Who u calling a wench lol
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Finally another update!
So, a couple things. Has anyone talked sense into me yet? Hell no!
I've gotten started, and have made a couple pieces. A couple small pieces. I had to make a fixture plate for the rotary table to hold onto these parts. The largest dimensions with the flanges is 1.5" x 2", .125" flange. They aren't finished yet, but I'm only going to be drilling a hole in each one, reaming the hole to 24mm, and cutting a slit in one side. Because this bike is a prototype, I decided that adjustable fork offset would be nice if I could make the small inserts, so these will be where the stem goes through on the triple trees. I'll likely make 3 sets. Holes centered, 3mm offset, and 6mm offset. Wanted to make these first as proof of concept for being able to make and hold onto the small pieces.
Also of interest, I finally acquired a TIG welder, and did my first practice yesterday. Tried with 1/8" mild steel first. Didn't look that great, but the welds were functional-ish.
Then I tried aluminum that was a little thinner.
Apparently, that was beginner's luck. Still, I think with practice, I'll be fine. I tested several different types of joints. Butt, lap, T, outside corner. With one of them, I only welded about about .75" long, and I almost couldn't break it by hand. Next up, I'll be making the lower triple, upper triple, steering stem, and bearing head tube.
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I guess I'll do another update. I have the upper triple mostly hogged out. Need to round off a few corners, cut some angled sides, drill and tap a few holes, and cut a couple slots. I think it's far enough along to be a good tease of the finished product. I did have one oops with an endmill. It's on the bottom side. Now that I have a TIG, I could always fill it back in, and then smooth it out, but I'm not sure if I'll bother.
This might also illustrate how I can have adjustable fork offset by making more oval pieces with holes off center.
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Looks like a jeep grill.My Katana-1100 17" wheel swap
http://katriders.com/vb/showthread.php?t=136894
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Originally posted by Parts man View PostA very custom jeep grill...I LIKE IT!! Nice triple clamp dude.
Put em on ebay..you'll make a pile of $$$
But here's the update. I still need to tap the hole for the set screw for the oval piece. The outer radius looks slightly odd because of sanding. I think I'm still going to smooth corners a bit and maybe polish. I'm contemplating having all the aluminum parts anodized, including the frame and swingarm.
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Originally posted by Parts man View PostTrue but think of the possibilities. ..anodizing..even powder coating
In other news, I'm wanting to document this as well as possible. I've started keeping a notebook with hand drawings and notes, as well as all the hardware/materials used. I've finally started trying to learn Fusion 360 as CAD/CAM. In the future, I may invest in building a CNC machine, which would make it even easier to make many parts in this.
I also did a little cyber monday shopping at 30% off.
It's beginning to look a lot like bike frames!
I also got some 1/8" sheet for making gussets and fairing mounting tabs out of.
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Originally posted by ygolohcysp View Postanodized blue would be amazing...
In the future, I may invest in building a CNC machine, which would make it even easier to make many parts in this.
Build a CNC machine ???? I thought they came pre-assembled.
Man, if you can afford one of those, why the hell are you building a Katana ?My Katana-1100 17" wheel swap
http://katriders.com/vb/showthread.php?t=136894
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I can't afford one, that's why I'd build one. Also, I'm not building a Katana. I'm building a smaller bike for miniGP racing as a one off total custom bike. It's going to be a 25hp 190cc Daytona engine, and I'm building this to compete with the Ohvale bikes that are getting imported now. $7000 for a bike that's the size of my pocket bike is ridiculous, so I'm building a bike I can fit on for an endurance race and be comfortable.
Ohvale bikes at https://www.risemoto.com/
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Well, I've gotten started on some other parts. I was waiting for aluminum for the lower triple and steering stem to come in, and got bored. First I cut one of the 8' aluminum tubes in half. Then, to be able to visualize how it would look like the cardboard frame, I covered it with blue tape.
That may have also helped with doing layout for the pie cuts. Maybe. The welding seemed to go alright. Did I mention that I'm actively learning to weld aluminum for this project, and doing practice work still? Yeah, I know that means it's insane to weld together my own frame like this. What's the worst that could happen? I mean, I've shattered the front wheel of a pocket bike while backing it into a turn.
After some welding, where I only got a couple crappy in progress shots, I decided I needed to make the headstock before going any further. The front part of the frame is "bent" to shape, with the forward pieces left a couple inches long so I could trim to fit. My goal is to get 8" between inner walls of the two frame pieces for the vertical portions for engine and swingarm mounts. I need the headstock to know where to trim, and then need to measure to get the right length. I laid it out on paper, but perfect angles work a lot better in math on paper than they do with pie cuts and bending/welding aluminum tubes.
Headstock:
And lastly, my super layout top tip. Giant graph paper post it notes!
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