Start with a sheet of 7075-T6 aircraft aluminum, 3mm thick:
and cut it to the correct dimensions with a hand saw, then mark the locations of the holes:
Drill the holes on a drill press and then draw the lines needed to make the bracket into a diamond shape:
Use the dremel cutting wheel and then a bench grinder to get one side into the correct shape:
Then repeat on the other side:
Install the RAM ball:
Install the bracket on the bike:
Use a short arm and a Garmin mount to attach the GPS:
After taking a ride with the GPS, it seems that the bracket works just fine. The next step is to make it black. I used a high heat flat black enamel:
I put on 3 layers on both sides, and then cured in the oven at 300 °F for 2 hours, like the instructions said. The bracket came out looking pretty good:
And here it is mounted on the bike:
Pay no attention to the wiring mess - I'm in the process of rewiring some things.
