File drop outs to fit nutted axle (Swytch ekit)

[deep_blue84]

Hi all. This is my first post, I'm trying to solve a problem I have.
I bought a Swytch ebike conversion kit a year ago, I installed it on an old fixed speed bike I had and was very pleased with the kit.

So, I decided to buy myself an upgrade a Trek FX2 Disc bike which I really like: https://www.trekbikes.com/gb/en_GB/bikes/hybrid-bikes/fitness-bikes/fx/fx-2-disc/p/35003/

However, only after purchasing it I realised that the fork drop outs on the FX2 are axle through and not U-shaped as it's required by the Swytch conversion kit.



So I'm trying to understand what are my options:
- file the fork to fit the Swytch kit wheel: this option is irreversible and, more importantly, might be dangerous? Anyone has ever done this before?
- buy a new fork with the U-shaped drop outs: I can potentially go back to the original specs if needed, plus it's safer - but where I can find a fork that will be compatible with the bike?

Any advise would be very much appreciated!

 

[thelarkbox]

I would probably err towards new forks, with suspension.. but if the budget jar is empty after getting the bike,,,

drilling and chopping out the back of the slot is your only option, it will weaken the metal since your removing some but i doubt it will be significant enough.

Perhaps a scan of fork pictures via a google search will inform you of the sort of dimensions needed in the metal your forks are constructed from.
IF post chop yours will be significantly smaller there are a few ways to add strength back.. welding, Steel putty, wire wrap, or strap wrap, cut and hammer a large diameter steel washer into a cage....

I would probably rely on a habitual check pre ride Every ride for any signs of cracking or deforming tho..

nice new bike btw shame about the forks..

EDIT** for one off (steel) welding jobs, walking into a local auto shop with small to medium sized pack of nice beer and the bit in need of attention often gets a quick and cheap ish result.. Aluminium welding is a bit more specialised however..

 

[Nealh]

You don't need suspension forks for a front motor, something steel like surly disc truckers are the perfect answer and will soak up alot of those road undulations.
Why knacker a set of thru axles up that aren't designed for a std drop out solution.