Yeah. I did text you a pic w/ the lowbrow ones after I had reworked them and extended them 6", but knew in my heart that I could do better.
Originally Posted by XwalkerX
Last edited by newman; 07-13-2016 at 02:25 PM.
That is some quality work.
All these chopper threads have made me start trolling the CL for a cheap HD.
I never thought I would say that...
So, when you got your womans bike for her the tail light and speedo didn't work? I bet you want to take a stab at British wiring issues don't you?
What's wrong with it? Generally I just rewire stuff from scratch, but with lots of bullshit like lights and horns, that's a lot of work.
Originally Posted by Quattro Krant
Originally Posted by newman
Tail light doesn't work, speedo and odometer, and the right blinker took a dump. The speedo/odometer issue is a cable/gear so that's no issue, and it doesn't matter for NYSI. The lights do. Everything else is spot on, even the lights on the back of the headlight to indicate ignition, high, etc. You know you want a British bike beached at your garage sir
Originally Posted by newman
Recently some dick on Instagram said to me "you're not a true fabricator, you just throw money at stuff". I really don't agree with what they said at ALL, but I wanted to prove them wrong. So I needed a project. Decided my factory Harley riser wasn't gonna cut it with my new front end. Also the long bars wanted to slip on me a bit because I didn't knurl them. Came up with a new design.
I guess the easy way to do this would be to get a casting, but aparantly that's not what "true fabricators" would do. So I made some drawings.
Started with this hunk of 316 from a scrap rack. Since I was trying not to buy anything, I used a piece of 2 X 2 X 10 and hogged off .500
That took a while.
By this point I'd vacuumed up all the chips at least 3x
Then I started making the roughing cuts. This also took a while. Stainless requires very slow machining.
After some rough shaping. The next step was to cut it off the band saw.
Then I put a bolt through the hole in the part so I could cut the OD shape on the rotary table.
Then I bored the part to the final ID.
And here are the two risers. Blocky and gross. The center piece was a HUGE nightmare because I had to bore the ID to fit tightly on my handlebar OD, which was .965 after all the polishing. The closest piece of scrap I could find was 1.25 OD x .75 ID. I had to remove nearly .250 with a tiny ass boring bar FIVE INCHES deep. .010 cuts at 1.5 inches per minute... do the math. ((.965-.75)/.010 * 5 / 1.5) = 71 minutes of cutting. Woof.
All that stuff took a while BUT shaping the risers took FOREVER. Used a sander and a file.
Here's the other one. It took about 4 hours to sculpt these two parts. The center piece is just a slip fit.
I decided it was time for a proper handlebar jig from steel (I'd been using aluminum before). Faced, drilled and bored to size.
Then came the polishing. As you can imagine, this took a long time as well.
Ok, so a few steps got missed here. The handlebars were cut in half in the center then inserted into the center piece (with a very light press fit). Then I plug welded the bars to the center piece. You can see the holes in the print in the third pic. The holes wind up under the risers' ring.
All that was left to was weld it up, so I did.
Dollars spent: Zero.
3000 dollar bridgeport
2000 dollar lathe
1200 dollar welder
I mean, I guess that's not cheap stuff, but I wouldn't exactly call it "just throwing money at it". The effort involved was pretty monumental (about 25 hours over 3 days (while still working an 8-5 office job)
I'm happy with the results.
You couldn't do that with hand tools?
As many of you know, I'm riding my sportster to Sturgis, then on to California. Obviously the 2 gallon peanut tank I have on there isn't going to be a great choice for a long trip like that, so I needed more fuel. First, I got a sheet of foam insulation.
Then I glued it together and cut it up into a shape I wanted. First time was perfect.
Another shot of the foam mockup.
Then I drew it in cad.
And printed it out in 1:1 scale. Then I glued it to a piece of 1/8 aluminum.
And cut out the pieces on the bandsaw.
Bent the pieces up in this old box break.
The pieces are just laying on each other here. The fitup was actually super bomber when assembled. No gaps bigger than 1/32, pretty good for hand tools.
Welded it up. This was actually my first time welding aluminum.
My starts and stops weren't the best.
All welded up.
Nearly ran out of filler though! Filler roach!
Next I made some bungs in the lathe.
I love working with aluminum, it machines so fast.
Welded in the bungs.
Then I ground off all my (relatively) pretty welds and polished the tank up with a DA and the buffer. Then I pressure tested it. Had one or two small leaks that I fixed.
Took a load off with a tall glass of catmilk. Nothing is more refreshing on a hot day.
Attached the fuel pump to the tank, made a pickup line. In hindsight, I should have used a rubber hose for the pickup tube because leaves a little fuel at the back left corner of the tank, but it will do for now.
After some testing, it became obvious that I had to vent my cap.
Mounted the tank with rubber isolators on the bottom.
And installed it. Fits well.
The other side. The fuel pump is controlled by a timed relay, which when given a momentary signal (since my bike is kick-only I used the "start" position on my ignition), will run for 3 minutes and then shut off. This is about the perfect time to pump all the fuel out of the reserve tank. The fuel flows from the pump through a one way check valve and refills the main tank. Capacity is about a gallon, or probably about 50 miles of riding. Tried it a few times and it works pretty well!
Welds look pretty damn good to me. Starts and stops suck on round stuff, seems like you can only do a few dips before having to rest again.
2). That's still not that much capacity
3). Be careful so as to not hear "Boy, you got a purdy mouth" out in the middle of nowhere
The polish looks great. What grit on the DA? Automotive buffer pad /compound deal?
The polish isn't as great as my stainless stuff. I really struggle with aluminum. I took it to 800 with the DA, then went to the pedestal buffer with tripoli. A rotary polisher would have been better, but I didn't have that.
Originally Posted by Mike93