I decided to make a robust station tag for my bike.
I'm starting a new job on Monday up in Mountain View, so I've decided to use my bike to ride to-and-from Caltrain, instead of parking my car at the Caltrain station for $5 per day.
I live about 1.5 miles from the Santa Clara station and the new job is about 1.5 miles from the Mountain View station.
I made this at TechShop in San Jose.
Step 1: The Parts to Build
Here're the parts for the bike tag:
8 of 3mm/.5 x 12mm screws
8 of 3mm/.5 nylock nuts
2 of 3" x 3.2" anodized aluminum tags
Step 2: Cut the Leather
Overall the leather strap is about 12" x 4", and the "windows" are about 3.1" x 2.6".
I may eventually add another half-inch to the strap, since it was a bit tough to get all the parts assembled. I may also change the size of the rectangular "window", since there's very little leather holding the aluminum tag in.
The leather.eps file attached will do the trick. I used 7oz. (about 1/8" thick) leather for this.
Step 3: Mill the Aluminum
Here's the design of the "C" that supports the aluminum tags. I left one end open to make it easier to change the station tags when needed. It's about 4" x 4". The holes are about 1/8", and accept 3mm screws.