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View Full Version : Boxing and plating a Triumph frame



KT
01-19-2010, 9:02 AM
Hey all did some work on my buddies Triumph he is building got some pictures of stuff thought I'd post for others to see ,maybe get ideas from ,who know ,anyways enjoy....

Step one have your work space as cluttered as possible and start making a battery box
http://i60.photobucket.com/albums/h1/Morel_Monkey/2-2.jpg

Then trace out your metal
http://i60.photobucket.com/albums/h1/Morel_Monkey/3-2.jpg

Then fire up that trusty torch and get to cutting out the rough shape
http://i60.photobucket.com/albums/h1/Morel_Monkey/4-2.jpg

This is what you end up with before cleaning and prepping for welding
http://i60.photobucket.com/albums/h1/Morel_Monkey/5-2.jpg

This is what you have after all that and welding,notice my metal wasnt big enough to get the whole seat area coverd I add a piece and fix this in next picture...
http://i60.photobucket.com/albums/h1/Morel_Monkey/7-2.jpg

http://i60.photobucket.com/albums/h1/Morel_Monkey/8-1.jpg

Then we moved on to the battery box area
http://i60.photobucket.com/albums/h1/Morel_Monkey/9-1.jpg
http://i60.photobucket.com/albums/h1/Morel_Monkey/10.jpg

Then I added a 1/4 x1/4 angle infront of the rear tire and added the last piece of plate
http://i60.photobucket.com/albums/h1/Morel_Monkey/11.jpg

Then we add a halo piece to fix the battery box in and also tie the end of the rear fender to the bike here....
http://i60.photobucket.com/albums/h1/Morel_Monkey/22.jpg
http://i60.photobucket.com/albums/h1/Morel_Monkey/21.jpg

Then we move on to making the oil tank bracket...look at that 100% penetration on the seat plate that piece isn't coming off without some serious cutting and grinding hehehe
http://i60.photobucket.com/albums/h1/Morel_Monkey/20.jpg

KT
01-19-2010, 9:03 AM
This is what we end up with after it is all in still need to fix the battery box in ..it is just laying in there in the pic
http://i60.photobucket.com/albums/h1/Morel_Monkey/24.jpg

We finished mounting the rear fender but it got late and we stopped taking pictures did a ton of work in 5 hours with justa 4 inch grinder a welder and a torch lol

KT
01-19-2010, 9:08 AM
found a pic of the rear fender mount in the frame
http://i60.photobucket.com/albums/h1/Morel_Monkey/15.jpg
http://i60.photobucket.com/albums/h1/Morel_Monkey/12.jpg

Jethro
01-19-2010, 9:31 AM
Great shots... and good job. Especially like the way you tied the fender in. Better than what I have done, and I'll keep that in mind for the next time. Funny thing is, I was bored last night and broke out my welding books to review some things... will be doing a few pieces this winter when I get the back back into the dining room.

gravelveins
01-21-2010, 8:21 PM
great pictorial run down of how you did this.
nice work.

flatblack34
01-21-2010, 10:16 PM
are you cutting off the swingarm bracket??

KT
01-21-2010, 10:50 PM
are you cutting off the swingarm bracket??

Nope owner wants to be able to put it back to stock if he wants ...1970 TR6R matching numbers ....Same as my bike ...I left all the tabs on my front loop for the same reason ...

I have more to do... guess the owner has a different way he wants to go on the fender struts so I need to change those and make a lid for the battery box electronics box and a extended brake rod for him also...

Pete
01-22-2010, 6:33 AM
Very cool. Nice welding too, it is amazing what you can do with just a few key tools and a bunch of desire!

KT
01-26-2010, 6:56 PM
Here is some more on this project I have been doing the metal work on ...I got the battery box done and the extended rod made ... I think the box came out so ..so ...I need to get my shop built come on spring .... anyways here ya go ....

First is a better pic of the battery box fender brace loop..
http://i60.photobucket.com/albums/h1/Morel_Monkey/28.jpg

Starts out with 1/8x1/2x1/2 angle notch and bend the frame for the lid...
http://i60.photobucket.com/albums/h1/Morel_Monkey/30.jpg

you end up with something like this..
http://i60.photobucket.com/albums/h1/Morel_Monkey/31.jpg

Cut out a piece of plate and cap it ...
http://i60.photobucket.com/albums/h1/Morel_Monkey/33.jpg
http://i60.photobucket.com/albums/h1/Morel_Monkey/35.jpg

KT
01-26-2010, 6:59 PM
http://i60.photobucket.com/albums/h1/Morel_Monkey/39.jpg

Then we take some carriage bolts and cut off the threaded part..
http://i60.photobucket.com/albums/h1/Morel_Monkey/41.jpg
http://i60.photobucket.com/albums/h1/Morel_Monkey/42.jpg

Here we welded the bolt ends to a small piece of the angle iron I had scrap of and created a clip and ear to bolt down the lid...

http://i60.photobucket.com/albums/h1/Morel_Monkey/43.jpg
http://i60.photobucket.com/albums/h1/Morel_Monkey/45.jpg

KT
01-26-2010, 7:02 PM
back side of the lid showing the threaded ears...

http://i60.photobucket.com/albums/h1/Morel_Monkey/47.jpg
http://i60.photobucket.com/albums/h1/Morel_Monkey/50.jpg

For this job I had a old box bent up laying around I modified some 1/4x1/4 angle iron, couple bolts and some plate scraps ...It took a 4 inch grinder with a cutting wheel ,a flapper wheel and a mig welder.....oh a vise and a hammer or two involved always need hammers

KT
01-26-2010, 7:08 PM
Here is my version of a brake rod extension on the cheap ...

one stick of 1/2 tube and your old brake rod ends...

http://i60.photobucket.com/albums/h1/Morel_Monkey/51.jpg

Tack the ends in making sure to tack them to the inside wall as to off set the 1/2 of tube to the outside so it does not interfere with the brackets on the pedal or drum...

http://i60.photobucket.com/albums/h1/Morel_Monkey/53.jpg
http://i60.photobucket.com/albums/h1/Morel_Monkey/52.jpg

Then weld them in making sure that you put a good amount of the old rod inside the tube so you get a good bond ....

http://i60.photobucket.com/albums/h1/Morel_Monkey/54.jpg
http://i60.photobucket.com/albums/h1/Morel_Monkey/55.jpg
http://i60.photobucket.com/albums/h1/Morel_Monkey/56.jpg