We can put water-bottle bosses into steel and aluminium frames without damaging the paint using a stainless-steel ‘nutsert’ or ‘rivnut’. This is essentially a threaded pop-rivet which, installed with a special tool, grips solidly in place. For a more permanent fixing, we can braze bottle-bosses in place prior to powdercoating or painting.
Huw is planning on a long bikepacking trip in the next few weeks and wants to carry more water, so he’s the first to use the new jig. See the photos below for detailed shots of the jig in action.
The process typically costs $40 including hardware ($70 for two sets) for a standard steel or aluminium frame with tubes up to 52 mm wide.