We bought new ebikes about two yrs ago, and went with 20” folders to help them fit better on our camper, as well as fit in the trunk of our car for other types of travel. And we really like them a lot! They are Evelo brand, “Dash” models, with mid-drive motors, dry belts instead of greasy chains, and 5 speed rear hubs. (unfortunately they just stopped offering them, and while their other full-sized bikes are terrific, if anyone asks me for a recommendation on a 20” folder now, I point them to the Blix) (whatever ebike you buy, be sure it has a torque sensor!)

We bought two spare batteries at the time, because these bikes, as with about 70% of ebikes, only have a (real) range of about 25 miles, and sometimes we like to go riding/exploring for a whole day, in some area we’ve never been before, and we love having the peace of mind that a spare batt gives you.

We also always use saddle bag “panniers” to carry stuff along (tools, lock, clothing, water, etc.). But the thing about 20” folders is that the back rack is so low, that not only do you need to use shorter panniers, but they often tend to rub on the tire occasionally. And yet we found that when we had our spare batts along, and would wrap some padding around them, and lay them on the rack first, and strap the panniers down over them, that the added mounting height completely solved the tire-rubbing issue! - However this took a little more time to finesse, and also did not secure the batt from possible theft from when we locked the bikes somewhere and hiked or ate lunch or visited a museum, etc.

So I kept thinking of how to make a cage that would mount on the rack permanently which would provide the better pannier height, and also allow the batt to lock in place. But the rack is aluminum and I haven’t mastered aluminum welding yet.

But then I thought: why not just wood? Just make it strong enough for the rigors of bike jolts. And really, since the panniers strap to the frame and cinch down tight, they additionally help reduce vibrational forces trying to take the wooden box apart.

So I did that, …and it turned out really great! These batteries have keyed extending bolt/pins for locking into the docking frame tube of the bike, and so I just made a similar spot for the pin to lock into on the 5/8” wood side of the box, with a small steel plate as seen in the pics below.

And now we can use the bikes better with the panniers, and/or the spare batts, or without either!

I told my contact at Evelo about it and he said “great idea…when we offer another 20” folder we will do just that!” (which I’m sure they will as it will promote sales of spare batts! :-)

These are the kinds of projects you think of to do with your spare time when you get old and can’t do 20 mile hikes anymore!

(click on any pic to enlarge)


I used 3/8 beadboard plywood for top, bottom, and small front piece, and then 5/8" ply for the sides (because that's all I had laying around. I would've used hardwood if I'd had any good scraps to use) I cut away sections fron and rear to allow the plastic buckles of the pannier's straps to fit thru, to loop around the rack's frame rails.

I dabbed paint on the end of the locking bolt/pin and slid the battery in and turned the key to get an exact registration mark to position the steel locking plate.

Then I coated all sides with polyeurethane to keep the rain out.

And then flat black..

Drilled matching holes in the bike rack's frame.

And painted the screw heads as well, because sheetrock screws will rust (ask me how I know)


Then I bolted it on with four #10 stainless steel bolts and locking "Nylock" nuts... and put the lid on with the ten 1.5" screws.


And the battery locks in place strong and tight with no rattling!


And the pannier bags clip on quick and easy, and no longer can they swing into and scrape the rotating tire! (they're also slightly farther from hitting our heel upon pedaling)

Win, win, win! ...this is the way the bike should've come in the first place! (IMHO)


Oh, here's what the bikes look like. That fat frame tube is where the battery goes normally, and slides in the opening and into a connector after it's folded. Then when it runs out, we just swap batteries and continue our journey for the day (noting the distance we've gone so far, and making sure we get back within that same mileage!) We don't actually fold them when on the camper, but we do take the seat off and fold the handlebars down, and then they're long and skinny and fit nicely, vertically, one on each rear Sprinter van door!