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Hi Chak,
The user/D1 you refer to had a little bit of rust however that wasn't the issue - the issue was the pins were seized from electrolysis. It's exactly how we say the port shouldn't be installed - if the injection moulded lead from your phone is at the bottom then water can't drain and creates a bath for which the 5V between the pins to pass. Two days is all it took for it to fail.
Is it an issue? Absolutely, but you'll have the same problem with any USB device not just the D1 - which is why our port is outside the device. Better to replace the port then throwing it in the trash sometime after the 1yr warranty ends (that's not the D1 warranty).
Best solution:
Ideally cable tie the connector directly under the stem with the wires from both the D1 and the USB device cable bending a little towards the ground - that way water can't hit it from above and water can't run into it.
Waterproofing:
The problem with waterproofing is once it fails the water sits there and creates this bath of water in which the pins dissolve. We made the port drainable (not via injection moulding which is half the price) to prevent this (it's not perfect but it's something) - but the user must have the D1 port at the bottom. It's not perfect though, any path the electricity can take between the 5v and 0v of the USB port will eat the pins.
I highly recommend installing under the stem for a long life. A dab of WD40/GT80 may help as well. If it does fail, we have the service on the website to replace it. Cost is about £5 posted back to you.
We're looking for alternatives but haven't found one as of yet. Prevention is better than cure - there are D1's touring the world for over 6 months now, no problems. It's all about how you install the port as to how long it'll last.
The D1 main unit should last forever. Zero failures so far, a record we are mighty proud off.
Regards,
Andrew
acharnley-
Hi Andrew.
First and foremost. Incredible service on your behalf, it floored me when he dropped off the unit earlier repaired and with the worksheet too. Massive kudos to you guys. You'll be my go to guys for anyone looking for USB capability for bikes.
As far as I'm concerned, the unit has ran perfectly since initial set up and I'm sure it will continue to do so.
The USB issue is simply something that the user has to adapt to since it is fundamentally and understandably the weakest link in the setup.The difficulty in this build is having to juggle the placement of the Igaro VS Di2 plugs, and as he is using TT bars, it complicated things somewhat. So it's basically hoses, di2, dynamo cables and the Igaro.
I've found a neat trick which I could use your advice on placement. I've taped the unit from the dynamo, by the head-tube, onto the front brake hose, as I found if I attached it to the head tube, there was far too much side to side flex in the Igaro cables, which worried me about longevity. This was the whole unit is static as he steers.
This simply leaves me to find a good spot to attach the USB port so it's out of the way, but still accessible.The customer is quite particular about placement, which is understandable as he'll be on the bike for hours on end. I might try drill a couple of small holes under the elbow bars of the TT bars so I can tie the USB port to it, so this way it'll have protection from the elements.
What do you think?
Great work by the way. It's an impressive piece of kit.
Chak
Replaceable, but a hassle to do so depending on how you feel about glue guns and soldering irons.
@gillies The two guys I installed for are both heading to TCR, so want absolute reliability or as close to. Only one's stopped charging so far after two 300k rides, so not sure what the issue might be, I was willing to investigate, but the guy decided to send back to Igaro.
The USB connector had a fair bit of rust, but I wouldn't have thought this would have been an issue electrically. I would personally try any options to help (paging @hippy for his idea). Simplest would be to leave the USB end in a TT mounted feedbag and use when needed.