Ironhead Boardtracker

[Dexter]

Then on to the welding
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Out of the jig in raw state
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Then with the lower shock mount welded to the bottom wishbone, you can also see the bushes have been pressed in and the pivot pins are trial fitted.
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[Dexter]

Then out with the grinder, file and flapper wheel to clean up the welds.
Top wishbone
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bottom wishbone
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And a pair
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Thanks for looking

[Buellbomb]

It's coming along nicely, can't wait to see the finished product.

[Dexter]

Thanks, want to get it on 2 wheels for christmas...... fingers crossed

[Dexter]

In last weeks episode we were feeling smug having cleaned up the wishbones ready for fitting to the yokes.
So the plan was to turn up single pivot pins to attach the wishbone to the yokes and then a solid bar through the front wishbone tube to mount the blades. We did a fair bit of planing on the shock front looking first at mountain bikes with gas canisters which looked good but the fear was that they would not be up to the job / weight and the final nail in the coffin was packaging the canister wanted to occupy space that wasnt available. In the front end design the shock lenght eye to eye was a critical dimension + we wanted 75mm of travel. So looked at car coilovers spoke to a few people picked Protech with rose jointed eyes, with the rebound set up for the bike weight, bit hit and miss with some bathroom scales and a trolley jack under the headstock to get a weight so some further fine tuning may be needed in the future.
So some various pics you will see at this stage the fixing bolts need cutting down so lots of washers so a bit jury rigged. You can see the wood under the bottom wishbone this has the trusty trolley jack underneath so we could pick the whole bike up to simulate it being on the front wheel.

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This is what angle of the wishbones should be once the bike is sitting on both wheels.


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The next stage was to cut down the pivot bolts so the pivot pins could be locked in place then some minor adjustments to get the wishbones moving freely.
You will see the gaps between the piviot pins and the yokes are not even at the moment these spaces will be sorted up in the next assembley once we make the brass washers to take up this gap, we couldnt find any premade at the right size so its back to the trusty lathe and lost of brass shavings.


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[SF]

That frame looks great...rear tire has been around a few corners and heat cycles!

[Dexter]

Yeah if i can lean the Harley over that far in the corners would be doing well.....

[Freewheeler]

Not bad going from a single garage, looks good.

Nick

[Dexter]

Thanks Nick

Keeps you fit when you have to keep bringing it outside to get a better look boy is it heavy, you may have noticed the sling round the headstock well that goes over my shoulder when it needs moving, guess i should just hurry up and get the front end finished....

Few more pic of the front end

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Also got the call that the blades are ready for collection so photos to follow soon.........

[Dexter]

BLADES but not very sharp

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[Dexter]

The turning of the final bushes is progressing front face yet to be profiled these will be a press fit, trial fit / hang on the bike..

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Wheel spindle bush
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Hanging off the wishbone shafts
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[Dexter]

Managed to take Monday off with plans to finish off the front end, maybe a bit ambitious but good progress made.
All the turned spacers to take the wishbone mounts are complete + had a result with the brass thrust washers. I bought some brass with the intention of drilling out 40mm discs but this was a right pain in the **** so popped down to a local metal working shop hoping to use a prpoer piller drill but they thought better of this and using a CNC punching machine poped out 12 shiny washers so all i needed to do was bore out the centers on the lathe to fit, what a nice bunch and FOC....
Anyway a few photos.

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Front wheel is just balanced in there

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Plan for this weekend is to sort out the blades so radius off the front leading edge, and add a surface finish to the sides before we get the press out to fit the bushes...

[Dexter]

So that leading edge profile not the quickest job..... so armed with some G clamps and a good sturdy bench the fun begins.

So clamped in position
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Trying out a surface finish this is with a flapper wheel
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This finish was made using a orbital sander but not sure I then tried a lined out look, no photos yet ran out of time.
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The next stage will be to get both blades looking the same, complete the surface finish then on to wasting the trailing edge to give an aero look + caliper mount........

[kacivic]

Were you going to do any cut-outs in those, or just leave them solid?

[SF]

So that leading edge profile not the quickest job..... so armed with some G clamps and a good sturdy bench the fun begins.

So clamped in position
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Trying out a surface finish this is with a flapper wheel
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This finish was made using a orbital sander but not sure I then tried a lined out look, no photos yet ran out of time.
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The next stage will be to get both blades looking the same, complete the surface finish then on to wasting the trailing edge to give an aero look + caliper mount........

How much do you think the front end will weight?