Step one is always planning and takes time if you are to end up with a job that not only looks good, but will last and most importantly is user friendly.
Electrics to be mounted are the...
twin double coils,
coil igniter box,
battery,
starter solenoid,
Fuse box,
junction strip and
switches.
James also wants the horn to be out of site and it looks like we would have plenty of room for that as well.
We decide to mount the coils at the front of the box. Some 30 x 3 flat bar and tubing do the trick...
and is temporarily tack welded at the bottom to a cross piece of 1" angle. Here can be seen measuring up to get them centred...
Another view. Each electrical component needs to be easily removed. These are not as easy as I would like them to be...
James wants the electrics box welded in to the frame as a part of the whole, so I do a whole lot of measurements and he cuts out a pattern from thin aluminium...
Pattern made. Bottom of box is 15mm clear of the swing arm on full compression. Rear of box also has to be clear of the tyre when wheel is fully forwards...
Chain movement has to be allowed for on left side. Wheel is set to its highest point and a straight edge run through...
When riding, the top of the chain will form an arc so we allow an extra 25mm to be safe...
Electrics box is made up of 1.6mm plate. The first part of the fab...
Base of box sitting in place...
Coils definitely need to be more easily removed, so we make the coil bracket itself removable. Here setting up the top mounting using a 8mm threaded bung...
Bottom will be held with a bracket and two M6 bolts. Here being measured up...
Bracket completed...
Nuts welded into the base...
Measuring for the top mount...
Countersinking the bung...
In place...
Base needs some extensions to make it water and mud proof. Here a pattern being made. A piece of sheet metal to be cut and welded into place can also be seen protruding at left...
Base and extensions welded in...
We keep the original rubber mount for the solenoid. A piece of 30mm rectangular tube save bending...
Basic bracket made. Will be drilled for two M6 bolts...
Solenoid mount completed and bolted to a welded in bracket. 25 x 6mm flat bar is welded in vertically to hold the igniter box. Again time is taken to plan location and make sure the components are easily accessed and easily removed. It is especially important that solenoid connections are readily accessible as they must stay tight and be occasionally cleaned to maintain good contact for the heavy current used by the starter...
Bottom of battery is retained by a simple 25 x 3 bent flat bar...
Horn mount is cut from a piece of 3mm wall square tube...
A captive bolt is welded to it, rather than a nut as it will be easier to start on the thread in the position it will be in...
Main components in place...
Battery has to be held down. I have no straps suitable and they would be hard to clip in anyway, so I build a clamp that will push the battery down. A piece of 30mm flat bar (red arrow) with a piece of tube rubber glued to it holds the battery. The removable hold down set up is made from a piece of M6 threaded rod (black arrow) that screws into a long skinny bung (white arrow) that will be welded to the electrics box base. We machine up an alloy nut. Rest of bracket (green arrows) is made from four pieces of shaped 25 x 3 flat bar...
View from on top...
Side view...
James will be up tomorrow and we will hopefully build the sides of the box and get them welded in, plus add some reinforcing gussets to the frame tube below the top shocker mounts...
