Race chassis

[richban]

You don't need a fully machined one piece headstock. A piece of largish OD MS tube say 2mm wall with the ends squared will do. Then you make up bearing carrier inserts in either steel or alloy and press them in once the welding's done...
I've "pressed" them in with a m'f big G clamp no probs.
Ducati and others did it like this for ages with no problems

That was the plan. Still is. The bit I had was 60.3 x 3.9mm. The plan was tidy up the inside 30mm in the tin the outer to make 2mm wall. Good to know thats how its ben done before.

I have one off these profile gauges on the way.

[Grumph]

Never used or needed one of them. A good eye and steady hand with a disc grinder will do most of it - and a good selection of round and half round files too.

If you're using 1.2mm wall tube, make yourself a split wood block to hold the tube in the vice.
Piece of softwood - pine is good - bored 25mm to suit your tube, then cut down the length of the hole.
Use on each side of the tube when clamping it up to cut or grind.
Made out of a short piece of 50 X 50 dressed pine would work.

[richban]

Never used or needed one of them. A good eye and steady hand with a disc grinder will do most of it - and a good selection of round and half round files too.

If you're using 1.2mm wall tube, make yourself a split wood block to hold the tube in the vice.
Piece of softwood - pine is good - bored 25mm to suit your tube, then cut down the length of the hole.
Use on each side of the tube when clamping it up to cut or grind.
Made out of a short piece of 50 X 50 dressed pine would work.

Top tip. Will do.

[Michael Moore]

for thin wall tube snips are fast for roughing cuts.

http://tonyfoale.com/progs/tubemiter.exe

should help you make patterns for the tubes. After some practice you'll get better at eyeballing them.

[guyhockley]

https://www.youtube.com/watch?app=de...&v=cdhuYjbZJt4

[husaberg]

https://www.youtube.com/watch?app=de...&v=cdhuYjbZJt4

Seems to have a PDS shock and you would expect a Progessive spring.
http://racetech.com/articles/ktm.htm

[husaberg]

Never used or needed one of them. A good eye and steady hand with a disc grinder will do most of it - and a good selection of round and half round files too.

If you're using 1.2mm wall tube, make yourself a split wood block to hold the tube in the vice.
Piece of softwood - pine is good - bored 25mm to suit your tube, then cut down the length of the hole.
Use on each side of the tube when clamping it up to cut or grind.
Made out of a short piece of 50 X 50 dressed pine would work.

Not sure if this was posted on he thread or not i watched it the other day.

[jasonu]

Hi Guys.


I did a little research around welding mild steel to Chromoly. Seams its ok as long as you heat the work before welding.

Steel to crmo no problem, just do it. Use ER70S filler wire. Don't over think it, just do it.

[jasonu]

Not sure if this was posted on he thread or not i watched it the other day.

I made a shit ton of these crmo aircraft motor mounts. We had ali tube cut patters we slide over the raw stock, draw around the edge, rough cut it with a vertical bandsaw then finish fit it using a 6" bench grinder on a solid floor mount with a grinding wheel dressed to a 1/2 round profile. Easy pesy. The way the guy in Husas vid is marking out his cuts is the way I did it if there was a new cut to make before I made a pattern.

BTW the big round donuts and the machined blocks are both mild steel and welded together fine, never had to or even thought of preheating them.

[Ocean1]

I made a shit ton of these crmo aircraft motor mounts. We had ali tube cut patters we slide over the raw stock, draw around the edge, rough cut it with a vertical bandsaw then finish fit it using a 6" bench grinder on a solid floor mount with a grinding wheel dressed to a 1/2 round profile. Easy pesy. The way the guy in Husas vid is marking out his cuts is the way I did it if there was a new cut to make before I made a pattern.

BTW the big round donuts and the machined blocks are both mild steel and welded together fine, never had to or even thought of preheating them.

Never learned the box and pour method eh?

[husaberg]

I made a shit ton of these crmo aircraft motor mounts. We had ali tube cut patters we slide over the raw stock, draw around the edge, rough cut it with a vertical bandsaw then finish fit it using a 6" bench grinder on a solid floor mount with a grinding wheel dressed to a 1/2 round profile. Easy pesy. The way the guy in Husas vid is marking out his cuts is the way I did it if there was a new cut to make before I made a pattern.

BTW the big round donuts and the machined blocks are both mild steel and welded together fine, never had to or even thought of preheating them.

there was one with the jig pattern as well on the same feed


this was cool as well

[mr bucketracer]

Not sure if this was posted on he thread or not i watched it the other day.

this is pain full lol , get the right size milling cutter for tube , close chuck of lathe with milling cutter in it (-; , clamp tube in tool holder , set on center....set to what angle you need , i will let you guys work out the rest lol

[jasonu]

this is pain full lol , get the right size milling cutter for tube , close chuck of lath with milling cutter in it (-; , clamp tube in tool holder , set on center....set to what angle you need , i will let you guys work out the rest lol

Assuming one has a lath....




or a lathe

[Grumph]

Assuming one has a lath....




or a lathe

One has a lathe - but one does not have the dosh for a range of milling cutters...

I do do swingarm to crosstube profiling in a jig with a holesaw though. It's the only time I do - and that's simply to accurately get the legs the same length...

[Michael Moore]

Guy, thanks for the video link. I wonder if he looked at Hoyt McKagen's bikes/patent before he built his KTM?

http://www.eurospares.com/mckagen/hoyt001a5.jpg

http://www.eurospares.com/graphics/c...US4627632A.pdf

It is nice to see someone do something different and actually get it to the track.