Xiaomi M365 Pro Luggage Rack

Xiaomi M365 Pro Luggage Rack

A 3D printable luggage rack design for the Xiaomi M365 Pro electric scooter that does not prevent the folding down of the handlebars for carrying.

Overview

The design includes a 3 part rack (left stay, right stay and rack surface) that mounts in place of the existing side covers of the M365 pro scooter. The rack is designed to fit around the existing hardware (such as the disc brake calliper) without the need to alter any parts. Since the rack blocks access to the original folding hook (mounted on the rear mudguard) the design includes a new hook design which is higher and placed further back to compensate for the angle of the original hook's mount.

The design requires a strong flexible plastic and is therefore suitable for filaments such as PETG and ABS. The design requires a printer with a 20x25cm print surface.

Maximum safe weight on the rack is approximately 5Kgs

Assembly instructions

Required hardware

The following hardware is required for assembly (in addition to the 3D printed parts):

M5x16mm screw (used to secure the hook in place of the original M5x10mm screw)

M5 Nylon nut (you could use a standard nut, but be sure to thread-lock it)

M5 spring washer

M5 washer

8x M3x0.5 threaded brass inserts

6x M3x10 screws

Superglue

Red Reflective tape 20mm wide

Craft knife

Assembly

Basic mounting

Remove the mudguard and the original hook. Place the new hook in the same place using the M5x16mm screw. The order should be screw, spring washer, washer, mudguard then hook. Note that the hook is designed so you can fit a 5mm spanner into the hook to tighten the nylon bolt.

Remove the original side covers. Glue 2 support pins into the centre holes of the rack stays. Insert two M3 brass inserts into each stay using a hot iron (such as a soldering iron) - ensure the insert is straight and flush with the surface. Superglue two support pins into each stay. Affix the left and right rack stays using the original hex screws (use thread-lock).

Press the rack surface onto the left and right stays as well as down into the 'U' mount of the hook (this should be easy to do and not require any force). Screw into place using 4x M3x10 screws (use thread-lock).

Note that the left stay and the rack surface have two additional slots each for M3 brass inserts (on the base of the stay, and under the rear of the surface). These are for attaching additional accessories such as a disc guard.

Apply the reflective tape to the sides and back of the rack (as shown in the pictures). The main reflective location is designed to take the full 20mm wide tape. For the stay struts and the back of the rack surface you will need to carefully cut thin strips of tape and affix.

Box fastener

In order to easily carry larger objects it is useful to affix a small plastic box to the rack (cheap plastic boxes with sealable lids can be sourced from many supermarkets and hardware stores). To make this easy the rack has 3 threaded holes. Print the 3 fasteners and drill holes in the box to allow them to pass through. Ensure the box is as central on the rack as possible (without excessive overhang on the sides of the rack). Mount the box using the 3 fasteners. The box can be easily removed when not required or if you need to fold the scooter for transport.

Disc guard

The disc guard is designed to protect the disc brake rotor from impact damage as well as large stones etc. To fit the disc guard use 2 M3x16 screws and attach to the left rack stay using the provided M3 fittings underneath the stay.

Recommended print settings

Rack surface

Number required: 1

Material: Prusament PETG (Prusa Jet Black)

Layer: 0.20mm (Quality)

Infill: 20% (Quality)

Supports: Support on build plate only

Print time (approximate): 10h 59m

Notes: None

Rack left

Number required: 1

Material: Prusament PETG (Jet Black)

Layer: 0.20mm (Quality)

Infill: 20% (Quality)

Supports: None

Print time (approximate): 6h 0m

Notes: Due to the configuration of the disc brake and the handlebars, the left and right rack stays are not the same size.

Rack right

Number required: 1

Material: Prusament PETG (Jet Black)

Layer: 0.20mm (Quality)

Infill: 20% (Quality)

Supports: None

Print time (approximate): 5h 33m

Notes: Due to the configuration of the disc brake and the handlebars, the left and right rack stays are not the same size.

Hook

Number required: 1

Material: Prusament PETG (Prusa Orange)

Layer: 0.20mm (Quality)

Infill: 50% (Quality)

Supports: Everywhere

Print time (approximate): 2h 36m

Notes: The hook should be printed on it's side to ensure the print layers are 90 degrees from the direction of force when lifting the scooter. This requires the use of supports 'everywhere' due to the shape.

Support pins

Number required: 1 (includes 4 pins per print)

Material: Prusament PETG (Prusa Orange)

Layer: 0.20mm (Quality)

Infill: 50% (Quality)

Supports: None

Print time (approximate): 0h 15m

Notes: To prevent the pins falling over during printing, turn on brim and set to 10mm.

Box fasteners

Number required: 1 (includes 3 fasteners per print)

Material: Prusament PETG (Prusa Orange)

Layer: 0.20mm (Quality)

Infill: 25% (Quality)

Supports: None

Print time (approximate): 3h 4m

Notes: These are only required if you wish to affix a box to the rack surface. The fastener threads are 0.25mm smaller in diameter than the threads on the rack surface to allow for printing tolerance. This is a pretty tight fit to begin with and you may need to insert and remove them several times to make the threads correctly mate. If insertion into the rack is too tight, either scale the print slightly or alter the design files according to your 3D printer. Alternatively, lightly sand the fastener's thread until it fits correctly.

Disc guard

Number required: 1

Material: Prusament PETG (Prusa Orange)

Layer: 0.20mm (Quality)

Infill: 15% (Quality)

Supports: None

Print time (approximate): 2h 10m

Notes: This part is optional.