subtotal | ~$512 |
⚡ E-Bike Parts
| Part | Product | Link | Price |
|---|---|---|---|
| Rear wheel (motor) | Bafang G020 pre-built 700c | GreenBikeKit | $209 |
| Controller | PSW 250W sine wave (bare PCB) | AliExpress | $19 |
| BMS | Slim 10S 36V 25A | AliExpress | $10 |
| Cells ×22 | 26650 5000mAh | AliExpress | $99 |
| PTFE liner tube | — | AliExpress | $7 |
| USB-PD trigger board | — | AliExpress | $3 |
| DC boost converter 20V→42V | — | AliExpress | $5 |
| Waterproof USB-C port | — | AliExpress | $6 |
| PAS sensor | — | GreenBikeKit | $10 |
| Buttons ×2 + grommets ×6 | — | AliExpress | $8 |
| Bayonet end cap (machined) | Machine shop | — | $30 |
| Nickel strip + wiring | — | AliExpress | $12 |
| E-bike subtotal | ~$418 |
💰 Grand Total
| Bike parts | ~$512 |
| E-bike parts | ~$418 |
| Frame | $180 |
| Total | ~$1,110 |
okay. add it. and find some aliexpres items for Rim tape ×2
~$5, not yet added
Headset spacers
~$3, not yet added so we complete the list
Found both. Here are the picks:
Rim Tape
PVC Rim Tape ×2 — 700c pair — comes as a pair (2 strips), 700c, PVC, ~$3. Simple, does the job. Just match the width to your inner rim — 16mm or 18mm for a standard 700c rim.1
Headset Spacers
Carbon Fiber Spacers 1-1/8" 28.6mm — matte black — set of mixed heights (2/3/5/10mm), matte black carbon, ~$2. Matches the carbon stem and fork aesthetic perfectly.2
Omera — Final Parts List ✅
🚲 Bike Parts
| Part | Product | Link | Price |
|---|---|---|---|
| Fork | Nologo 700C Disc Carbon, UD Gloss Black | AliExpress | $44 |
| Headset | 1-1/8" Integrated Threadless, alloy, black | AliExpress | $15 |
| Headset Spacers | Carbon Fiber 1-1/8" 28.6mm, matte black set | AliExpress | $2 |
| Stem | No Logo 3K Carbon Stem, 31.8mm | AliExpress | $30 |
| Handlebar | NO LOGO 3K Full Carbon Flat Bar, 31.8mm | AliExpress | $25 |
| Grips | ODI Elite Motion clone, silicone lock-on, all black | AliExpress | $14 |
| Brakes F+R + Levers | Shimano MT200 Hydraulic Set (incl. levers) | AliExpress | $38 |
| Rotors F+R | Shimano Deore SM-RT56 6-Bolt, 180mm F / 160mm R | AliExpress | $22 |
| Crankset | 130 BCD 165mm Square Taper, 5-arm, black | AliExpress | $19 |
| Bottom Bracket | BSA 68mm Square Taper, sealed bearing | AliExpress | $6 |
| Pedals | Ultra Light Alloy Flat, black | AliExpress | $9 |
| Gates CDX Belt | Gates Carbon Drive CDX | Bikeman | $60 |
| Gates CDX Front Sprocket | Gates CDX Chainring, 130 BCD 5-bolt | Bikable | $55 |
| Gates CDX Rear Sprocket | Gates CDX Thread-On | Bike Components | $29 |
| Front Wheel | Pasak 700c Disc Hub, thru axle | AliExpress | $55 |
| Rim Tape ×2 | PVC 700c pair, 16/18mm | AliExpress | $3 |
| Tires ×2 | Kenda Kwest 700x25c all-black slick | AliExpress | $30 |
| Tubes ×2 | 700c standard | AliExpress | $8 |
| Saddle | ULLICYC Ultralight Full Carbon, black | AliExpress | $35 |
| Seatpost | NO LOGO Carbon Seatpost 27.2mm, matte black | AliExpress | $22 |
| Seatpost Clamp | Standard 31.8mm, black | AliExpress | $6 |
| Bike subtotal | ~$527 |
⚡ E-Bike Parts
| Part | Product | Link | Price |
|---|---|---|---|
| Rear wheel (motor) | Bafang G020 pre-built 700c | GreenBikeKit | $209 |
| Controller | PSW 250W sine wave (bare PCB) | AliExpress | $19 |
| BMS | Slim 10S 36V 25A | AliExpress | $10 |
| Cells ×22 | 26650 5000mAh | AliExpress | $99 |
| PTFE liner tube | — | AliExpress | $7 |
| USB-PD trigger board | — | AliExpress | $3 |
| DC boost converter 20V→42V | — | AliExpress | $5 |
| Waterproof USB-C port | — | AliExpress | $6 |
| PAS sensor | — | GreenBikeKit | $10 |
| Buttons ×2 + grommets ×6 | — | AliExpress | $8 |
| Bayonet end cap (machined) | Machine shop | — | $30 |
| Nickel strip + wiring | — | AliExpress | $12 |
| E-bike subtotal | ~$418 |
💰 Grand Total
| Bike parts | ~$527 |
| E-bike parts | ~$418 |
| Frame | $180 |
| Total | ~$1,125 |
✅ Status: Complete
All previously flagged issues resolved:
Chain→ Not needed, full belt drive3Bottom bracket→ BSA 68mm square taper addedCrankset incompatible→ Swapped to 130 BCD 5-arm, Gates CDX sprocket bolts on4Brake hoses→ Included in MT200 set5Rim tape→ ×2 pair added1Headset spacers→ Carbon set added2Grips→ ODI clone addedValve extenders→ Not needed, standard rim depthFront wheel size→ Confirmed 700c to match tires
$1,125 for a stealth carbon belt drive e-bike. List is locked. 🔒
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Footnotes
-
https://www.cyclingabout.com/carbon-belt-drive-everything-you-ever-need-to-know/ ↩
-
https://www.bike-components.de/en/Gates/CDX-Front-Belt-Drive-Sprocket-5-Arm-130-mm-Bolt-Circle-Diameter-p83799/ ↩
-
https://www.bike-discount.de/en/shimano-br-mt200-disc-brake-set ↩
-
https://www.aliexpress.com/w/wholesale-headset-spacers.html ↩
-
http://www.aliexpress.com/w/wholesale-bicycle-wheel-rim-tape.html ↩
yes
Here's a good one:
RISK 1-1/8" Carbon Steerer Compression Plug + Top Cap — ~$61
- 28.6mm, designed specifically for carbon steerers
- Alloy expansion body with knurled grip — won't slip
- Includes the top cap — so you get both pieces in one
- Black anodized, clean look
The RISK brand is well-known for this part — it's one of the most reviewed compression plugs on AliExpress. The expansion mechanism extends the full length of the stem clamp zone, which properly supports the carbon from the inside when you tighten the stem bolts.2
Pro tip: apply a thin layer of carbon grip paste inside the steerer before inserting — massively improves hold strength.2
Omera — Final Parts List ✅
🚲 Bike Parts
| Part | Product | Link | Price |
|---|---|---|---|
| Fork | Nologo 700C Disc Carbon, UD Gloss Black | AliExpress | $44 |
| Headset | 1-1/8" Integrated Threadless, alloy, black | AliExpress | $15 |
| Compression Plug + Top Cap | RISK 1-1/8" 28.6mm, carbon steerer, black | AliExpress | $6 |
| Headset Spacers | Carbon Fiber 1-1/8" 28.6mm, matte black set | AliExpress | $2 |
| Stem | No Logo 3K Carbon Stem, 31.8mm | AliExpress | $30 |
| Handlebar | NO LOGO 3K Full Carbon Flat Bar, 31.8mm | AliExpress | $25 |
| Grips | ODI Elite Motion clone, silicone lock-on, all black | AliExpress | $14 |
| Brakes F+R + Levers | Shimano MT200 Hydraulic Set (incl. levers) | AliExpress | $38 |
| Rotors F+R | Shimano Deore SM-RT56 6-Bolt, 160mm × 2 | AliExpress | $22 |
| Crankset | 130 BCD 165mm Square Taper, 5-arm, black | AliExpress | $19 |
| Bottom Bracket | BSA 68mm Square Taper, sealed bearing | AliExpress | $6 |
| Pedals | Ultra Light Alloy Flat, black | AliExpress | $9 |
| Gates CDX Belt | Gates Carbon Drive CDX | Bikeman | $60 |
| Gates CDX Front Sprocket | Gates CDX Chainring, 130 BCD 5-bolt | Bikable | $55 |
| Gates CDX Rear Sprocket | Gates CDX Thread-On | Bike Components | $29 |
| Front Wheel | Pasak 700c Disc Hub, thru axle | AliExpress | $55 |
| Rim Tape ×2 | PVC 700c pair, 16/18mm | AliExpress | $3 |
| Tires ×2 | Kenda Kwest 700x25c all-black slick | AliExpress | $30 |
| Tubes ×2 | 700c standard | AliExpress | $8 |
| Saddle | ULLICYC Ultralight Full Carbon, black | AliExpress | $35 |
| Seatpost | NO LOGO Carbon Seatpost 27.2mm, matte black | AliExpress | $22 |
| Seatpost Clamp | Standard 31.8mm, black | AliExpress | $6 |
| Bike subtotal | ~$533 |
⚡ E-Bike Parts
| Part | Product | Link | Price |
|---|---|---|---|
| Rear wheel (motor) | Bafang G020 pre-built 700c | GreenBikeKit | $209 |
| Controller | PSW 250W sine wave (bare PCB) | AliExpress | $19 |
| BMS | Slim 10S 36V 25A | AliExpress | $10 |
| Cells ×22 | 26650 5000mAh | AliExpress | $99 |
| PTFE liner tube | — | AliExpress | $7 |
| USB-PD trigger board | — | AliExpress | $3 |
| DC boost converter 20V→42V | — | AliExpress | $5 |
| Waterproof USB-C port | — | AliExpress | $6 |
| PAS sensor | — | GreenBikeKit | $10 |
| Buttons ×2 + grommets ×6 | — | AliExpress | $8 |
| Bayonet end cap (machined) | Machine shop | — | $30 |
| Nickel strip + wiring | — | AliExpress | $12 |
| E-bike subtotal | ~$418 |
💰 Grand Total
| Bike parts | ~$533 |
| E-bike parts | ~$418 |
| Frame | $180 |
| Total | ~$1,131 |
✅ All Issues Resolved
Every gap is closed. The only pre-order decisions left are:
- Gates belt tooth count — use the Gates calculator with your frame's chainstay length3
- Front wheel axle standard — confirm fork and wheel are both 12×100mm thru-axle
- Frame builder brief — belt split, 135mm rear dropouts, horizontal/sliding dropouts for belt tension, 68mm BSA shell4
$1,131 for a stealth carbon belt drive e-bike. List locked. 🔒
567891011121314151617
Footnotes
okay give me a combined spec sheet.
Here's the complete spec sheet for the Dosnoventa®03 Detroit frameset:
Frame Specifications
| Specification | Value |
|---|---|
| Frame Material | Columbus Airplane 7005-T6 triple butted alloy |
| Fork | Full carbon, tapered 1-1/8" |
| Headset (included) | Columbus Compass 1-1/8" carbon |
| Seat Clamp (included) | Columbus aluminum |
| Bottom Bracket | BSA 68mm |
| Seat Post Diameter | 27.2mm Ø |
| Fork Rake | 45mm |
| Tire Clearance (frame) | 700×28c max |
| Tire Clearance (fork) | 700×32c max |
| Ground Clearance | 290mm |
| Frame Weight (M) | 1450g |
| Fork Weight | 410g |
| Down Tube Length (calculated) | ~562mm (S) / ~581mm (M) / ~609mm (L) |
| Down Tube Profile | Ovalized (custom Columbus Airplane) |
Geometry by Size
| Measurement | S | M | L |
|---|---|---|---|
| Rider Height | 154–170cm | 171–182cm | 183–192cm |
| Seat Tube (C-C) | 470mm | 510mm | 550mm |
| Seat Tube (C-T) | 510mm | 550mm | 580mm |
| Head Tube Length | 90mm | 110mm | 140mm |
| Effective Top Tube | 505mm | 530mm | 565mm |
| Head Tube Angle | 74° | 74° | 74° |
| Seat Tube Angle | 76° | 76° | 76° |
| Stack | 468mm | 487mm | 516mm |
| Reach | 388mm | 408mm | 436mm |
| BB Drop | 41mm | 41mm | 41mm |
| Chainstay Length | 382mm | 382mm | 382mm |
| Down Tube Length (calculated) | ~562mm | ~581mm | ~609mm |
| Down Tube Angle | 42.7° | 41.0° | 38.8° |
Note: This is for the current aluminum Jet Black version. The new cromo-hybrid Detroit (releasing today, March 12, 2026) will have two chromoly tubes and 6mm dropouts — full specs not yet published.12
Footnotes
From the top (head tube end). Here's why:
Gravity Works For You
The down tube slopes downward from the head tube to the BB at about 41° from horizontal on the Detroit M. So:
Top loading (head tube end):
- Cells slide down into the tube by gravity when loading ✅
- Cells stay seated while riding — gravity pulls them away from the opening ✅
- To remove: tip the bike forward or use a pull-tab/ribbon to slide them out
- The electronics sit at the bottom (BB end) — permanently wired to the motor/PAS at the BB shell, short cable runs
Bottom loading (BB end):
- Have to push cells uphill against gravity when loading ❌
- Cells want to slide out toward the opening while riding — needs a more robust lock ❌
- BB area is crowded — crankset, PAS sensor, motor cable all converging there
- Electronics would sit at the top, far from the motor — longer wiring
Layout in the Tube
HEAD TUBE END (top, accessible)
├── Bayonet cap / hinge door ← battery loads here
├── Cell row 1 (3× 21700)
├── Cell row 2
├── Cell row 3
├── Cell row 4
├── Cell row 5
├── ~~~ 190mm electronics zone ~~~
├── BMS (63×52×12mm)
├── KT controller PCB
├── Boost converter + PD trigger
└── Fixed wiring → motor, PAS, USB-C port
BB END (bottom, sealed permanently)
Electronics at the bottom is better because:
- Short wire runs to the motor (exits at BB shell dropout) [ppl-ai-file-upload.s3.amazonaws](https://ppl-ai-file-upload.s3.amazonaws.com/web/direct-files/attachments/139085844/29f8498e-62b4-487c-8778-4da05be1fbe4/emotor.pdf)
- Short wire runs to PAS sensor (mounted at BB)
- Permanently sealed — no user access needed, weather-protected
- Heat sinks downward — electronics heat rises away from the battery above
The hinge/lock mechanism at the head tube end can be elegant — a machined aluminium cap that matches the head tube junction aesthetic. Black anodized, quarter-turn lock, flush fit. From the outside it just looks like the normal weld junction between the down tube and head tube.
I want the user to be able to take out the battery. the idea is to cut the alu frame. use the cut out as part of the battery. and have plastic that is glued to the cutout where the batteries goes in. we just slide all bats in. fasten them with some screw thing. and pop the battery into the frame. a lock melanism and hinge thing fastens it to the frame. also we should be able to charge the battery so it needs a charger port built into the battery. the user can swap out the individual bats them selfs by unscrewing 3 caps and pushing them out with gravity.
exactly. now we can make a smaller battery. more portable. comfy room for electronics. we need room for hinge and lock mechanism etc as well. yes update the price list
Here's the full updated BOM. Everything priced out:
Omera — Full Parts List (v2 — 48V/54V)
🚲 Bike Parts
| Part | Product | Link | Price |
|---|---|---|---|
| Fork | Nologo 700C Disc Carbon, UD Gloss Black | AliExpress | $44 |
| Headset | 1-1/8" Integrated Threadless, alloy, black | AliExpress | $15 |
| Compression Plug + Top Cap | RISK 1-1/8" 28.6mm, carbon steerer, black | AliExpress | $6 |
| Headset Spacers | Carbon Fiber 1-1/8" 28.6mm, matte black set | AliExpress | $2 |
| Stem | No Logo 3K Carbon Stem, 31.8mm | AliExpress | $30 |
| Handlebar | NO LOGO 3K Full Carbon Flat Bar, 31.8mm | AliExpress | $25 |
| Grips | ODI Elite Motion clone, silicone lock-on, all black | AliExpress | $14 |
| Brakes F+R + Levers | Shimano MT200 Hydraulic Set (incl. levers) | AliExpress | $38 |
| Rotors F+R | Shimano Deore SM-RT56 6-Bolt, 160mm × 2 | AliExpress | $22 |
| Crankset | 130 BCD 165mm Square Taper, 5-arm, black | AliExpress | $19 |
| Bottom Bracket | BSA 68mm Square Taper, sealed bearing | AliExpress | $6 |
| Pedals | Ultra Light Alloy Flat, black | AliExpress | $9 |
| Gates CDX Belt | Gates Carbon Drive CDX | Bikeman | $60 |
| Gates CDX Front Sprocket | Gates CDX Chainring, 130 BCD 5-bolt | Bikable | $55 |
| Gates CDX Rear Sprocket | Gates CDX Thread-On | Bike Components | $29 |
| Front Wheel | Pasak 700c Disc Hub, thru axle | AliExpress | $55 |
| Rim Tape ×2 | PVC 700c pair, 16/18mm | AliExpress | $3 |
| Tires ×2 | Kenda Kwest 700x25c all-black slick | AliExpress | $30 |
| Tubes ×2 | 700c standard | AliExpress | $8 |
| Saddle | ULLICYC Ultralight Full Carbon, black | AliExpress | $35 |
| Seatpost | NO LOGO Carbon Seatpost 27.2mm, matte black | AliExpress | $22 |
| Seatpost Clamp | Standard 31.8mm, black | AliExpress | $6 |
| Bike subtotal | ~$533 |
⚡ E-Bike Parts (Updated to 48V/54V)
| Part | Product | Link | Price |
|---|---|---|---|
| Rear wheel (motor) | Bafang G020 48V pre-built 700c, 135mm freewheel | GreenBikeKit | $209 |
| Controller | KT T06S 48V 250W sine wave, 15A | AliExpress | $23 |
| BMS | Bisida 15S 54V Li-ion, balanced | AliExpress | $15 |
| Cells ×15 | EVE 50E 21700 5000mAh 3.65V | AliExpress | $60 |
| PTFE liner tube | — | AliExpress | $7 |
| USB-PD trigger board | — | AliExpress | $3 |
| DC boost converter 20V→63V | — | AliExpress | $6 |
| Waterproof USB-C port | — | AliExpress | $6 |
| PAS sensor | — | GreenBikeKit | $10 |
| Buttons ×2 + grommets ×6 | — | AliExpress | $8 |
| Bayonet end cap (machined) | Machine shop | — | $30 |
| Nickel strip + wiring | — | AliExpress | $12 |
| E-bike subtotal | ~$389 |
💰 Grand Total
| Bike parts | ~$533 |
| E-bike parts | ~$389 |
| Frame | $180 |
| Total | ~$1,102 |
What Changed (36V → 48V/54V)
| Old 36V | New 54V | Δ | |
|---|---|---|---|
| Cells | 22× 26650 ($99) | 15× 21700 ($60) | −$39 |
| Controller | PSW 36V ($19) | KT T06S 48V ($23) | +$4 |
| BMS | 10S ($10) | 15S ($15) | +$5 |
| Boost converter | $5 | $6 | +$1 |
| E-bike subtotal | $418 | $389 | −$29 |
Fewer cells, lower cost, more space in the tube, higher voltage (more efficient motor operation), and room for the hinge/lock mechanism. The battery pack itself is only 350mm long — leaving ~190mm in a 541mm tube for everything else.12
Down Tube Layout
[===== 350mm battery (15× 21700) =====][=== 190mm electronics + hinge/lock ===]
$1,102 total. Under budget. Single tube. Done. 🔒
34567891011121314151617181920212223242526272829
Footnotes
-
https://www.greenbikekit.com/rm-g020-swx02-bafang-hub-motor-750w-500w.html ↩
-
https://www.powallon-e.com/collections/bafang-ebike-conversion-kit-with-battery ↩
-
https://queenbattery.com.cn/our-products/812-4v-72v-2s1p-samsung-21700-50e-battery-pack-inr21700-50e-5000mah-with-pcmpcb-3a-5a-conwith-22awg-silicon-wire.html ↩
-
https://www.walmart.com/ip/48V-500W-Bafang-700C-Rear-Wheel-Hub-Motor-Kits-EBike-Conversion-Kits-with-500C-Battery-is-not-Included/14786214238 ↩
-
https://endless-sphere.com/sphere/threads/smallest-battery-suggestions-for-6-mile-ride-and-bafang-bbshd.93440/ ↩
-
https://www.aliexpress.com/w/wholesale-battery-48v-150a-bms.html ↩
-
https://www.facebook.com/groups/electricmotorcyclebuilds/posts/3238232149647467/ ↩
-
https://budgetlightforum.com/t/test-review-of-samsung-inr21700-50e-5000mah-cyan/56601 ↩
This is a legit engineering concern. Cutting 50% of a structural tube for 400mm is serious — but it's a solved problem. Every modern e-bike with a removable down tube battery does exactly this.leoguarbikes+1
The Structural Issue
The down tube handles compression + bending — it's one of the most loaded frame members. A 50mm tube with a 400mm × 50% cutout becomes an open C-channel, which has dramatically less stiffness and strength in certain directions. Without the battery cartridge in place, the frame would be dangerously weak.[scienpg]
How to Solve It — The Battery IS Structure
This is already in your concept and it's the correct approach. The battery cartridge, when locked in, restores the tube to a closed section. The key is:[patents.google]
The Cartridge Must Be Load-Bearing
The aluminium cutout piece becomes the cartridge shell — same material, same curve, same wall thickness[ppl-ai-file-upload.s3.amazonaws]
When locked in, the tube is effectively whole again
The hinge and lock mechanism must handle shear loads, not just hold the door shut
Minimum Requirements
That brings the grand total from ~$1,102 to ~$1,227. Still well under $1,500. And you get a removable, chargeable, cell-swappable battery cartridge that doubles as a structural member.
Want me to update the master BOM with the frame cost revision?
The Structural Issue
The down tube handles compression + bending — it's one of the most loaded frame members. A 50mm tube with a 400mm × 50% cutout becomes an open C-channel, which has dramatically less stiffness and strength in certain directions. Without the battery cartridge in place, the frame would be dangerously weak. [scienpg](https://scienpg.com/scs/index.php/engineering/article/view/scse.2025.3.149)
How to Solve It — The Battery IS Structure
This is already in your concept and it's the correct approach. The battery cartridge, when locked in, restores the tube to a closed section. The key is: [patents.google](https://patents.google.com/patent/EP2134592B1/en)
The Cartridge Must Be Load-Bearing
- The aluminium cutout piece becomes the cartridge shell — same material, same curve, same wall thickness [ppl-ai-file-upload.s3.amazonaws](https://ppl-ai-file-upload.s3.amazonaws.com/web/direct-files/attachments/139085844/29f8498e-62b4-487c-8778-4da05be1fbe4/emotor.pdf)
- When locked in, the tube is effectively whole again
- The hinge and lock mechanism must handle shear loads, not just hold the door shut
Minimum Requirements
| Feature | Spec | Why |
|---|---|---|
| Hinge | Steel pin hinge, BB end | Pivot point at the high-stress end |
| Lock | Cam lock or over-centre latch, head tube end | Pulls cartridge tight against tube edges |
| Contact faces | Full-length rails along both cut edges | Distributes load evenly, not point-loaded |
| Fit tolerance | <0.5mm gap (laser cut) | Tight fit = load transfers through contact, not just through the hinge/lock |
| Gasket | Neoprene strip along rails | Weather seal + vibration damping |
| Cartridge material | Same 7005-T6 alu, 1.5mm | Matches frame stiffness |
What You CANNOT Do
- Never ride with the battery removed — the frame is an open C-section without it and could buckle [bikeforums](https://www.bikeforums.net/bicycle-mechanics/889745-aluminum-frame-how-tell-if-structural-integrity-has-been-compromised.html)
- Include a blank insert (dummy cartridge, no cells) for riders who want to go non-electric — same shell, no cells, maintains structural integrity
Where to Put the Hinge and Lock
HEAD TUBE END
└── Lock mechanism (cam latch, quarter-turn)
↑ user opens from here
│
│ ← 400mm cutout, underside of down tube
│ (hidden from view when bike is upright)
│
↓
└── Hinge pin (steel, 6mm)
BB END
Hinge at the BB end makes sense because:
- The cartridge swings down and forward to open — gravity assists
- The BB junction is a reinforced node (thick alu where 3 tubes meet) — strong anchor point for the hinge
- The lock at the head tube end pulls the cartridge up and tight against the frame rails
Charging Port
Build a USB-C female port into the cartridge near the head tube end (top of the cartridge when closed). When the cartridge is in the frame, this port is accessible through a small hole or flush-mounted in the frame surface. When the cartridge is removed, same port charges standalone — exactly like the old concept's removable cartridge idea. [ppl-ai-file-upload.s3.amazonaws](https://ppl-ai-file-upload.s3.amazonaws.com/web/direct-files/attachments/139085844/29f8498e-62b4-487c-8778-4da05be1fbe4/emotor.pdf)
Cell Replacement — 3 End Caps
Each of the 3 columns has a threaded aluminium end cap at the head tube end of the cartridge. Unscrew → cells slide out by gravity (tube is angled). Replace cells → screw cap back on. Brilliant because:
- User never touches wiring — nickel strips connect between rows inside
- Each column is independent — replace just the cells that degraded
- Standard 21700 from any supplier, forever [ppl-ai-file-upload.s3.amazonaws](https://ppl-ai-file-upload.s3.amazonaws.com/web/direct-files/attachments/139085844/29f8498e-62b4-487c-8778-4da05be1fbe4/emotor.pdf)
One Concern: Cost
The cartridge/hinge/lock mechanism adds manufacturing complexity. Updated estimate:
| Part | Old estimate | New estimate |
|---|---|---|
| Frame (plain) | $180 | — |
| Frame with cutout + rails + hinge mount | — | $220 |
| Machined cartridge (from cutout) | — | $40 |
| Hinge + cam lock hardware | — | $15 |
| 3× threaded end caps | $30 | $30 |
| Frame total | $180 | ~$305 |
That brings the grand total from ~$1,102 to ~$1,227. Still well under $1,500. And you get a removable, chargeable, cell-swappable battery cartridge that doubles as a structural member.
Want me to update the master BOM with the frame cost revision?
Here's the full design spec for your removable battery cartridge system.
The Core Idea
The down tube gets CNC-cut lengthwise into two pieces — the top 40% stays permanently welded to the frame as the structural backbone, and the bottom 60% becomes the removable battery cartridge. When locked in, it looks like a normal down tube.
How It Works
Battery cartridge = the aluminum cutout + plastic insert glued inside with 3 cell channels:
- Each channel holds 5 × 21700 cells in a line (Ø21.5mm bore)
- 3 knurled screw caps at the head tube end seal each channel
- Caps double as spring-loaded negative terminals (wave spring washer)
- To swap a cell: unscrew cap → tip cartridge down → cell drops out by gravity → insert fresh cell → screw cap back
Hinge + Lock
- BB end: stainless piano hinge — cartridge swings open like a door
- Head tube end: quarter-turn cam lock (keyed, like a laptop battery) — one-hand operation, anti-theft
Electrical
- All 15 cells wired 15S1P via nickel strips along the channels — 54V / 270 Wh
- Slim 15S BMS (65 × 30 × 3mm) sits in the pocket behind the cells
- USB-C PD charge port (65W) recessed into the aluminum shell with rubber cap — ~4 hour full charge
- XT30 output connector flush-mounted, mates automatically with a frame-side socket when cartridge locks shut (or spring pogo pins for a seamless look)
Structural Concern
Cutting 60% of the tube circumference is aggressive — the top 40% shell alone won't handle full riding loads. The overlap lip at the cut seam is critical: when the cartridge is locked in, the interlocking lip restores the tube's cross-section and load-bearing capacity. Consider adding 2mm extra wall thickness at the cut edges, or a small internal reinforcing sleeve at both ends where the cartridge meets the frame.
Weatherproofing
Silicone D-profile gasket along the full cut seam, O-ring on the lock, rubber cap on USB-C — gets you to IP54 (rain riding, no submersion). A 1mm drainage hole at the lowest point of the cartridge prevents trapped water.
This is a genuinely patentable design — the down tube IS the battery, user-swappable cells, no external case visible. Want me to create a proper parts BOM with sourcing links?
Here's the full updated BOM — saved as a CSV for you .
Omera v2 — Master BOM
🚲 Bike Parts — $533
40 parts. $1,262. Everything in the down tube. Removable, chargeable, cell-swappable. 🔒
Omera v2 — Master BOM
🚲 Bike Parts — $533
| # | Part | Product | Price |
|---|---|---|---|
| 1 | Fork | Nologo 700C Disc Carbon, UD Gloss Black | $44 |
| 2 | Headset | 1-1/8" Integrated Threadless, alloy, black | $15 |
| 3 | Compression Plug + Top Cap | RISK 1-1/8" 28.6mm, carbon steerer | $6 |
| 4 | Headset Spacers | Carbon Fiber 1-1/8" 28.6mm matte black set | $2 |
| 5 | Stem | No Logo 3K Carbon, 31.8mm | $30 |
| 6 | Handlebar | NO LOGO 3K Full Carbon Flat Bar, 31.8mm | $25 |
| 7 | Grips | ODI Elite Motion clone, silicone lock-on | $14 |
| 8 | Brakes F+R + Levers | Shimano MT200 Hydraulic Set | $38 |
| 9 | Rotors F+R | Shimano Deore SM-RT56 6-Bolt, 160mm × 2 | $22 |
| 10 | Crankset | 130 BCD 165mm Square Taper, 5-arm | $19 |
| 11 | Bottom Bracket | BSA 68mm Square Taper, sealed | $6 |
| 12 | Pedals | Ultra Light Alloy Flat | $9 |
| 13 | Gates CDX Belt | Gates Carbon Drive CDX | $60 |
| 14 | Gates CDX Front Sprocket | 130 BCD 5-bolt | $55 |
| 15 | Gates CDX Rear Sprocket | Thread-On | $29 |
| 16 | Front Wheel | Pasak 700c Disc Hub | $55 |
| 17 | Rim Tape ×2 | PVC 700c pair | $3 |
| 18 | Tires ×2 | Kenda Kwest 700x25c all-black slick | $30 |
| 19 | Tubes ×2 | 700c standard | $8 |
| 20 | Saddle | ULLICYC Ultralight Full Carbon | $35 |
| 21 | Seatpost | NO LOGO Carbon 27.2mm matte black | $22 |
| 22 | Seatpost Clamp | Standard 31.8mm | $6 |
⚡ E-Bike Parts — $369
| # | Part | Product | Price |
|---|---|---|---|
| 23 | Rear wheel (motor) | Bafang G020 48V pre-built 700c, 135mm freewheel [greenbikekit](https://www.greenbikekit.com/rm-g020-swx02-bafang-hub-motor-750w-500w.html) | $209 |
| 24 | Controller | KT T06S 48V 250W sine wave [aliexpress](https://www.aliexpress.com/item/1005005378030779.html) | $23 |
| 25 | Smart BMS | GreenBikeKit 15S 54V, Bluetooth [greenbikekit](https://www.greenbikekit.com/battery-bms-smart-13s-14s-10s-11s-12s-15s-16s-17s-48v-52v-50a-60a-80a.html) | $25 |
| 26 | Cells ×15 | EVE 50E 21700 5000mAh [aliexpress](https://www.aliexpress.com/item/1005009078634233.html) | $60 |
| 27 | PTFE liner tube | 26mm ID sleeve for cell columns | $7 |
| 28 | USB-PD trigger board | 20V PD negotiation | $3 |
| 29 | DC boost converter | 20V→63V CC/CV charge profile | $6 |
| 30 | Waterproof USB-C port | Panel mount on cartridge | $6 |
| 31 | PAS sensor | 12-magnet, BB mount | $10 |
| 32 | Buttons ×2 | Weatherproof rubber flush | $5 |
| 33 | Rubber grommets ×6 | 6mm cable protection | $3 |
| 34 | Nickel strip + wiring | Cell connection harness | $12 |
🔧 Frame + Cartridge — $330
| # | Part | Product | Price |
|---|---|---|---|
| 35 | Custom alu frame | 7005-T6, 50mm DT, 135mm drops, cutout + rails + hinge mount | $220 |
| 36 | Battery cartridge | Machined from DT cutout, 3D-printed cell sled | $40 |
| 37 | Hinge + cam lock | Steel pin hinge (BB end) + cam latch (HT end) | $15 |
| 38 | Threaded end caps ×3 | Machined alu, O-ring seal, one per column | $30 |
| 39 | Neoprene gasket strip | Weather seal along cartridge rails | $5 |
| 40 | Dummy insert | Blank cartridge for riding without battery | $20 |
💰 Totals
| Bike parts | $533 |
| E-bike parts | $369 |
| Frame + cartridge | $330 |
| Shipping estimate | $30 |
| Grand total | $1,262 |
🔋 Battery Cartridge Spec
| Cells | 15× 21700 (EVE 50E, 5000mAh) |
| Config | 15S1P — 3 columns × 5 rows, all series |
| Voltage | 54.0V nom / 63.0V max |
| Energy | 270Wh |
| Cartridge weight | ~1,300g (cells + shell + hardware) |
| Cartridge length | ~400mm |
| Charging | USB-C PD port built into cartridge |
| Cell swap | 3 threaded end caps, cells slide out by gravity |
| Structural | Cartridge restores tube section when locked in |
40 parts. $1,262. Everything in the down tube. Removable, chargeable, cell-swappable. 🔒
Mostly solid, a few things I'd push back on:
✅ Good
Knurled screw caps with wave spring washers as negative terminals — this is clever. The spring maintains constant pressure on the cell stack as the bike vibrates, preventing intermittent connections. Elegant dual-purpose design.
XT30 auto-mating connector — clean. When the cartridge clicks shut, the XT30 male/female engage automatically. No user wiring. Rated for 30A continuous which is way more than your ~5A draw. Cheap, proven, weatherproof if greased.
1mm drainage hole — small detail, huge practical value for Oslo weather.
USB-C PD charge port with rubber cap on the cartridge itself — means you can charge in-frame or on the kitchen table. Exactly the original concept's vision.[ppl-ai-file-upload.s3.amazonaws]
⚠️ Concerns
60/40 split is too aggressive. 50/50 is already pushing it structurally. At 60% removed, the remaining top shell is a shallow channel that will flex and eventually fatigue-crack at the cut edges under braking loads. I'd go 50/50 — still plenty of access to slide cells in, but significantly stronger remaining section. The 3× 21700 triangular pack is only ~43.5mm wide — you don't need 60% of a 50mm tube open to access it.[scienpg]
Piano hinge is overkill and fragile. A full-length piano hinge along a vibrating bicycle tube will eventually work-loose or corrode. Two discrete pin hinges (one at each end of the cutout near the BB) are stronger, simpler to replace, and easier to seal against water.
BMS behind the cells (in the cartridge) — this means the BMS is removable with the cartridge. That's fine for the battery, but the BMS also needs to talk to the controller which lives in the frame's electronics bay. Every time you remove/insert the cartridge, the BMS-to-controller data connection must mate cleanly. The XT30 handles power, but you'd need a second connector for the BMS balance/comm wires — or put the BMS in the frame-side electronics bay instead, with only the raw cell taps coming through the connector.
I'd actually keep the BMS in the cartridge as proposed — it means the cartridge is a self-contained smart battery that protects itself regardless of what it's plugged into. Just add a small 4-pin signal connector alongside the XT30 for BMS→controller comms.
"Genuinely patentable" — probably not. EP2134592B1 covers bicycle frames with integrated detachable batteries in structural tubes. There's extensive prior art. But that's a branding concern, not an engineering one.[patents.google]
Revised Spec
Both connectors are cheap (<$2 total), waterproof variants exist, and they're polarized so you can't plug them wrong.
The overall design is sound. The other agent did good work — just needs the 50/50 correction and the signal connector addition. Want me to update the BOM with the revised cartridge spec?
✅ Good
Knurled screw caps with wave spring washers as negative terminals — this is clever. The spring maintains constant pressure on the cell stack as the bike vibrates, preventing intermittent connections. Elegant dual-purpose design.
XT30 auto-mating connector — clean. When the cartridge clicks shut, the XT30 male/female engage automatically. No user wiring. Rated for 30A continuous which is way more than your ~5A draw. Cheap, proven, weatherproof if greased.
1mm drainage hole — small detail, huge practical value for Oslo weather.
USB-C PD charge port with rubber cap on the cartridge itself — means you can charge in-frame or on the kitchen table. Exactly the original concept's vision. [ppl-ai-file-upload.s3.amazonaws](https://ppl-ai-file-upload.s3.amazonaws.com/web/direct-files/attachments/139085844/29f8498e-62b4-487c-8778-4da05be1fbe4/emotor.pdf)
⚠️ Concerns
60/40 split is too aggressive. 50/50 is already pushing it structurally. At 60% removed, the remaining top shell is a shallow channel that will flex and eventually fatigue-crack at the cut edges under braking loads. I'd go 50/50 — still plenty of access to slide cells in, but significantly stronger remaining section. The 3× 21700 triangular pack is only ~43.5mm wide — you don't need 60% of a 50mm tube open to access it. [scienpg](https://scienpg.com/scs/index.php/engineering/article/view/scse.2025.3.149)
Piano hinge is overkill and fragile. A full-length piano hinge along a vibrating bicycle tube will eventually work-loose or corrode. Two discrete pin hinges (one at each end of the cutout near the BB) are stronger, simpler to replace, and easier to seal against water.
BMS behind the cells (in the cartridge) — this means the BMS is removable with the cartridge. That's fine for the battery, but the BMS also needs to talk to the controller which lives in the frame's electronics bay. Every time you remove/insert the cartridge, the BMS-to-controller data connection must mate cleanly. The XT30 handles power, but you'd need a second connector for the BMS balance/comm wires — or put the BMS in the frame-side electronics bay instead, with only the raw cell taps coming through the connector.
I'd actually keep the BMS in the cartridge as proposed — it means the cartridge is a self-contained smart battery that protects itself regardless of what it's plugged into. Just add a small 4-pin signal connector alongside the XT30 for BMS→controller comms.
"Genuinely patentable" — probably not. EP2134592B1 covers bicycle frames with integrated detachable batteries in structural tubes. There's extensive prior art. But that's a branding concern, not an engineering one. [patents.google](https://patents.google.com/patent/EP2134592B1/en)
Revised Spec
| Detail | Other agent | My revision |
|---|---|---|
| Split ratio | 60/40 | 50/50 — still fits, much stronger |
| Hinge | Piano hinge full-length | 2× discrete pin hinges at BB end |
| Lock | Quarter-turn cam, keyed | ✅ Agree — keep as-is |
| BMS location | In cartridge | ✅ Agree — self-contained smart battery |
| Power connector | XT30 auto-mate | ✅ Agree |
| Signal connector | Not specified | Add 4-pin JST for BMS→controller |
| Wall reinforcement | 2mm extra at cut edges | ✅ Agree — thicken the lip zone |
| Screw caps | Knurled + wave spring | ✅ Agree — elegant |
| Drainage | 1mm hole at lowest point | ✅ Agree |
| Weatherproofing | Silicone D-gasket + O-rings | ✅ Agree — IP54 realistic |
Updated Connector Spec
When the cartridge locks shut, two connections mate automatically:
| Connector | Carries | Rating |
|---|---|---|
| XT30 | Battery power (54V, 5A continuous) | 30A max |
| 4-pin JST-SM | BMS UART + temperature sense | Signal level |
Both connectors are cheap (<$2 total), waterproof variants exist, and they're polarized so you can't plug them wrong.
The overall design is sound. The other agent did good work — just needs the 50/50 correction and the signal connector addition. Want me to update the BOM with the revised cartridge spec?
All your revisions are incorporated. Here's the updated BOM:
Cost Breakdown
€296 total with primary choices (€280 with cheapest alternatives). The spot welder is a one-time tool purchase — subtract €45 if you already have one or borrow from a maker space.
Sourcing for Oslo
nkon.nl (Netherlands) — cells + nickel strip. Best EU prices, handles Li-ion shipping properlynkon+1
electrokit.com (Sweden) — wire, heat shrink, nickel strip backup. 1–3 day delivery next door[electrokit]
Biltema / Clas Ohlson (local Oslo) — gaskets, O-rings, adhesive, misc hardware
euro-locks.com — quarter-turn cam lock, IP65 rated, keyed alike option[euro-locks]
AliExpress (2–3 week lead) — XT30AW waterproof connectors, spot welder, USB-C panel mount[aliexpress]
One Flag: The Knurled Caps
The CNC thumbscrew caps (€36 for 3) are the most custom part. Options to reduce cost:
Shapeways / JLCPCB CNC — upload a STEP file, get 6 machined in aluminum for ~€50–70 total
3D print in brass-fill PETG as prototype, then CNC the final version
Or simplify to a quarter-turn bayonet instead of threaded — cheaper to machine, faster to operate, no cross-threading risk
The BMS with Bluetooth is a nice touch — you can monitor cell voltages, temperature, and charge state from your phone via the app. The UART output goes through the JST-SM to your motor controller for SOC display / low-voltage cutoff.greenbikekit+1
Cost Breakdown
€296 total with primary choices (€280 with cheapest alternatives). The spot welder is a one-time tool purchase — subtract €45 if you already have one or borrow from a maker space.
| Category | Cost | % |
|---|---|---|
| Cells (15× Samsung 50E) | €51.75 | 17% |
| Plastic insert + adhesive | €47.00 | 16% |
| Cell retention (CNC caps + springs) | €45.00 | 15% |
| Spot welder (one-time tool) | €45.00 | 15% |
| BMS (15S smart, BT + UART) | €35.00 | 12% |
| Wiring (nickel, silicone, kapton) | €29.65 | 10% |
| Hinge + lock | €18.00 | 6% |
| Connectors (XT30AW + JST-SM + USB-C) | €14.10 | 5% |
| Sealing (gaskets, O-rings, caps) | €10.50 | 4% |
Sourcing for Oslo
- nkon.nl (Netherlands) — cells + nickel strip. Best EU prices, handles Li-ion shipping properly nkon
- electrokit.com (Sweden) — wire, heat shrink, nickel strip backup. 1–3 day delivery next door electrokit
- Biltema / Clas Ohlson (local Oslo) — gaskets, O-rings, adhesive, misc hardware
- euro-locks.com — quarter-turn cam lock, IP65 rated, keyed alike option euro-locks
- AliExpress (2–3 week lead) — XT30AW waterproof connectors, spot welder, USB-C panel mount [aliexpress](https://www.aliexpress.com/item/1005007906822275.html)
One Flag: The Knurled Caps
The CNC thumbscrew caps (€36 for 3) are the most custom part. Options to reduce cost:
- Shapeways / JLCPCB CNC — upload a STEP file, get 6 machined in aluminum for ~€50–70 total
- 3D print in brass-fill PETG as prototype, then CNC the final version
- Or simplify to a quarter-turn bayonet instead of threaded — cheaper to machine, faster to operate, no cross-threading risk
The BMS with Bluetooth is a nice touch — you can monitor cell voltages, temperature, and charge state from your phone via the app. The UART output goes through the JST-SM to your motor controller for SOC display / low-voltage cutoff. greenbikekit
Much tighter now. Everything fits with the reduced 35mm sealed section at the head tube end:
The BMS runs 4mm past the cutout edge into the sealed zone — that's actually fine since the hinge is right there and the BMS just needs to physically sit in that space. The controller lives in the sealed BB section, permanently wired to the motor.
No wasted space. Everything packed tight from head tube to BB.s3.amazonaws
There are three solid options, each with a different UX feel:
Option 1: Quarter-Turn Cam Latch (Recommended)
Southco E5 Mini or generic equivalent — the industry standard for panel access.southco+1
Turn 90° with a coin, hex key, or custom tool to open
Ramped cam pulls the cartridge tight against the frame (anti-vibration)[southco]
Flush mount, ~16mm diameter cutout
Stainless steel or zinc alloy, IP66 rated when sealed[alibaba]
~$2–5 on AliExpress for generic clones[aliexpress]
This is what most e-bike battery locks use (Bosch, Shimano, etc.) — proven in bikes. You could use a keyed version for anti-theft, so the battery can't be removed without the key.[support.biktrix][youtube]
Option 2: Push-to-Close Rotary Latch
Southco R4 Micro — push the cartridge closed, it clicks and locks.southco+1
No tool needed to close — just push the cartridge up and it latches
Release via a small lever or cable pull
Completely concealed — nothing visible from outside
Tolerates misalignment (good for a hand-fitted cartridge)
Anti-vibration bumper built in
~$5–10 on AliExpress
This is used in automotive panels and EV battery doors. More elegant UX but slightly bulkier internally.
Option 3: Push-Push Spring Latch
Simple spring-loaded plunger — push to close, push again to pop open.fornd+1
Simplest mechanism, zero moving parts on the outside
No key, no tool — completely invisible flush surface
Cheapest: ~$1–2 on AliExpress
BUT: no anti-theft. Anyone who knows where to push can open it
Weaker holding force — may rattle on rough roads
Comparison
My Pick
Quarter-turn cam latch, keyed — specifically the Southco E5 Mini or a generic clone. It's what every major e-bike brand uses for removable batteries because it solves anti-theft and anti-vibration in one $3 part. The small keyhole on the underside of the down tube is invisible from normal viewing angles, and you already carry a key for your bike lock anyway.[southco]
Want to go with the keyed quarter-turn, or do you prefer the push-to-close for the cleaner UX?
Option 1: Quarter-Turn Cam Latch (Recommended)
Southco E5 Mini or generic equivalent — the industry standard for panel access. southco
- Turn 90° with a coin, hex key, or custom tool to open
- Ramped cam pulls the cartridge tight against the frame (anti-vibration) [southco](https://southco.com/en_any_int/e5-1-125-170)
- Flush mount, ~16mm diameter cutout
- Stainless steel or zinc alloy, IP66 rated when sealed [alibaba](https://www.alibaba.com/pla/Southco-E5-Quarter-Turn-Cam-Lock_1600267310866.html?mark=google_shopping&biz=pla&searchText=locks&product_id=1600267310866&pcy=gb_en)
- ~$2–5 on AliExpress for generic clones [aliexpress](https://www.aliexpress.com/w/wholesale-southco-latch.html)
This is what most e-bike battery locks use (Bosch, Shimano, etc.) — proven in bikes. You could use a keyed version for anti-theft, so the battery can't be removed without the key. [support.biktrix](https://support.biktrix.com/kb/guide/en/replacing-a-hidden-battery-lock-cZ7hhQN5t9/Steps/1116481)
Option 2: Push-to-Close Rotary Latch
Southco R4 Micro — push the cartridge closed, it clicks and locks. southco
- No tool needed to close — just push the cartridge up and it latches
- Release via a small lever or cable pull
- Completely concealed — nothing visible from outside
- Tolerates misalignment (good for a hand-fitted cartridge)
- Anti-vibration bumper built in
- ~$5–10 on AliExpress
This is used in automotive panels and EV battery doors. More elegant UX but slightly bulkier internally.
Option 3: Push-Push Spring Latch
Simple spring-loaded plunger — push to close, push again to pop open. fornd
- Simplest mechanism, zero moving parts on the outside
- No key, no tool — completely invisible flush surface
- Cheapest: ~$1–2 on AliExpress
- BUT: no anti-theft. Anyone who knows where to push can open it
- Weaker holding force — may rattle on rough roads
Comparison
| Quarter-Turn Cam | Rotary (R4) | Push-Push | |
|---|---|---|---|
| Anti-theft | ✅ Keyed option | ❌ None | |
| Anti-vibration | ✅ Ramped cam | ✅ Integrated bumper | |
| Stealth | ✅ Fully concealed | ✅ Fully concealed | |
| UX to close | Turn 90° with key | Push shut, clicks | Push shut, clicks |
| UX to open | Turn key 90° | Pull lever/cable | Push again |
| Price | ~$3 | ~$8 | ~$1 |
| Proven in e-bikes | ✅ Bosch, Shimano use this | ❌ Not common | |
| Weather sealed | ✅ IP66 variants exist | ✅ Sealed versions |
My Pick
Quarter-turn cam latch, keyed — specifically the Southco E5 Mini or a generic clone. It's what every major e-bike brand uses for removable batteries because it solves anti-theft and anti-vibration in one $3 part. The small keyhole on the underside of the down tube is invisible from normal viewing angles, and you already carry a key for your bike lock anyway. [southco](https://southco.com/en_any_int/e5-m-142-uu1)
Want to go with the keyed quarter-turn, or do you prefer the push-to-close for the cleaner UX?
The term you're looking for is "keyed to differ" — each lock gets a unique key combination, so no two customers can open each other's battery.
How It Works
Lock manufacturers offer two keying modes:
At scale (100+ frames), you can get Euro-Locks to supply a master key system — each customer has their unique key, but you hold a master that opens all units for warranty service.[euro-locks]
How It Works
Lock manufacturers offer two keying modes:
| Mode | Meaning | Use Case |
|---|---|---|
| Keyed alike | All locks use the same key | Your own fleet / prototyping |
| Keyed to differ | Each lock has a unique key | Selling to individual customers ✅ |
When you order "keyed to differ," each lock ships with its own unique key combination. Standard cam locks typically have hundreds to thousands of key differs — enough that the chance of two customers having the same key is negligible. ironmongerydirect.co
Best Options for Unique Keys
Euro-Locks F328 — Keyed to Differ
The same IP65 cam lock, but each unit gets a unique key. Available on RS Components Norway as a different SKU:
- RS Norway (keyed to differ, 1242E series): [no.rs-online.com/web/p/camlocks/3851968](https://no.rs-online.com/web/p/camlocks/3851968) no.rs-online
- RS Norway (keyed to differ, 455E series): Same F328 body, different key group [elfa](https://www.elfa.se/en/euro-locks-lowe-fletcher-group-company-camlock-16mm-panel-to-tongue-23-20-2mm-cutout-key-unlock-euro-locks-lowe-fletcher-group-company-f328-03-455e/p/30489295?pos=5&origPos=6&origPageSize=50&track=false&itemList=manufacturer)
- Each lock ships with 2 keys + gasket
Standard 16mm Cam Lock — Keyed to Differ
Cheaper options if IP65 isn't critical (your gasket already handles sealing):
- A&H Brass — 16mm, keyed to differ, multiple finishes, ~£8.20: [ahbrass.co.uk](https://ahbrass.co.uk/products/cabinet-cam-lock-k-differ-16-mm-hole) ahbrass.co
- Ironmongery Direct — 19×16mm, you choose "keyed to differ" at checkout, ~£8: [ironmongerydirect.co.uk](https://www.[ironmongerydirect.co](https://www.ironmongerydirect.co.uk/product/cam-lock-19-x-16mm-keyed-alike-differ-1-nickel-plated--802812).uk/product/cam-lock-19-x-16mm-keyed-alike-differ-1-nickel-plated--802812) ironmongerydirect.co
- Maxus 16mm — keyed to differ default, 2 keys included: [lockstation.co.uk](https://www.[lockstation.co](https://www.lockstation.co.uk/maxus-standard-cam-lock-16mm-keyed-to-differ).uk/maxus-standard-cam-lock-16mm-keyed-to-differ) lockstation.co
Scaling Up: Key Management
If you're producing these frames as a product, consider the ABUS One Key approach — each customer gets a unique key code, and can later order spare keys or matching locks using that code. Euro-Locks and Lowe & Fletcher offer the same service for their cam locks: every lock has a stamped key number, and replacements can be ordered by code years later. lowe-and-fletcher.co
For a production run, you'd order something like:
| Qty | Model | Keying | Price Est. |
|---|---|---|---|
| 1–10 pcs | Euro-Locks F328 keyed to differ | Each unique | ~€15–25 each (retail) |
| 50+ pcs | Euro-Locks F328 keyed to differ (bulk) | Each unique, codes tracked | ~€8–12 each (contact Euro-Locks sales) |
| 100+ pcs | Custom cylinder from Lowe & Fletcher | Your own key profile | Quoted per project |
At scale (100+ frames), you can get Euro-Locks to supply a master key system — each customer has their unique key, but you hold a master that opens all units for warranty service. [euro-locks](https://www.euro-locks.com/en/products/mechanical-locks/quarter-turn-locks/)
Now I have a crucial finding. The Dosnoventa Detroit specs say "Columbus Compass 1-1/8" Carbon" headset dosnoventabikes+1. This is the straight 1-1/8" version (IS42/28.6 both top and bottom), which uses a head tube with 46mm OD and 41.2mm ID fishtailcyclery+2. However, looking more carefully at the newer Dosnoventa Detroit spec (), the fork is listed as "TAPERED 1-1/8"", and the Cinelli Vigorelli version (same Columbus Airplane) uses IS 42/28.6 | IS 52/40 (tapered) [scalibruno]. Let me verify which version the current Detroit actually uses.
Looking at the data from (the current Dosnoventa Detroit frameset page), it clearly states: "FULL CARBON FORK . TAPERED 1-1/8"" and "COLUMBUS COMPASS . 1-1/8" CARBON". The "Tapered 1-1/8"" description on the fork means the fork steerer starts at 1-1/8" and tapers, but the frame headset listed is "Columbus Compass 1-1/8" Carbon" which is the straight version (IS42/IS42). This means the head tube is straight 1-1/8" (not tapered).
Now I have enough data to compile the answer. Let me consolidate everything.
Now I have all the data I need from the Columbus Airplane aluminum catalog and the Dosnoventa Detroit specifications. Here's what I found from the actual Columbus Airplane aluminum 7005 catalog (the framebuilder catalog from Columbus):[framebuilding]
Columbus Airplane 7005-T6 Tube Specifications
The Columbus Airplane is an OEM aluminum tubeset — it doesn't appear in the standard Columbus steel catalog. The specifications come from the Columbus aluminum catalog:[framebuilding]
Key Clarifications
The down tube at Ø42mm is the standard Airplane road/track DT — it's round triple butted, not the Ø48 oversized option. The Facebook post mentioning a MASH Cinelli Airplane frame listed "down tube 45mm", but that likely reflects an ovalized/hydroformed profile measurement rather than the nominal tube OD.facebook+1
The top tube at Ø35mm is consistent across the Airplane catalog — both listed TT codes are Ø35. This is oversized compared to standard steel (25.4mm) but standard for modern aluminum track frames.[framebuilding]
The seat tube at Ø31.7mm is standard for 27.2mm seatpost frames, confirmed by Dosnoventa's own spec.dosnoventabikes+1
The head tube is more complex. The Columbus catalogs list raw head tubes (CYRA18 series at Ø38mm) that accept brazed-in IS cups. The finished head tube with integrated bearing seats has a 46mm OD at the bearing race and 41.2mm ID, per Columbus Compass 1-1/8" headset specs.fishtailcyclery+2
The chainstays at Ø26mm are the track-specific Airplane stays (AT78 series), shorter and lighter than the Ø28mm road versions. These get ovalized/shaped toward the BB end.[framebuilding]
The seatstays at Ø19mm are larger than typical steel track stays (14mm) because aluminum requires larger diameters to achieve equivalent stiffness.[framebuilding]
Looking at the data from (the current Dosnoventa Detroit frameset page), it clearly states: "FULL CARBON FORK . TAPERED 1-1/8"" and "COLUMBUS COMPASS . 1-1/8" CARBON". The "Tapered 1-1/8"" description on the fork means the fork steerer starts at 1-1/8" and tapers, but the frame headset listed is "Columbus Compass 1-1/8" Carbon" which is the straight version (IS42/IS42). This means the head tube is straight 1-1/8" (not tapered).
Now I have enough data to compile the answer. Let me consolidate everything.
Now I have all the data I need from the Columbus Airplane aluminum catalog and the Dosnoventa Detroit specifications. Here's what I found from the actual Columbus Airplane aluminum 7005 catalog (the framebuilder catalog from Columbus): [framebuilding](http://www.framebuilding.com/acrobat%20files/Columbusaluminium2009.pdf)
Columbus Airplane 7005-T6 Tube Specifications
The Columbus Airplane is an OEM aluminum tubeset — it doesn't appear in the standard Columbus steel catalog. The specifications come from the Columbus aluminum catalog: [framebuilding](http://www.framebuilding.com/acrobat%20files/Columbusaluminium2009.pdf)
| Tube | OD (mm) | Notes / Source |
|---|---|---|
| Down tube | 42mm | Code ZALH12670 — Ø42, L=670mm, 2.2/1.0/1.4 triple butted, 260g. A Ø48 option (ZALS12670) also exists but is for larger/different frames [framebuilding](http://www.framebuilding.com/acrobat%20files/Columbusaluminium2009.pdf) |
| Top tube | 35mm | Code ATPS11600 — Ø35, L=600mm, 1.2/0.7/1.1 triple butted, 131g. Also ZALH11610 at Ø35, L=610mm with heavier walls [framebuilding](http://www.framebuilding.com/acrobat%20files/Columbusaluminium2009.pdf) |
| Seat tube | 31.7mm | Code ATPM13635001 — Ø31.7, L=635mm, 2.25/0.9/1.4 triple butted, 180g. This matches the confirmed 27.2mm seatpost diameter spec (31.7mm OD accommodates a 27.2mm post with appropriate wall thickness) framebuilding |
| Head tube | 46mm OD / 41.2mm ID | The Detroit uses the Columbus Compass 1-1/8" straight headset (IS42/28.6 top and bottom), which requires a head tube with 46mm OD and 41.2mm ID fishtailcyclery. The Columbus catalog lists the CYRA18240/600 head tube at Ø38 for integrated headsets, which is the shell OD that gets the IS cups brazed/welded in [ceeway](http://ceeway.com/acrobat%20files/Cat.%20COLUMBUS%20tubi2013_web.pdf) |
| Chainstay | 26mm (shaped/tapered) | Code AT7814OV420 — Ø26, L=420mm, 1.45/0.85 butted, shaped tapered, 92g. The Airplane catalog also lists a Ø28 option (ZALL14OV425). The Detroit's short 382mm chainstay [dosnoventabikes](https://dosnoventabikes.com/frames/ninepointnine-2/dosnoventa03-det-ninepointnine-frameset/) suggests the Ø26 track-specific stay [framebuilding](http://www.framebuilding.com/acrobat%20files/Columbusaluminium2009.pdf) |
| Seatstay | 19mm (tapered) | Code AT7915560001 — Ø19, L=560mm, 1.0 wall, round tapered, 72g [framebuilding](http://www.framebuilding.com/acrobat%20files/Columbusaluminium2009.pdf) |
| BB shell | ~42mm OD / 68mm wide | BSA 68mm confirmed in all Dosnoventa Detroit specs dosnoventabikes. Standard BSA shell OD is ~39.7–42mm |
Key Clarifications
- The down tube at Ø42mm is the standard Airplane road/track DT — it's round triple butted, not the Ø48 oversized option. The Facebook post mentioning a MASH Cinelli Airplane frame listed "down tube 45mm", but that likely reflects an ovalized/hydroformed profile measurement rather than the nominal tube OD. facebook
- The top tube at Ø35mm is consistent across the Airplane catalog — both listed TT codes are Ø35. This is oversized compared to standard steel (25.4mm) but standard for modern aluminum track frames. [framebuilding](http://www.framebuilding.com/acrobat%20files/Columbusaluminium2009.pdf)
- The seat tube at Ø31.7mm is standard for 27.2mm seatpost frames, confirmed by Dosnoventa's own spec. dosnoventabikes
- The head tube is more complex. The Columbus catalogs list raw head tubes (CYRA18 series at Ø38mm) that accept brazed-in IS cups. The finished head tube with integrated bearing seats has a 46mm OD at the bearing race and 41.2mm ID, per Columbus Compass 1-1/8" headset specs. fishtailcyclery
- The chainstays at Ø26mm are the track-specific Airplane stays (AT78 series), shorter and lighter than the Ø28mm road versions. These get ovalized/shaped toward the BB end. [framebuilding](http://www.framebuilding.com/acrobat%20files/Columbusaluminium2009.pdf)
- The seatstays at Ø19mm are larger than typical steel track stays (14mm) because aluminum requires larger diameters to achieve equivalent stiffness. [framebuilding](http://www.framebuilding.com/acrobat%20files/Columbusaluminium2009.pdf)
You're absolutely right — ball plungers alone won't hold under hard riding. You need an auto-engaging catch that locks the cartridge shut the moment it closes, with no user action required. The cam lock then adds anti-theft security on top.
The Fail-Safe Approach: Layered Retention
Total add: ~€15. The over-center latch is your "never forget" safety net.
The Fail-Safe Approach: Layered Retention
| Layer | Mechanism | User Action | Holds Against |
|---|---|---|---|
| 1. Auto-catch | Spring-loaded latch | None — auto-engages on close | Vibration, potholes, jumps |
| 2. Cam lock | Quarter-turn keyed | Manual (optional security) | Theft |
| 3. Ball plungers | Spring ball detent | None — alignment only | Nothing (just positioning) |
The auto-catch is the critical safety layer. Even if the user never touches the cam lock, the battery stays in.
Best Mechanism: Over-Center Draw Latch
An over-center latch is the gold standard for vibration-proof panel retention. The curved spring blade flexes over center when closing, creating tension that actively pulls the cartridge tight against the frame shell. It cannot open from vibration — it requires deliberate manual release. wdscomponents
Option A: Southco 97 Series Over-Center Latch
The industry reference for exactly this application. [southco](https://southco.com/en_any_int/latches/draw-latches/fixed-grip-draw-latches/97-over-center-series-latches)
- Spring blade curves over center = self-locking, vibration-proof
- No visible springs — tension is built into the blade curve
- Stainless steel, multiple sizes
- Smallest size: ~52mm mounting length
- Buy (Norway): [no.rs-online.com](https://no.rs-online.com/web/p/door-latches/2888537) — stainless steel spring-loaded draw latch [no.rs-online](https://no.rs-online.com/web/p/door-latches/2888537)
Option B: WDS Hidden Over-Center Draw Latch
Concealed design — all hardware hidden inside. Matt black powder coat. [wdscomponents](https://www.wdscomponents.com/en-gb/over-centre-hidden-fastening-draw-latch-small-matt-black)
- Tamper-proof: concealed fastenings, can't be pried open
- Over-center = positive lock under vibration
- Zinc alloy housing, 304 stainless internals
- M3 countersunk screw mounting
- ~£4.90 (~€5.70)
- Buy: [wdscomponents.com](https://www.[wdscomponents](https://www.wdscomponents.com/en-gb/over-centre-hidden-fastening-draw-latch-small-matt-black).com/en-gb/over-centre-hidden-fastening-draw-latch-small-matt-black) wdscomponents
Option C: Push-to-Close Spring Catch
Like a cabinet push latch — cartridge swings shut, spring catch grabs automatically. Press a button/tab to release. [aliexpress](https://www.aliexpress.com/item/1005005961733321.html)
- Simplest, cheapest (~€1–2)
- Auto-engages on close
- Release via thumb push on tab
- Buy: [AliExpress — push catch latch](https://www.aliexpress.com/item/1005005961733321.html) — €1.14, rated for cabinet/motorhome use [aliexpress](https://www.aliexpress.com/item/1005005961733321.html)
⚠️ Weakest of the three — fine for cabinets, marginal for bike vibration
My Recommendation: Combine Hidden Over-Center + Cam Lock
CLOSING SEQUENCE:
1. Swing cartridge shut
↓
2. Ball plungers guide alignment (click)
↓
3. Over-center latch AUTO-ENGAGES (snap!) ← SAFETY HOLD
→ Cartridge is now mechanically locked
→ Survives any vibration, potholes, jumps
↓
4. (Optional) Turn cam lock with key ← ANTI-THEFT
→ Now nobody can release the over-center latch
OPENING SEQUENCE:
1. Turn cam lock with key (releases latch guard)
↓
2. Flip over-center latch lever (manual)
↓
3. Cartridge swings open on hinges
The WDS hidden over-center latch is the best fit — it's compact, concealed, vibration-proof, and the matt black finish disappears into the frame. Mount it mid-seam on the cartridge. Position the cam lock so its tongue blocks the latch lever when locked — this means you physically can't release the over-center catch without the key first. [wdscomponents](https://www.wdscomponents.com/en-gb/over-centre-hidden-fastening-draw-latch-small-matt-black)
Updated BOM Addition
| Item | Qty | Price | Source |
|---|---|---|---|
| WDS over-center hidden draw latch, matt black | 1 | ~€5.70 | wdscomponents.com wdscomponents |
| M5 ball plungers (keep for alignment) | 2 | ~€4.60 ea | Misumi [uk.misumi-ec](https://uk.misumi-ec.com/vona2/detail/221005518857/) |
| — | — |
Total add: ~€15. The over-center latch is your "never forget" safety net.
You're absolutely right — ball plungers alone won't hold under hard riding. You need an auto-engaging catch that locks the cartridge shut the moment it closes, with no user action required. The cam lock then adds anti-theft security on top.
The Fail-Safe Approach: Layered Retention
Total add: ~€15. The over-center latch is your "never forget" safety net.
The Fail-Safe Approach: Layered Retention
| Layer | Mechanism | User Action | Holds Against |
|---|---|---|---|
| 1. Auto-catch | Spring-loaded latch | None — auto-engages on close | Vibration, potholes, jumps |
| 2. Cam lock | Quarter-turn keyed | Manual (optional security) | Theft |
| 3. Ball plungers | Spring ball detent | None — alignment only | Nothing (just positioning) |
The auto-catch is the critical safety layer. Even if the user never touches the cam lock, the battery stays in.
Best Mechanism: Over-Center Draw Latch
An over-center latch is the gold standard for vibration-proof panel retention. The curved spring blade flexes over center when closing, creating tension that actively pulls the cartridge tight against the frame shell. It cannot open from vibration — it requires deliberate manual release. wdscomponents
Option A: Southco 97 Series Over-Center Latch
The industry reference for exactly this application. [southco](https://southco.com/en_any_int/latches/draw-latches/fixed-grip-draw-latches/97-over-center-series-latches)
- Spring blade curves over center = self-locking, vibration-proof
- No visible springs — tension is built into the blade curve
- Stainless steel, multiple sizes
- Smallest size: ~52mm mounting length
- Buy (Norway): [no.rs-online.com](https://no.rs-online.com/web/p/door-latches/2888537) — stainless steel spring-loaded draw latch [no.rs-online](https://no.rs-online.com/web/p/door-latches/2888537)
Option B: WDS Hidden Over-Center Draw Latch
Concealed design — all hardware hidden inside. Matt black powder coat. [wdscomponents](https://www.wdscomponents.com/en-gb/over-centre-hidden-fastening-draw-latch-small-matt-black)
- Tamper-proof: concealed fastenings, can't be pried open
- Over-center = positive lock under vibration
- Zinc alloy housing, 304 stainless internals
- M3 countersunk screw mounting
- ~£4.90 (~€5.70)
- Buy: [wdscomponents.com](https://www.[wdscomponents](https://www.wdscomponents.com/en-gb/over-centre-hidden-fastening-draw-latch-small-matt-black).com/en-gb/over-centre-hidden-fastening-draw-latch-small-matt-black) wdscomponents
Option C: Push-to-Close Spring Catch
Like a cabinet push latch — cartridge swings shut, spring catch grabs automatically. Press a button/tab to release. [aliexpress](https://www.aliexpress.com/item/1005005961733321.html)
- Simplest, cheapest (~€1–2)
- Auto-engages on close
- Release via thumb push on tab
- Buy: [AliExpress — push catch latch](https://www.aliexpress.com/item/1005005961733321.html) — €1.14, rated for cabinet/motorhome use [aliexpress](https://www.aliexpress.com/item/1005005961733321.html)
⚠️ Weakest of the three — fine for cabinets, marginal for bike vibration
My Recommendation: Combine Hidden Over-Center + Cam Lock
CLOSING SEQUENCE:
1. Swing cartridge shut
↓
2. Ball plungers guide alignment (click)
↓
3. Over-center latch AUTO-ENGAGES (snap!) ← SAFETY HOLD
→ Cartridge is now mechanically locked
→ Survives any vibration, potholes, jumps
↓
4. (Optional) Turn cam lock with key ← ANTI-THEFT
→ Now nobody can release the over-center latch
OPENING SEQUENCE:
1. Turn cam lock with key (releases latch guard)
↓
2. Flip over-center latch lever (manual)
↓
3. Cartridge swings open on hinges
The WDS hidden over-center latch is the best fit — it's compact, concealed, vibration-proof, and the matt black finish disappears into the frame. Mount it mid-seam on the cartridge. Position the cam lock so its tongue blocks the latch lever when locked — this means you physically can't release the over-center catch without the key first. [wdscomponents](https://www.wdscomponents.com/en-gb/over-centre-hidden-fastening-draw-latch-small-matt-black)
Updated BOM Addition
| Item | Qty | Price | Source |
|---|---|---|---|
| WDS over-center hidden draw latch, matt black | 1 | ~€5.70 | wdscomponents.com wdscomponents |
| M5 ball plungers (keep for alignment) | 2 | ~€4.60 ea | Misumi [uk.misumi-ec](https://uk.misumi-ec.com/vona2/detail/221005518857/) |
| — | — |
Total add: ~€15. The over-center latch is your "never forget" safety net.
Here's where we stand and what's left:
✅ Decided
Battery: 15S1P, 15× 21700, 54V, 270Wh
Down tube: 50mm OD, 435mm cartridge cutout
Cartridge: hinged at BB, cam lock at HT, ball plungers, USB-C PD
Electronics: BMS in cartridge, controller in sealed BB section
Motor: Bafang G020 48V, pre-built 700c wheel
Controller: KT T06S 48V sine wave
Full BOM: $1,262
Lock: keyed quarter-turn cam + ball plunger snap
🔲 Still Need
The frame builder brief is the critical path — nothing else can start until the frame is ordered. That document needs to be tight: exact tube dimensions, geometry numbers, mount positions, and the cutout spec with tolerances.
Want to start on the frame builder brief?
Here's where we stand and what's left:
✅ Done
Frame geometry (Detroit clone, 135mm rear dropout)
Down tube battery design (50mm OD, 50/50 split, removable cartridge)
Battery config (15S1P, 3×5 × 21700, 54V / 270 Wh)
Cell retention (knurled caps + wave springs, gravity-swap)
Lock & snap mechanism (ball plungers + keyed cam lock)
Connectors (XT30AW power + JST-SM signal + USB-C PD charge)
BMS (15S smart, UART + BT, self-contained in cartridge)
Sealing & weatherproofing (IP54)
Full BOM with Oslo-friendly sourcing (~€296)
SVG technical drawing
🔲 Still To Do
What do you want to tackle next?
Good thinking. Here's everything you need to know spatially before you draw. Detroit vibe, Omera design.
Geometry (Detroit-Inspired, Not Copied)
The Detroit runs 74° HT / 76° ST / 382mm chainstay — aggressive pursuit geometry. Your Omera keeps the same spirit but the 50mm downtube is wider than Detroit's 42mm Columbus Airplane tube, so the frame silhouette will already look distinct. That fat downtube is the design identity.[ppl-ai-file-upload.s3.amazonaws]
Down Tube — The Main Event
This is where almost everything lives. 581mm center-line length (M size), 50mm OD, 47mm ID, 1.5mm wall.[ppl-ai-file-upload.s3.amazonaws]
Three zones from HT to BB:
HT sealed zone (0–35mm) — cam lock + over-center latch mount, ball plunger holes, frame-side XT30 female + JST-SM female socket
Cartridge cutout (35–470mm, 435mm long) — the 50/50 split, underside, hidden from view. Hinge rails along both long edges
BB sealed zone (470–581mm, ~110mm) — KT T06S controller PCB, PAS wiring, motor cable exit hole toward rear dropout
Inside the cartridge (435mm long):
351mm cell zone: 3 channels × 5 cells, PETG plastic insert glued inside the alu shell[ppl-ai-file-upload.s3.amazonaws]
95mm BMS/port zone (HT end of cartridge): 15S BMS (65×30×3mm), USB-C PD port with rubber cap, XT30 male + JST-SM male (auto-mate when locked)
3 knurled screw caps at HT end for cell swapping[ppl-ai-file-upload.s3.amazonaws]
When drawing the cross-section (looking from BB end):
textFRAME (top 50%, welded) ╭─────────────────────╮ │ lip lip │ │ ○ ○ ○ │ ← 3× 21700 triangle pack │ ○ ○ │ fits in 43.5mm envelope ╰─────────────────────╯ CARTRIDGE (bottom 50%, removable)
BB Junction — Crowded Node
Draw this area carefully, five things converge here:[ppl-ai-file-upload.s3.amazonaws]
Down tube enters from above-front (at ~41° from horizontal)
Seat tube rises at 76°
Chainstays exit rearward (both sides)
BSA 68mm shell sits at the center
2× pin hinges for cartridge mount on the underside of the DT/BB junction
What fits inside the sealed BB zone of the downtube (~110mm):
KT T06S controller bare PCB (~80×40mm)[ppl-ai-file-upload.s3.amazonaws]
Motor cable exits through a grommeted hole in the chainstay toward the rear dropout
PAS sensor cable exits at BB shell (left side, crank-mounted sensor)
Head Tube Junction
The clean end — this is what people see first:[ppl-ai-file-upload.s3.amazonaws]
Cam lock keyhole on the underside of the DT, near the HT junction — hidden from normal viewing angle
Over-center latch lever also underside, blocked by cam lock tongue when locked
USB-C charge port on the cartridge surface, accessible through a small hole in the frame when cartridge is installed. Rubber cap flush with frame surface
3 knurled cell-swap caps face toward the HT end — accessible when cartridge is swung open
When locked, this junction should look like a clean weld — the seam, lock keyhole, and USB-C port are all on the underside, invisible from standing height.
Rear Triangle — Belt Split + Motor
Two critical constraints:
135mm horizontal/sliding dropout for the Bafang G020 hub motor (not track 120mm)[ppl-ai-file-upload.s3.amazonaws]
Gates CDX belt needs a frame split point — either the right seatstay or right chainstay must be splittable to thread the belt through. Most belt-drive frames split the right seatstay with a coupler
Disc brake mount on the left chainstay (IS or post mount for 160mm rotor)
Motor cable runs inside the right chainstay from BB area to rear dropout
Seat Tube — Keep It Simple
Nothing special here anymore — all electronics moved to the downtube:[ppl-ai-file-upload.s3.amazonaws]
31.7mm OD, standard 27.2mm carbon seatpost
Seatpost clamp at top
That's it. Clean.
What Makes It Omera, Not Detroit
When you draw, these are the visual differentiators:
The 50mm downtube — 8mm fatter than the Detroit's 42mm. This is the design statement. It's bold, hints at something inside, but doesn't scream e-bike[ppl-ai-file-upload.s3.amazonaws]
Disc brakes — the Detroit runs rim brakes. Omera has hydraulic disc, so you need fork/stay mounts and rotor clearance
135mm rear — wider than track 120mm, changes the rear triangle proportions slightly
The seam line — a hairline laser-cut line on the underside of the downtube. Your signature detail. On matte black, nearly invisible
No top tube battery — Detroit has a standard 35mm TT. So does Omera. The difference is all in the DT
Drawing Checklist
When you sit down on iPad tomorrow, draw these views:
Side profile — full bike silhouette, get the geometry angles right, show the fat DT proportion relative to the 35mm TT and 19mm stays
DT underside — the seam line, keyhole position, USB-C port, drain hole
DT cross-section at BB end — 50/50 split, 3-cell triangle, lip overlap, gasket
DT longitudinal cutaway — the three zones (HT sealed / cartridge / BB sealed), cell rows, BMS pocket, controller pocket
BB junction detail — how DT, ST, and chainstays meet, where the hinge pins sit, cable exit holes
Rear dropout — 135mm horizontal slot, disc mount, belt path, motor cable entry
Cartridge removed — the cartridge as a standalone object with USB-C port, caps, XT30/JST connectors visible
Geometry (Detroit-Inspired, Not Copied)
The Detroit runs 74° HT / 76° ST / 382mm chainstay — aggressive pursuit geometry. Your Omera keeps the same spirit but the 50mm downtube is wider than Detroit's 42mm Columbus Airplane tube, so the frame silhouette will already look distinct. That fat downtube is the design identity. [ppl-ai-file-upload.s3.amazonaws](https://ppl-ai-file-upload.s3.amazonaws.com/web/direct-files/attachments/139085844/e4366386-60b4-4746-a0f8-1aad86b7378e/fixie-dream.pdf)
| Dimension | Detroit (M) | Omera (your call) |
|---|---|---|
| Head tube angle | 74° | 74° (keep it) |
| Seat tube angle | 76° | 75–76° |
| Chainstay | 382mm | 390–400mm (need room for 135mm hub + belt) |
| BB drop | 41mm | 41mm |
| Down tube OD | 42mm round | 50mm round (battery lives here) |
| Top tube OD | 35mm | 35mm (no battery, just structure) |
| Seat tube OD | 31.7mm | 31.7mm (27.2mm seatpost) |
| Head tube | 1-1/8" straight | 1-1/8" straight |
| Seatstay | 19mm | 19mm |
| Chainstay | 26mm | 26mm |
| BB shell | BSA 68mm | BSA 68mm |
| Rear dropout | track 120mm | 135mm horizontal (G020 motor) |
Down Tube — The Main Event
This is where almost everything lives. 581mm center-line length (M size), 50mm OD, 47mm ID, 1.5mm wall. [ppl-ai-file-upload.s3.amazonaws](https://ppl-ai-file-upload.s3.amazonaws.com/web/direct-files/attachments/139085844/e4366386-60b4-4746-a0f8-1aad86b7378e/fixie-dream.pdf)
Three zones from HT to BB:
- HT sealed zone (0–35mm) — cam lock + over-center latch mount, ball plunger holes, frame-side XT30 female + JST-SM female socket
- Cartridge cutout (35–470mm, 435mm long) — the 50/50 split, underside, hidden from view. Hinge rails along both long edges
- BB sealed zone (470–581mm, ~110mm) — KT T06S controller PCB, PAS wiring, motor cable exit hole toward rear dropout
Inside the cartridge (435mm long):
- 351mm cell zone: 3 channels × 5 cells, PETG plastic insert glued inside the alu shell [ppl-ai-file-upload.s3.amazonaws](https://ppl-ai-file-upload.s3.amazonaws.com/web/direct-files/attachments/139085844/e4366386-60b4-4746-a0f8-1aad86b7378e/fixie-dream.pdf)
- 95mm BMS/port zone (HT end of cartridge): 15S BMS (65×30×3mm), USB-C PD port with rubber cap, XT30 male + JST-SM male (auto-mate when locked)
- 3 knurled screw caps at HT end for cell swapping [ppl-ai-file-upload.s3.amazonaws](https://ppl-ai-file-upload.s3.amazonaws.com/web/direct-files/attachments/139085844/e4366386-60b4-4746-a0f8-1aad86b7378e/fixie-dream.pdf)
When drawing the cross-section (looking from BB end):
FRAME (top 50%, welded)
╭─────────────────────╮
│ lip lip │
│ ○ ○ ○ │ ← 3× 21700 triangle pack
│ ○ ○ │ fits in 43.5mm envelope
╰─────────────────────╯
CARTRIDGE (bottom 50%, removable)
BB Junction — Crowded Node
Draw this area carefully, five things converge here: [ppl-ai-file-upload.s3.amazonaws](https://ppl-ai-file-upload.s3.amazonaws.com/web/direct-files/attachments/139085844/e4366386-60b4-4746-a0f8-1aad86b7378e/fixie-dream.pdf)
- Down tube enters from above-front (at ~41° from horizontal)
- Seat tube rises at 76°
- Chainstays exit rearward (both sides)
- BSA 68mm shell sits at the center
- 2× pin hinges for cartridge mount on the underside of the DT/BB junction
What fits inside the sealed BB zone of the downtube (~110mm):
- KT T06S controller bare PCB (~80×40mm) [ppl-ai-file-upload.s3.amazonaws](https://ppl-ai-file-upload.s3.amazonaws.com/web/direct-files/attachments/139085844/e4366386-60b4-4746-a0f8-1aad86b7378e/fixie-dream.pdf)
- Motor cable exits through a grommeted hole in the chainstay toward the rear dropout
- PAS sensor cable exits at BB shell (left side, crank-mounted sensor)
Head Tube Junction
The clean end — this is what people see first: [ppl-ai-file-upload.s3.amazonaws](https://ppl-ai-file-upload.s3.amazonaws.com/web/direct-files/attachments/139085844/e4366386-60b4-4746-a0f8-1aad86b7378e/fixie-dream.pdf)
- Cam lock keyhole on the underside of the DT, near the HT junction — hidden from normal viewing angle
- Over-center latch lever also underside, blocked by cam lock tongue when locked
- USB-C charge port on the cartridge surface, accessible through a small hole in the frame when cartridge is installed. Rubber cap flush with frame surface
- 3 knurled cell-swap caps face toward the HT end — accessible when cartridge is swung open
When locked, this junction should look like a clean weld — the seam, lock keyhole, and USB-C port are all on the underside, invisible from standing height.
Rear Triangle — Belt Split + Motor
Two critical constraints:
- 135mm horizontal/sliding dropout for the Bafang G020 hub motor (not track 120mm) [ppl-ai-file-upload.s3.amazonaws](https://ppl-ai-file-upload.s3.amazonaws.com/web/direct-files/attachments/139085844/e4366386-60b4-4746-a0f8-1aad86b7378e/fixie-dream.pdf)
- Gates CDX belt needs a frame split point — either the right seatstay or right chainstay must be splittable to thread the belt through. Most belt-drive frames split the right seatstay with a coupler
- Disc brake mount on the left chainstay (IS or post mount for 160mm rotor)
- Motor cable runs inside the right chainstay from BB area to rear dropout
Seat Tube — Keep It Simple
Nothing special here anymore — all electronics moved to the downtube: [ppl-ai-file-upload.s3.amazonaws](https://ppl-ai-file-upload.s3.amazonaws.com/web/direct-files/attachments/139085844/e4366386-60b4-4746-a0f8-1aad86b7378e/fixie-dream.pdf)
- 31.7mm OD, standard 27.2mm carbon seatpost
- Seatpost clamp at top
- That's it. Clean.
What Makes It Omera, Not Detroit
When you draw, these are the visual differentiators:
- The 50mm downtube — 8mm fatter than the Detroit's 42mm. This is the design statement. It's bold, hints at something inside, but doesn't scream e-bike [ppl-ai-file-upload.s3.amazonaws](https://ppl-ai-file-upload.s3.amazonaws.com/web/direct-files/attachments/139085844/e4366386-60b4-4746-a0f8-1aad86b7378e/fixie-dream.pdf)
- Disc brakes — the Detroit runs rim brakes. Omera has hydraulic disc, so you need fork/stay mounts and rotor clearance
- 135mm rear — wider than track 120mm, changes the rear triangle proportions slightly
- The seam line — a hairline laser-cut line on the underside of the downtube. Your signature detail. On matte black, nearly invisible
- No top tube battery — Detroit has a standard 35mm TT. So does Omera. The difference is all in the DT
Drawing Checklist
When you sit down on iPad tomorrow, draw these views:
- Side profile — full bike silhouette, get the geometry angles right, show the fat DT proportion relative to the 35mm TT and 19mm stays
- DT underside — the seam line, keyhole position, USB-C port, drain hole
- DT cross-section at BB end — 50/50 split, 3-cell triangle, lip overlap, gasket
- DT longitudinal cutaway — the three zones (HT sealed / cartridge / BB sealed), cell rows, BMS pocket, controller pocket
- BB junction detail — how DT, ST, and chainstays meet, where the hinge pins sit, cable exit holes
- Rear dropout — 135mm horizontal slot, disc mount, belt path, motor cable entry
- Cartridge removed — the cartridge as a standalone object with USB-C port, caps, XT30/JST connectors visible
Yes — essentially. The process goes like this:[youtube]qualityinspection+1
The Actual Process
Step 1: You send them drawings
Not final production CAD at first. Most factories start with:
A 2D geometry drawing with all dimensions (tube lengths, angles, BB type, dropout spacing, head tube size)
Reference images of what you want (your iPad drawing is perfect for this)
A spec list (material, wall thickness, seatpost diameter, etc.)
Step 2: They make the CAD
The factory's engineer converts your drawing into their own technical production drawing and sends it back for you to approve. This is a 1:1 blueprint showing every tube, every angle, every weld point. You check it, request changes, iterate.[vpic-group][youtube]
Step 3: You approve, pay deposit
Typically 50% upfront, 50% before shipping.[youtube]
Step 4: They manufacture (4–8 weeks)
Tube cutting → bending/shaping → welding → heat treatment (T6) → alignment check → powder coat → ship.pinheadbikelocks+1
What You Actually Need to Send
You Don't Need
Full SolidWorks/Fusion 360 CAD (they make their own)[youtube]
Engineering stress analysis (they know tube specs for bikes)
Manufacturing drawings (that's their job)
Your iPad drawing tomorrow + the spec sheet we've already discussed is genuinely enough to get quotes started. The factory turns your sketch into real engineering. The key is being very precise about dimensions and special machining(the downtube cutout, hinge mounts, cartridge tolerances) — that's the non-standard part they'll need clarity on.[qualityinspection][youtube]
The Actual Process
Step 1: You send them drawings
Not final production CAD at first. Most factories start with:
- A 2D geometry drawing with all dimensions (tube lengths, angles, BB type, dropout spacing, head tube size)
- Reference images of what you want (your iPad drawing is perfect for this)
- A spec list (material, wall thickness, seatpost diameter, etc.)
Step 2: They make the CAD
The factory's engineer converts your drawing into their own technical production drawing and sends it back for you to approve. This is a 1:1 blueprint showing every tube, every angle, every weld point. You check it, request changes, iterate. [vpic-group](https://www.vpic-group.com/bicycle-manufacturing)
Step 3: You approve, pay deposit
Typically 50% upfront, 50% before shipping. [youtube](https://www.youtube.com/watch?v=8t1yex_8VjY)
Step 4: They manufacture (4–8 weeks)
Tube cutting → bending/shaping → welding → heat treatment (T6) → alignment check → powder coat → ship. pinheadbikelocks
What You Actually Need to Send
| What | Format | Notes |
|---|---|---|
| Geometry sketch | PDF / JPG from iPad | All angles, tube lengths, stack, reach |
| Tube spec | Text / table | 50mm OD downtube, 35mm TT, wall thickness, etc. |
| Special features | Annotated drawing | Downtube cutout dimensions, hinge mount positions, cable routing holes, belt split location |
| Reference photos | JPG | Detroit-style stays, the seatstay bend you like |
| Component list | Text | BB type (BSA 68), head tube (1-1/8"), dropout (135mm horizontal), disc mount, seatpost (27.2mm) |
You Don't Need
- Full SolidWorks/Fusion 360 CAD (they make their own) [youtube](https://www.youtube.com/watch?v=8t1yex_8VjY)
- Engineering stress analysis (they know tube specs for bikes)
- Manufacturing drawings (that's their job)
Your iPad drawing tomorrow + the spec sheet we've already discussed is genuinely enough to get quotes started. The factory turns your sketch into real engineering. The key is being very precise about dimensions and special machining (the downtube cutout, hinge mounts, cartridge tolerances) — that's the non-standard part they'll need clarity on. qualityinspection
For your workflow — CAD modelling + photorealistic renders + factory-ready STEP export — all free on Mac:
Best Free Option: FreeCAD + Blender
FreeCAD 1.0 (released late 2025) for the actual engineering model:[eufymake][youtube]
Fully free, including commercial use — no subscription, no limits[youtube]
Parametric — change one dimension, everything updates
Exports STEP files which factories read directly[youtube][wiki.freecad]
Runs natively on Mac including Apple Silicon
Blender for renders:style3d+1
Import the STEP/STL from FreeCAD
Cycles renderer produces photorealistic studio shots — Instagram-ready
Free forever, open source
Alternative: Onshape (Free Tier)
Cloud-based, runs in the browser, no install. Professional parametric CAD with STEP export. The free tier requires your designs to be public (anyone can see them) — which may or may not matter at concept stage.[youtube]
Comparison
Recommended Workflow
iPad — sketch proportions and vibe in Procreate/Concepts
FreeCAD on Mac — build the precise 3D model with real dimensions, STEP export for factory
Blender on Mac — import model, add materials (matte black alu, carbon fibre texture), studio lighting, render hero shots for website/IG
FreeCAD has a learning curve but there are tons of bike frame tutorials on YouTube. Since you're already technical, you'll pick it up fast.[youtube]
Best Free Option: FreeCAD + Blender
FreeCAD 1.0 (released late 2025) for the actual engineering model: [eufymake](https://www.eufymake.com/ca/blogs/printing-guides/3d-modeling-software-mac)
- Fully free, including commercial use — no subscription, no limits [youtube](https://www.youtube.com/watch?v=DYTuXe4k4vg)
- Parametric — change one dimension, everything updates
- Exports STEP files which factories read directly [youtube](https://www.youtube.com/watch?v=sDxoJrs0yAM)
- Runs natively on Mac including Apple Silicon
- freecad.org eufymake
Blender for renders: style3d
- Import the STEP/STL from FreeCAD
- Cycles renderer produces photorealistic studio shots — Instagram-ready
- Free forever, open source
- blender.org
Alternative: Onshape (Free Tier)
Cloud-based, runs in the browser, no install. Professional parametric CAD with STEP export. The free tier requires your designs to be public (anyone can see them) — which may or may not matter at concept stage. [youtube](https://www.youtube.com/watch?v=DYTuXe4k4vg)
Comparison
| FreeCAD | Blender | Onshape Free | |
|---|---|---|---|
| Price | Free forever | Free forever | Free (public files only) |
| Modelling | Parametric, engineering-grade | Mesh/sculpt, artistic | Parametric, professional |
| STEP export | ✅ factory-ready | ❌ (STL/OBJ only) | ✅ factory-ready |
| Rendering | Basic | Best-in-class (Cycles) | Basic |
| Learning curve | Medium-steep | Steep for CAD, great for renders | Easiest of the three |
| Commercial use | ✅ unlimited | ✅ unlimited | ❌ free tier is public |
| Mac native | ✅ | ✅ | ✅ (browser) |
Recommended Workflow
- iPad — sketch proportions and vibe in Procreate/Concepts
- FreeCAD on Mac — build the precise 3D model with real dimensions, STEP export for factory
- Blender on Mac — import model, add materials (matte black alu, carbon fibre texture), studio lighting, render hero shots for website/IG
FreeCAD has a learning curve but there are tons of bike frame tutorials on YouTube. Since you're already technical, you'll pick it up fast. [youtube](https://www.youtube.com/watch?v=CwjfDEKbqUk)
The stereotypical fixie (fixed-gear bicycle) rider look is heavily inspired by bike messenger culture and hipster aesthetics — think functional, urban, and deliberately understated. Here's what the typical outfit involves:
Bottoms
- Skinny jeans or cuffed jeans — worn tight or rolled up at the cuff to prevent pant legs from getting caught in the chain psupopculture.wordpress
- Cutoff denim shorts with frayed edges, especially in warmer weather adepttextiles
- Dickies work pants — durable, lightweight, and a popular no-nonsense choice among riders [reddit](https://www.reddit.com/r/FixedGearBicycle/comments/137waky/fixed_friendly_clothing_brands/)
Tops
- Vintage or band t-shirts (Joy Division is the running joke) [reddit](https://www.reddit.com/r/FixedGearBicycle/comments/137waky/fixed_friendly_clothing_brands/)
- Windbreaker jackets and layered urban tees [adepttextiles](https://www.adepttextiles.com/blog/fashion/the-urban-fixie-gear-bicycle-sub-culture-has-a-unique-fashion-style-that-has-grown-across-the-world-with-bike-courier-that-deliver-and-are-a-part-of-the-urban-fashion-culture-in-metropolitan-cities/)
- Collared shirts or simple, unfussy tops — nothing too sporty or lycra-based [adepttextiles](https://www.adepttextiles.com/blog/fashion/the-urban-fixie-gear-bicycle-sub-culture-has-a-unique-fashion-style-that-has-grown-across-the-world-with-bike-courier-that-deliver-and-are-a-part-of-the-urban-fashion-culture-in-metropolitan-cities/)
Footwear and Accessories
- Vans slip-ons or Chuck Taylors — skate-adjacent shoes, never clip-in cycling shoes [reddit](https://www.reddit.com/r/FixedGearBicycle/comments/137waky/fixed_friendly_clothing_brands/)
- Messenger/cross-body bags (like Chrome Barrage) instead of backpacks, because they're easier to access while riding psupopculture.wordpress
- Custom hats or caps, tattoos, and piercings round out the look [adepttextiles](https://www.adepttextiles.com/blog/fashion/the-urban-fixie-gear-bicycle-sub-culture-has-a-unique-fashion-style-that-has-grown-across-the-world-with-bike-courier-that-deliver-and-are-a-part-of-the-urban-fashion-culture-in-metropolitan-cities/)
The Overall Vibe
The style sits at a crossroads of skateboarder fashion and urban streetwear — practical enough for riding but deliberately not "cyclist gear". As one Reddit user put it, combining road biking with skate fashion is how you "really end up looking fixie af". The culture also emphasizes the bike itself as fashion — brightly colored frames, flashy wheels, and colored tires are part of the total image. The whole aesthetic spread globally, even stimulating fixie-inspired clothing lines in countries like China. sixthtone
Given your interest in bicycle design and engineering, you probably already spot these riders around Oslo!




Got it — the file has the full Sparton carry-over breakdown. Here's the complete unified list with totals:[ppl-ai-file-upload.s3.amazonaws]
Omera — Complete Parts List
Bike Parts (New Purchases)
Total (excl. frame): ~$1,048
Frame: TBD (custom Detroit-style CrMo)
Omera — Complete Parts List
Bike Parts (New Purchases)
From Sparton Build (Carry-Over)
Total (excl. frame): ~$1,048
Frame: TBD (custom Detroit-style CrMo)