This was an expensive Altera genio pro bike rack fitted to the tow ball at the back of a Mercedes-Benz van and unfortunately for my customer the pedal got damaged and completely broke of.
He liked the genio pro rack and he could of got a replacement but he doubted it would stand the test of time and would end up breaking again so he asked us to conduct a stronger repair. We reversed engineered the shape of the pedal and waterjet cut a new stainless steel plate which fit on the underside, we then made one spacers and bolted it all together leaving a nice neat finish with a much stronger pedal.
Shown above and below is the finished repair which you can see is neat and strong as the pedal is now backed up by 3mm of stainless steel!
There was another problem, this was an expensive bike rack and when fitted to the toe ball at the back of a Mercedes-Benz van there was an issue with the rear door lifting up and not missing the genio pro rack when the rack was in the lowered position.
To avoid the door hitting the rack the rack needed to lower down a little it more but the two lug keeps were stopping this from happening. so we manufactured and welded an extension onto the lugs so it held the genio pro rack in the correct position to stop the door from hitting the altera bike rack
shown above are the original Genio pro lug keeps and below is our extended version where we have added a section to the end and machined a second hole for the lug keep to mount to the altera bike rack.
E7966 & E7939