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Topics - RiderDan

#1
If anyone's wondering how to install the 35A controller upgrade, there's a very simple solution using part of the stock mounting bracket.  Go to the hardware store and look for some generic stainless steel u-bolts.  What you're looking for specifically is the bar that the u-bolt inserts into.  The u-bolt itself can be tossed.  The ones I purchased are 2121xB with an inside diameter of 1-1/8".  Google search 2121xB and you'll find a ton.  You need two of them (make sure they have the bars!), four 8-32 1.75" long machine screws, and four 8-32 nylock nuts.

The mounting tabs of the controller are flimsy so we can't bolt directly to it without reinforcement, thus, the u-bolt bars.  Use the stock clamp from the original controller, put the 8-32 1.75" screws through the holes and place around the frame.  Now, insert the bar from the u-bolt on first!  This is what provides the reinforcement.  You'll want to insert a thin piece of rubber between the bar and the frame to prevent damage to the frame.  Next, mount the controller then the nylock nuts.  Tighten the nuts equally on both sides.  Done.

I wish I took pictures during the install to show the steps, but it's simple enough to figure out.  Just make sure you put the bar between the controller and the frame as that is what's providing the mounting reinforcement needed.  Attached are pics of the finished mount.