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  1. #41
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    Firstly thanks for the responses I sort of knew that the front forks would be a bit of a Marmite thing....

    AndyNZ
    No plans to cut any shapes in the blades what I have is all part of the plan but I still have some further work to complete on them.

    LoddyToddy
    As above on the marmite thing but give me time I may win you round - or not

    Philphine
    I have had the front end in the planning stages for some time so they are fully grown on me but again let's see how the build progresses, from what I have seen with the bars as an example small things can make a big change to the overall proportions - I will bin the bars as they spoil the line and wreck the proportions.

    Nuklnd
    No worries all comments are welcome, the blades do have more work to be completed but to reach my self imposed deadline and get the bike on 2 wheels ... The basic plan is to make the caliper mount next, I bought some billet Ali yesterday so need to get this mocked up and mounted then the rear edge of the blade is to be shaped into a narrow point sort of like a arrow head when you look at the blade from above. As I want this shape to match both blades and there is a single caliper the mount is the first part off the puzzle, but for sure this will change the whole proportions again Its just getting the ideas from the head to the metal....

    Please keep the comments coming
    Last edited by Dexter; 12-24-2014 at 10:40 AM.

  2. #42
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    The start of the gear change foot peg holder

    [/IMG]
    Last edited by Dexter; 10-31-2015 at 2:13 AM.

  3. #43
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    Move on from teh front end to foot pegs and contols, this weekend its been the rear brake.

    I wanted to retain the origonal pegs but make up some new mounts which would relocate the peg and then fab up the new rear brake lever and slave cylinder
    [/IMG]
    [/IMG]
    [/IMG]
    [/IMG]
    Still a bit to go need to modify the push rod and plan to use a rose joint with a new pivot pin oh and a spring return and a lever stop........
    Last edited by Dexter; 10-31-2015 at 2:17 AM.

  4. #44
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    Not much going on with the front end so moved back to the engine. The head steady needs to cover a few duties.

    Steady the head
    [/IMG]
    Mount for the gear change in progress, hold the coil and ignition key
    [/IMG]
    Last edited by Dexter; 10-31-2015 at 2:29 AM.

  5. #45
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    great work I like, but I think you passed the board tracker style awhile back

  6. #46
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    Long time no post, but the sun was out.
    New handlebars to replace the rabbit ears tack welded in place, and starting to mock up the leaf spring + tractor seat.
    Also trying out a rear mudguard - not sure may go back to the flared one which came with the bike back when it looked a bit different......
    Just bought a milling machine so the front brake billet mounting bracket and profiles to the front blades may start soon.

    [/IMG]
    Last edited by Dexter; 10-31-2015 at 2:32 AM.

  7. #47
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    So those rabbit handlebars needed to go found something more in keeping with the look I wanted managed to re use my mounts from last pair .

    [/IMG]

    The seat mounting method and the leaf spring suspension went through several variations if only in my head and ended up with the following solution.

    [/IMG]
    [/IMG]


    The next stage is finding a successful method of drilling holes in a leaf spring.....
    Last edited by Dexter; 10-31-2015 at 2:36 AM.

  8. #48
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    Petrol tanks and oil tanks both needed for this build but not easy to find anything i like that could be modified did spend some days trawling various bike jumbles but that was a bust.
    So the plan evolved to make my own and if this was to be my design then oil tank was also to be part of the tank design, just to make it interesting the tank was to be in 3 pieces 1 half fuel and the second half cut in 2, 1 part petrol and the other oil.
    Not a finished article and like the rest of the bike it may be Marmite to some......

    The bay is my friend for sheet steel 0.9mm
    [/IMG]
    First a wood template was made to fit into the triangle space above the engine and then 2 steel shapes cut out using the trusty jig saw making each piece around 10mm bigger than the template


    I used a length of angle iron with some 6mm clamping screws to hold each steel shape in place and then folded over the extra 10mm to make right angle flange. These would be the inner faces of each side.
    [IMG][/IMG]
    [/IMG]
    [/IMG]
    ]TT[/IMG]
    Last edited by Dexter; 10-31-2015 at 2:42 AM.

  9. #49
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    Same process for the top section although this was made to size - overlaping required.
    [/IMG]
    Then the bottoms with a simple fold.
    [/IMG]
    Next welding the top section to the top of the first inner side, only really tacking at this stage and some forming of the pieces to follow the contours.
    [/IMG]
    [/IMG]
    And then there were 2
    Last edited by Dexter; 10-31-2015 at 2:47 AM.

  10. #50
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    And from another angle
    [/IMG]
    Next the sides again shaped each one to follow the contour of top and bottom and the welding gets a bit more tricky, never used the welder with such a low amp setting.
    [/IMG]
    [/IMG]
    Ok so having made 2 of them it was time to cut 1 in half or not half but a sort of half....
    [/IMG]
    [/IMG]
    And thats about it new fuel taps, weld in tank necks, and oil pipe fittings waiting in the wings + lots more welding.
    Last edited by Dexter; 10-31-2015 at 2:59 AM.

  11. #51
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    Not been posting but working honest
    So started on a spending spree of sorts, new Harley fuel taps, then went in search for weld in bungs with the 22mm threads got these in the UK, then searching on the same web site found the fuel filler necks so the cast was set for the type of fuel caps which came from India.....quality is good like the internal throttle which came from the same source. Bit a brass theme going on.....
    Ok so the fuel side sorted for parts at least I moved onto the oil tank and looked at types of fittings, took a trip to my friendly hydraulic specialist been going there for years and once I had there attention and the banter was over we looked at 8mm brass tube but when it came down to fittings it all looked a but chunky, moved onto what could be used with a cloth covered rubber hose and came up with a push on system they promise once its assebled will only come off with a knife - time will tell.
    So back to the main plot one half of the tank was to be split in 2 - one half oil the other petrol, I wanted to be able to join these back together and the chosen method was to be weld in threaded plugs in 1 half and a steel plate welded to the other half so they can be aligned and bolted back together.
    Holes to accept the bungs
    [/IMG]
    And home turned bungs with 6mm blind threads
    [/IMG]
    And ready to be welded
    [/IMG]
    Weld on fuel neck - this was shortend and profiled to match the curve of the top surface, decided that the neck would be welded on top of the tank not through so a 40mm hole was made in the tank first for fill ups.
    Neck tacked in position, the pliers help to keep things in place and not distort as the welding is progressed.
    [/IMG]
    More to come....
    Last edited by Dexter; 10-31-2015 at 3:04 AM.

  12. #52
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    And in more news.... so with the oil tank pipes bought it was time to drill off the bottom of the tank and weld in what will become the oil feed and return, as part of my spend the oil return also got a new length of steel tube welded on for good measure.
    [/IMG]
    The oil filler was another purchase although not in stock so just the fixing nut, this was turned down with a step about the same thickness as the sheet steel, this would allow welding from the outside and give a nice register to keep everthing in place.
    [/IMG]
    Then cut and shaped the end plate an tacked in place - seam welding to be finished off.
    [/IMG]
    Last edited by Dexter; 10-31-2015 at 12:44 PM.

  13. #53
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    Just to prove i haven't been slacking the petrol tank half now needed the the fuel tap bung, this had a quick session on the lathe to reduce the outer edge to help make the weld to the tank.
    [/IMG]
    And welded in place
    [/IMG]
    And then the end plated and tacked in place - final seam welding to complete
    [IMG][/IMG]
    Last edited by Dexter; 10-31-2015 at 12:50 PM.

  14. #54
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    Welding has now drawn to a halt as the argon bottle is empty
    Part of the plan with this bike was to remove or hide things that could be hidden, so the whole petrol tank choice is as much about getting rid of the need for a seperate oil tank. Once the idea of using the top frame tube to hold the oil had been discounted the petrol tank was always destined to hold the oil somehow. In a similar vein hiding the battery was another thing at the top of my list to hide with a sneeky plan to get rid of it all together but that's for a later day when the engine gets a rebuild, anyway I digress the tank design also had to work with hiding the battery so my solution was to mount the battery in the frame tube triangle along with any wiring so the 2 parts of the tank would cover the battery in its new hiding place.
    The right size battery took some searching as not only did in need to fit within the said triangle it could'nt be to wide or it would push the 2 parts of the tank apart, this is the mounting solution still a work in progress... oh and hopefully with enough grunt to start the engine....

    So folded this up from the same sheet as the tank.

    [/IMG]
    The side fold is only one side as its tight when its all in position so the battery can only be slid in from one side.
    [/IMG]
    This is only balanced on position welding will come once the tank is completed and final fit can be checked.

    [/IMG]
    [/IMG]
    The battery will need to be secured to the mount in its final form and non conductive covers for the terminals, not sure 12v and petrol would be healthy... still so much to do.
    Last edited by Dexter; 10-31-2015 at 12:55 PM.

  15. #55
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    No further progress on the battery mount and not much luck with the Argon Bottle, using a new supplier and have had 3 duff regulator valves which have stopped play.
    But in between managed to weld up a few bits, as part of the fuel and oil tank works I had borrowed a number of fittings with the understanding that what used I payed so not wanting to hold on to these and take the p@@s , I could sellect the best options on straight and 90 connectors. With this in mind and wanting to get the final parts of the oil system complete we moved on to oil filter mouning and in / out oil feeds.
    The origonal Ironhead used the front engine plate to mount the fillter and this looked to be a simple solution so we did a variation on this but just had the space to mount the fillter in between the plates for that hidden look.
    Hopefully you can just make out the filter
    [/IMG]
    To make the centre oil fillter connection we bought a male / male threaded union bored a hole through the engine plate and welded this union in place this also allowed us to use a 90 swivel fitting so things could be taken apart if needed, the other 90 fitting was modified to remove the swivel section and the 90 was welded straight on to the engine plate, this takes the oil from the other side of the fillter to be joined up to the front oil pump take off.

    [/IMG]
    [/IMG]
    [/IMG]
    Last edited by Dexter; 10-31-2015 at 1:29 PM.

  16. #56
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    In between all this tank building we also wanted to move some other parts foward, so those who have be following you may have noticed the rear mudguard ? after buying a new guard and then rejecting it for fit and looks ( 17" sports bike wheels size don't help ) we pulled out the original Ironhead guard which had some nice shapes but needed some shaping of the outer edge to match the tyre dia, so after marking out the guard and triming off the sides its started to look better, we also needed to stretch the width to give it clerance to the tyre which has sort of V profile lots of huffing and puffing.
    Next up was some stifferning so after all the original internal cable mounts and the whole thing cut to the required lenght we rolled up some 3mm steel strap to the inner guard shape and tack welded this in position.
    [/IMG]
    next the fixing bolts were welded in position, these locate the guard to the frame and can be cut down at a later date, with the whole guard now looking a bit more like it we looked at the room between the guard and the tyre and as the guard has a rasied center section this looked like a nice place to mount the rear light. The plan was to make an LED light to fit the space but these are so cheap now this when out the window.
    [/IMG]not bad for 5

    This light has some brass threaded inserts so just a case of drilling clearance holes and a couple of dome screws.
    [/IMG]
    And the on the bike may need an finishing trim piece, just need to wire it up....mount the battery......
    [/IMG]
    Last edited by Dexter; 10-31-2015 at 1:33 PM.

  17. #57
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    Back on the tank this week, now the mounting of these has been an interesting process from hidden tubes to brackets over the frame then screwed into threaded inserts in the tank top.....the list of ideas was ok but never came up with something we could hang the old hat on.
    parts have been made like the threaded inserts and drawings of the over the top mounts but today this whole idea was shelved. So what came out of today was a new approach to what we have considered the main problem we were wrestling with is trying to get a good alignment to the frame tubes and also taking the weight of fuel and oil - so this will be over a couple of posts so dont get to excited nothing happens quickly......and no garantee its gong to work....

    Trusty sissors and cardboard + plus some shamless advertising..think this was from the fuel tap supplier
    [/IMG]
    Marked out and cut awaiting shaping
    [/IMG]
    And ready to be welded and bent to shape, the holes were to bolt both bits together so they end up the same shape.
    [/IMG]
    Part 2 coming right up
    Last edited by Dexter; 10-31-2015 at 1:44 PM.

  18. #58
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    Ok Part 2

    And now the rear
    [/IMG]
    [/IMG]
    And now using the headsteady bolt and the rear mount
    [/IMG]
    Last edited by Dexter; 10-31-2015 at 1:46 PM.

  19. #59
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    Lots of progress this weekend, internal throttle now fitted bit of a faff but well happy with the result. Took a bit of a punt and spyed this on ebay manufactured in India and to be fair really nice quality but no instructions... I had previously replaced the rabbit ear bars with the beachcomber style so chopped off the bar and then had to turn a section to increase the internal dia so the throttle fitted only a 0.5 skim required but we wnated a nice snug fit, then welded the section of bar back on needed to drill and tap 2 holes used to pin the cable outer retainer and hold everything in place, so a grub screw top and bottom completed this. The action is nice and smooth so just need to make up a new cable and decide where the cable will exit the bars.

    [/IMG]
    Next up the battery holder needed to be welded in place but first we added some threaded plates which will double up to support the bottom of the tank and allow a small adjustment to align the tank if needed and just keep the pressure off the battery as its all a bit tight, just tacked in place for now and will be seam welded when the bike gets stripped down - and this will also be the earth point for the battery.

    [/IMG]
    Then we moved onto a mass welding session to complete all the tank joints, the main driver was the new tank fixing had to be an add on the outer edge so all the seams needed to be completed first on hopefully fuel / oil tight. Holding 3 things at once and lining up the gaps took some patience when it came tim eto start the line up of the new mounts, we started with the rear mount first as this had a bolt fixing to use as a datum point using the trusty marker then tack welding and re assembley to check possition, then the final seam weld.

    [/IMG]
    [/IMG]


    Next up front mount.....
    Last edited by Dexter; 10-31-2015 at 1:57 PM.

  20. #60
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    Ok so now the front - in the previous post front plates had been cut and shaped, the plan was to wrap these round the headstock tube, so we started again with a mock up on the bike now the rear was fixed in position this freeded up some hands once the alignment was right we marked a line for the front tank position relative to the plate. The plate was then folded in a vice to get an angle to allow the tank to move closer to the frame - try the pics these may help my bad explanation, then we used an old exhaust pipe of the right dia to bend the front section of the mount to match the headstock profile. This plate was then again tacked in position then finally after the finished seam weld we drilled and taped the plate and headstock for a fixing bolt.

    [/IMG]
    We even managed to get the star points to align with the headstock center line....

    [/IMG]
    And some shots of the first side in position


    [/IMG]
    [/IMG]
    Off to a local bike swap meet Sunday so who knows what I might find.....
    Last edited by Dexter; 10-31-2015 at 2:05 PM.

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