Mag mount kill switch for e-bikes

thingiverse

A clever two-part assembly is designed for attaching a magnetic motor kill switch directly onto a Shimano BRM446 hydraulic front (RHS) brake of an e-bike. It effortlessly clips onto the rubber shroud surrounding the handlebar/cylinder bracket, and the other part securely fastens to the lever itself. No bolts or modifications are required, so users can easily test it out and discard if necessary without making any changes to their existing lever/bracket setup. This particular design was carefully crafted with 50% fill PLA printing in mind, while utilizing a budget-friendly Chinese N.O. push button switch for under 50p. The assembly's flexibility allows for a solid contact between the switch and the lever, ensuring it will fail open circuit if damaged. This means that even if the entire setup becomes dislodged, the motor will continue to function. After several iterations, I was finally able to perfect this design. However, I discovered that additional reinforcement with tie-wraps is still necessary to keep it securely in place on the handlebar bracket. For my personal project, the total cost came out to be approximately 70p. The process itself involved quite a bit of experimentation and trial-and-error.