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Step 2Cut the Washer
The 1" I.D. washer is used to hold the water bottle in place while it is being pumped up. With a 1" inside diameter, the washer just happens to slide nicely over the neck of the bottle - but a notch will need to be cut out! Note that if you've got some scrap sheet metal lying about, you may go head and use it instead of buying a washer.
With a permanent marker and a ruler, draw a line starting at one edge of the hole outwards. Draw a second line parallel to the first, on the other side of the hole. These are your cut lines.
I used a Dremel tool with a cut-off wheel to cut the washer, but you may use whatever you've got that will cut hardened steel. Work carefully, and try to get the cuts as smooth as you can. If you're using a dremel, you may need to flip the washer over and cut from the other side as well.
When the section is cut out, you may want to smooth it out with a grinding bit. The modified washer should slide easily behind the lip under the threaded potion of the bottle's nozzle. It should not slip past the lip even if it's push all the way to one side.
Next you may drill a hole in the washer, through which the brake cable will eventually be secured. Use a drill bit meant for cutting steel (a nice cobalt bit works great), that matches the diameter of the brake cable clamp. Alternatively, if you don't have such a clamp, you can drill and tap the hole and just use a regular screw.
When drilling the hole, run the drill at a slow rpm, and keep the work cool using a bit of oil. Doing this will prevent the bit from getting dull.
With a permanent marker and a ruler, draw a line starting at one edge of the hole outwards. Draw a second line parallel to the first, on the other side of the hole. These are your cut lines.
I used a Dremel tool with a cut-off wheel to cut the washer, but you may use whatever you've got that will cut hardened steel. Work carefully, and try to get the cuts as smooth as you can. If you're using a dremel, you may need to flip the washer over and cut from the other side as well.
When the section is cut out, you may want to smooth it out with a grinding bit. The modified washer should slide easily behind the lip under the threaded potion of the bottle's nozzle. It should not slip past the lip even if it's push all the way to one side.
Next you may drill a hole in the washer, through which the brake cable will eventually be secured. Use a drill bit meant for cutting steel (a nice cobalt bit works great), that matches the diameter of the brake cable clamp. Alternatively, if you don't have such a clamp, you can drill and tap the hole and just use a regular screw.
When drilling the hole, run the drill at a slow rpm, and keep the work cool using a bit of oil. Doing this will prevent the bit from getting dull.
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