- Joined
- Jan 23, 2012
- Messages
- 1,216
mine are the center two in the picture of four.
for thepast few days ive been making reproduction signal light brackets for older 750honda motorcycles. Left and right hadversions. My boy has three of them. The orig. ones are not available any longerand they are prone to snap off if the bike is dropped. . . “help dad !”
so I mentallydysected the orig ones he borrowed from a friend, got a few hunks of sheetmetal about 14ga thick, bent it into a channel shape about 1” x 1”x 1”, 6inches long, leaving a bunch of extra material on all sides for jig-ability, I locatedand drilled some 8 odd indexing holes with the mill and the dro;s (not a shamelessplug) for assisting in repeatability. Usingthe index holes I cut the pie shape wedge out for more bending with my cut offwheel in a die grinder. After the threebends were made, I welded up the holes and where the pie cuts were made.
Next was todrill one hole and end mill a slot then off to the vice again to do the edgecontours. Most of the contours weredone with a .032 cut off wheel on a air die grinder. (they have been one of my bestest tools in mycollection). Then some belt sanding andcleaning up with a scotch brite disc on a rol-loc pad and die grinderagain. Then to the scotch brite wheel onmy bench grinder,
Of coursethe peg or stem that the light fits onto is a metric size so the mill was againmy partner. Figure out the location angle with my angle cube, and heavy tac weld them on all 4 edges.
They willbe painted flat black and if the boy wants to fill the back side that’s notvisible, that’s up to him.
Anyway itwas a fun project and a test of my cardboard engineering again.
Now I need tomake documents and sketches so I can make more. . . .. . . oh boy, ebay here I come. . . . NOT !
for thepast few days ive been making reproduction signal light brackets for older 750honda motorcycles. Left and right hadversions. My boy has three of them. The orig. ones are not available any longerand they are prone to snap off if the bike is dropped. . . “help dad !”
so I mentallydysected the orig ones he borrowed from a friend, got a few hunks of sheetmetal about 14ga thick, bent it into a channel shape about 1” x 1”x 1”, 6inches long, leaving a bunch of extra material on all sides for jig-ability, I locatedand drilled some 8 odd indexing holes with the mill and the dro;s (not a shamelessplug) for assisting in repeatability. Usingthe index holes I cut the pie shape wedge out for more bending with my cut offwheel in a die grinder. After the threebends were made, I welded up the holes and where the pie cuts were made.
Next was todrill one hole and end mill a slot then off to the vice again to do the edgecontours. Most of the contours weredone with a .032 cut off wheel on a air die grinder. (they have been one of my bestest tools in mycollection). Then some belt sanding andcleaning up with a scotch brite disc on a rol-loc pad and die grinderagain. Then to the scotch brite wheel onmy bench grinder,
Of coursethe peg or stem that the light fits onto is a metric size so the mill was againmy partner. Figure out the location angle with my angle cube, and heavy tac weld them on all 4 edges.
They willbe painted flat black and if the boy wants to fill the back side that’s notvisible, that’s up to him.
Anyway itwas a fun project and a test of my cardboard engineering again.
Now I need tomake documents and sketches so I can make more. . . .. . . oh boy, ebay here I come. . . . NOT !