Man, one work week down! I was so tired after work on Monday! Everyday I get a little stamina back.
So, this isn't
technically a quarantine project, but I feel like sharing. A friend is trying to mount Harley Davidson saddlebags on his Vulcan, so he got the brackets and asked me to modify them. The following is his design to mount up the bags to his rear fender.
This is the pair of brackets.
The plates were welded on by me. He'll use these plates to drill/bolt the bags on. The holes in the plate will be used to mount the bracket to the bike.
Gussets on the back side. All this stuff was welded with 110V flux core. My trusty old Lincoln SP135! I bought it in 2001, it's almost 20 years old!
He also needed a backer plate made for the air cleaner. Here's the template.
The plate fits into this grommet for an air tight fit.
I thought I'd be slick and cut this thing out with the lathe. If I'd have known what a pain it was going to be I would have just sheared it out and sanded it down!
To get the clearance I needed I set up to cut the OD from the back side. The metal is 1/8" 5052 aluminum. The thickness is just right for the grommet.
Nother view.
Inverted tooling! Craziness!!!
Holy chatter! I had an awful time with this. Chatter was very very bad. A few times the tool caught and caused the piece to spin on the arbor. I tried a few different speeds even down to back gears. The slower the better for this. I tried to feed in with the carriage as slowly as possible but it was extremely easy to catch the part and cause the arbor to slip. Eventually the tool caught bad enough to break the tip off.
I finished cutting it out the old fashioned way. I love this little shear! It was very easy to follow the kerf made on the lathe. It was over halfway through.
I put it back on the arbor and cleaned up the OD. Even this chattered badly. I tried a tool with lots of negative rake thinking it would help and it kind of did. I again ran the lathe very slow. Out of all the passes I did only one of them yielded a nice quiet cut with well formed strings of aluminum peeling off the part. What I needed was a beefier arbor I think. Trying to turn a 6.5" round disc on a 1" arbor is pretty asinine if you think about it, which I didn't until now.
All that's left is the ID. I should be able to hold this in the 4 jaw and bore it out. The finished size is around 1.875" so I may hole saw 1-3/4" to start.
Fun fact: you can see there's a concentric ring on the face which is where I almost cut the part too small! I did a scratch then double checked the size with a tape measure. Always double check!
A final view of the edge. I filed it a lot to get this finish. It's not great but better than the lathe cut finish. Didn't feel like doing the sandpaper/polish bit.
Tomorrow I'll tackle the ID. I hope it goes better!