Time to catch up on Jason's work.
Front oil tank brackets (on seat post) don't match new frame and are cut off. Brackets on other frame are cut off and welded in position...
They are not strong enough for my liking, so we add in some small triangular sections. Straight edge is used to keep them in line.
Threaded bungs on top of top tube are completely cut out instead of being ground off because they protrude right down into the frame and will prevent us from running an internal wiring loom...
Large holes re plugged with solid bar...
Plugs and frame need to be chamfered so we get full weld penetration. Wires are to prevent plugs falling into holes at beginning of welding...
Despite full welding, this is still a weak spot especially considering its position on the backbone; the most stressed spot...
A 4mm plate is shaped to the od of the top tube. Ends are shaped to a point. This is important as a weld straight across a tube creates a stress point. Doing a fish mouth or bringing plate to a point reduces this tendency...
Jason liked the idea of a bit more rake, so after determining that we would stay within the 550 RidikulusRool, we decided on 3 degree raked bearing cups. These provide true rake not false rake (derake) you get with 'raked triple trees'. Bearing cups spent overnight in the bottom of the freezer. They will be 'pressed' in with the 1" diameter threaded bar. As an extra precaution, we lock them in with 'Bearing Mount'. Cups have to be carefully aligned; punch marks are provided...
Some gentle tapping with a small hammer as we tighten the threaded rod, helps start the bearing cups...
Screwing them in. The quicker the better before the cold is trasfered...
Installed...
Now the exciting part. Installing the front end and getting the chopper on its wheels!!! Wow! Jason falls in love immediately.
Now to measure up for steering stops. Using after market ones is not an option as Jason undertands my explanation that the more lock you can get with a long front end, the more manoeuvrable and easy to ride a chopper will be.
Forks are turned to each side until they just clear the tank and marks are made. Piece of paper allows us to measure 'on the curve'. A 6mm flat bar is bent to the right curve and length...
... and tack welded into place. Turns out perfectly...
Chopper will now stay on the ground as we complete seat and pipe mounts and make sure EVERYTHING fits. Once it is completely assembled it will be dismantled, welding is completed and frame moulded and painted. Here Jason has machined up an aluminium spacer so the original ignition/engine mount can be used...
After a most frustrating and time consuming search Jason finally takes ownership of a non offset centre for the front pulley. After trying every method under the sun, Jason drills out the old socket head cap screws. Now how hard will it be to separate the old centre from the pulley. Will this little press be ok? Well I'll be the damn thing falls out with no effort at all! New centre is installed with new screws and slipped onto the motor.
Gearbox bolts are very tight on the slots awhihc actually need to be lengthened about three mil. This is done with a die grinder and burrs are removed with a minibelt sander.
Tins have now been painted and frame got done today... more pics soon.
Chopit'nrideit... Prof