Building headstock, yokes, etc from scratch

[karl beacham]

Hey guys.

I'm making a chopper style ebike. I've got my initial design I'm just struggling with some of the more specific details.

I plan on having a square headtubeout of 60mm2 box. 5mm thick wall. I'll then machine out a 55mm dia round recess to sit the taper bearings in.

I'm not sure on how best to make the yokes and connect them to the forks as I want the forks to be 40mm x 20mm box too.

Any advice on this would be awesome. I know I've left it a little vague. I'm hoping you guys will have some questions so I can provide more info for you.

I've attached an image of the bike from the front to get an idea.

Thanks in advance karlos

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[us56456712]

What are yokes? Do you perhaps mean drops?

 

[hamqqea]

I believe Karl is asking for advice about making a triple clamp for square tube legs.

 

[karl beacham]

I believe Karl is asking for advice about making a triple clamp for square tube legs.

Yep. Sorry. Yokes are more motorcycle I guess.

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[hamqqea]

A boxed head would be unique. Rather than a conventional large diameter round steering tube, a axle and sealed bearings top/bottom could be implemented. Angled slots on either side could form grooves for the legs to connect. Rotating the legs 45 degrees would look more appealing as well. May need an offset. I try to make a model in Blender.

 

[nosferatu1381]

the last time i did that i had access to a cnc and it was for putting inverted fork legs on a bandit. the 45 degree tubing is what is selling these days. the clamps on most of these "chopper style bicycles really are just a strip of steel with one screw to cinch it up. I like hampea's idea. I am guessing that is a battery box in your frame?

 

[karl beacham]

A boxed head would be unique. Rather than a conventional large diameter round steering tube, a axle and sealed bearings top/bottom could be implemented. Angled slots on either side could form grooves for the legs to connect. Rotating the legs 45 degrees would look more appealing as well. May need an offset. I try to make a model in Blender.

Struggling to visualise this. So a drawing would be awesome

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[karl beacham]

the last time i did that i had access to a cnc and it was for putting inverted fork legs on a bandit. the 45 degree tubing is what is selling these days. the clamps on most of these "chopper style bicycles really are just a strip of steel with one screw to cinch it up. I like hampea's idea. I am guessing that is a battery box in your frame?

Yeah. Battery, controller and bms

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[nosferatu1381]

If I welded the back of this seat clamp here it would legit be beefier that most box store fork leg clamps. I like the axle idea. It is over kill. Or I would make the top fasten to the end of the fork legs. Hang on

 

[nosferatu1381]

This just has pegs that fit into the top of those legs. The headset holds it together. I made that fork.

 

[nosferatu1381]

i just put a plate on top with pegs welded to the bottom of it that fit into the top of the fork legs. It is wicked rigid

the headtube nut holds it all together

 

[karl beacham]

How would you attach the bottom? Would that weld straight to the fork?

Or compression clamp on the side?

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[karl beacham]

And dude. Your bike looks bad .... Very similiar look to what my next one will be

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[nosferatu1381]

i would make it all one welded unit that slides into the head tube from the bottom,
hang on

 

[nosferatu1381]

weld everything below that top plate. Yo can put a threaded plate in the top of the fork legs to bolt the top plate down but you really dont need it as long as that lower tree is solid

reallythe simplest way to do that, that top nut holds the plate down on the fork legs and the plate just has male protrusions that slide into the legs

 

[hamqqea]

From top view. The top and bottom plates are welded to angle brackets the same length as the head tube. I mention the use of an axle so it could be installed and removed like a hub. some offset may be needed so that you can turn the wheel further during parking maneuvers

 

[nosferatu1381]

I would just start with one of these and use two plates to box the bottom then on thick one at the top

 

[nosferatu1381]

That reminds me. I wanted to make that fork with this but changed my mind.

 

[karl beacham]

That reminds me. I wanted to make that fork with this but changed my mind.
View attachment 137688

Is that a leaf spring?

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[karl beacham]

I'm going to draw up those ideas on the frame and see what they look like. Thanks guys.

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