Pancake Horn Mounting Bracket

[MazdaFlyer]

I picked up this “W” pancake horn sans the bracket. I don’t have much in the way of fabricating tools so I’m always on the hunt for things to repurpose when needing missing parts. I’m unsure of what the “W” stands for.
I’ve seen a bunch of these pancake horns offered up for mega bucks, some with mounting brackets and battery tubes. I picked this one up for $35 at a flea market. There are bargains out there to be found.

I’m thinking I want to mount it on this bike.

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[MazdaFlyer]

I scrounged around my shop then went to HD. At HD I picked up a water closet flange repair piece. The radius pretty much matches the horn OD.

I had the hardware and a couple pieces of GI bracket cutoffs.

I cut the straps to length and drilled a couple of holes. Test assembled the pieces and then I bent the flange for a mounting tab. I also ground off the strap ends to finished length and added radiuses to ends.

Now to work out bike bar mount.


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[MazdaFlyer]

I found that I had some .064 x 0.750 brass stock. So I set out to fab a handlebar bracket. With hand tools, a vise and brut force I mocked up a bracket on the fly. I still need verify the fit, tweak the bends and radius the square ends. I’ll probably run down a couple of brass bolts for the bracket.

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[MazdaFlyer]

I ground off the square corners, filed the burrs on the mounting bracket. Then came the test fit which worked pretty well the first time. The top twist of the mount needed a small twist to be 90 degrees to the bars. I also added a rubber shim around the bars for a little more stability.

For the present the horn is ornamental, not sure if it is functional. Next step is sourcing a 6v power source to find out if it has a second life in its future.


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[MazdaFlyer]

I put together a 6v battery pack along with some temporary low voltage wire, a switch and a couple of alligator clips I was able to wake up the horn. It required adjusting the diaphragm screw to find the sweet spot of noise.
The battery pack can hide in the tank. I’ll use some final wiring and add a momentary button.
See the photo rotated.

 

[MazdaFlyer]

 

[MazdaFlyer]

Phase II mock-up and wiring, new horn button. Batteries in tank .

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[MazdaFlyer]

Button activated pancake noise.

Old Stuff is Good Stuff!!!

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[MazdaFlyer]

Got rid of the green painters tape and experimented with a couple of other attachment methods. Used wire ties and Velcro ties for a start.

Still in the hunt for a replacement fork for the horn’s bike.

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[GuitarlCarl]

What's the chances you have an old headlight with the same approximate diameter?

Carl.

 

[MazdaFlyer]

What's the chances you have an old headlight with the same approximate diameter?

Carl.

Working on LED conversion for the old motorcycle headlight.
I can see the horn mounted in an old fog light or tractor light housing.


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[clamdigger]

Nice find. Compliments the bike well. With the " W " , I am thinkin' Willys.

 

[buickmike]

saved yourself ton of money what kind of shape are the wheels on this bike? Will it run.

 

[MazdaFlyer]

saved yourself ton of money what kind of shape are the wheels on this bike? Will it run.

Thanks! The bracket is bulky but works. I rebuilt the front wheel with a triple step to match the rear. It I rideable as is, and I recently replaced the front fork as it had a Brocken dropout tab.
I need to service the rear wheel hub and bottom bracket. It wouldn’t hurt to clean the chain.


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[buickmike]

 

[buickmike]

Larger horn was $35 Smaller was $$$ neither are hook to batteries-for now..Woud like to find pair of triples steps with decent plating
Are the triple steps made double thickness like S-2 and drop centers?

 

[MazdaFlyer]

Larger horn was $35 Smaller was $$$ neither are hook to batteries-for now..Woud like to find pair of triples steps with decent plating
Are the triple steps made double thickness like S-2 and drop centers?

Horns were probably 6V, think I paid $35 for mine. It works with 6Vs. You ought to be able to fab apiece to complete your brackets.
The triple steps are single layer steel as far as I can tell. The triple step gives them rigidity. They don’t have a hook for the tire bead so you can’t use skinny tires on them or they pop off. I’m using 26”x2.125” tires.


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