I hit some issues installing a Nitto BM-5R rack (1, 2) on my Brompton Electric:
Having fastened 3 of the 4 rack/stay mount points (as well as 2 stay-frame points and the rack/fender/frame and rack/fender points), the 4th rack/stay mount is misaligned beyond my ability to force it into place.
I'm not sure if I've installed it incorrectly, or what. The light cable is also ≈½" too short to reach the light-mount points on the back of the rack.
Here are some close-ups:
Getting the 3rd of 4 of these mounts to align was a real struggle; I managed to jam the bolt through at a scary angle, and as I screwed it, it caught threads on the inner (rack) mount, and the whole rig flexed to where the bolt went straight through. I thought the bolt was going to snap though, it did not feel great.
With 3 of 4 bolts in place (I've loosened them a bit to maximize available flex for the 4th one) I cannot get the bolt through the stay and rack holes.
One of my only ideas for how to proceed is to change the order or composition of the frame/rack/fender mount point:
I think I put this back together the way I found it (minus the rear-light mount piece and an associated washer, which now doesn't make sense to leave there since the rack would block the light), but maybe changing something here would change the alignment of the rack vs. stays?
Here's the Nitto rack instructions page:
Thoughts/advice welcome!