Re: 3-Star Delusion - aluminum bits
OK, well, I've made up the aluminum panels. My father had most of what I needed around his workshop, so I worked over there for this part of the project. I marked out the pieces of aluminum sheet using the templates:
Then proceeded to cut them out on the band saw:
Here are all the parts cut out, ready to be deburred and filed to suit.
The scoop pieces were further marked for bending. It may not be immediately obvious, but I did elect to shorten and somewhat reshape the tail fin. It's actually about a 1/2" shorter than the template, and the curve at the front end is sharpened up a bit. I think this is more consistent with the lines of the tank and chain guard. Yes, there is a notch in the back of the fin; this is to clear the tail light that I'm going to try to use. If it doesn't pan out, I'll cut another fin out. I may recut it smaller yet anyway.
Trial fit on the bike:
And then back to the scoops - My means of forming them isn't sophisticated, but it worked:
Just clamping them to the edge of the bench with a block to distribute the load. The actual bending was done by hand (carefully, because the edges were still a bit sharp). Just a little tweaking to get both forms to sit evenly on a flat surface. Formed and ground:
Then it was time to attach them to the filler panels. I drilled holes in the mounting flanges, transferred the pattern to the panels, and drilled to match. Then (borrowing the rivet gun from my father's shop) riveted them on. Pretty simple. I also found a scrap of stainless steel mesh while over there, and I might be able to make a pair of inlet cover screens for the scoops. We'll see how that comes out...