Tweaker's Rehab - Continued

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tjwilson

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This all started as a redo of a previous redo as part of RRBO16. Didn't make that deadline but you can see the earlier posts and build progress here. Time totally got away from me in trying to keep up on the build off, other's builds and, posting on my own build. Anyway, this is a bit of a lightening round catchup to where it sits to date and a continuation of the build.
 

tjwilson

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Fork Leg Ends

Last update was the start of the fork legs. This is the start of the leg ends that will connect to the front rockers. Started with a quick template.

01_template.jpg


Improvised a metal brake with clamps. Took a few attempts to eventually get the bend I wanted.
02_improvisedBrake01.jpg


03_improvisedBrake02.jpg


04_bentBlanks.jpg


Shaped ends and stiffener pieces.
05_legShoesWithStiffeners.jpg


Clamped for weld up.
06_clamp4weld.jpg


Initial weld, shaping, additional weld and shape.
07_weldup.jpg


08_firstPassShape.jpg


09_additionalShaping.jpg
 

tjwilson

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Springer Legs

To taper these I cut the tubing lengthwise on only one side. The tubes curved because of heat when welded. After cleaning up the welds I was able to re-straighten the legs by running them through the tubing bender.

01_initialCutSqueeze.jpg


02_ends.jpg


03_ends4weld.jpg


04_endsWelded.jpg


05_weldWarp.jpg


06_cleanupStraighten.jpg
 

tjwilson

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Springer Leg Bridge

Really wish the first welds on this looked as good as the later ones. Took a few attempts to dial the settings in.

01_bridgePieces.jpg


02_bridgeWeldup.jpg


This is the first of two cut/plug welds at the top of the springer legs. This was to reduce the ID to eventually fit a 3/8" bolt.
03_springLegCutExtend.jpg


04_springLegPlugWelds.jpg


05_bridgeWeld2legs01.jpg


06_bridgeWeld2legs02.jpg


07_lowerSpringPerch.jpg
 

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