Adding a ps with a couple mechanical tips.
My project above was all about replacing the road-shock truss of a V-O front rack with the mini rack that mounts to the CP front brake, and bring the fork back to life.
At the same time, replacing inadequate side-pull brakes compounded by the added fender preload through the brake pivot bolt.
Added Nitto lamp holder 8L to the mini rack, plus Paul Gino to hold my Cygo head lamp.
If you guys have never used a Nordlock, these things are amazing.
The Nitto 8L bracket is attached to the rack through M5 rack boss - bolt from the outside.
Inside, I have small diameter M5 (#10) nordlock washer pair on the rack boss shoulder, the Nitto bracket, larger-O.D. M5 nordlock pair, then flanged M5 nylok nut. Contact between bracket and the rack nose is dampened by a small piece of rubber squeezed in the contact.
Nordlocks make this joint monolithic. The paired wedge washer design gets thicker if it tries to loosen, increasing clamping force in the joint - they can't get loose- vibration and shock makes the joint tighter.
The blue Gino lamp holder has an M5 guide hole, but since the Nitto bracket guide hole is for M6, I used a roll-forming tap to put M6 threads in the Gino, M6 bolt, and bellville spring washers on each side of the joint.
The light is never going anywhere until I relax torque on those joints.