I had a pair of IMS Pro Series footpegs meant for Kawasaki '99-01 KX125 250 (#293112-4) laying around which I had purchased for a previous project of mine but never ended up using them. After getting rid of that bike I stored them for later use. At one point I had them for sale too but after time went by and I still had them I decided to utilize them in this build.
I designed a pair of brackets to be able to fit them to frame of my GT250K with help of four weldable inserts and M8 bolts. Inserts were turned in lathe out of 18 mm round steel bar and parts of brackets cut out of 6 mm steel sheet using water jet cutter and welded together.
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| Footpeg assembly |
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Pair of IMS Pro Series footpegs
for '99-01 Kawasaki KX125/250 (#293112-4) |
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Pair of pins, 10x49.5 (#92043-1564)
and springs, step (#92144-1951) |
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| Dimension drawing of M8 frame inserts |
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| Inserts were turned in a lathe out of 18 mm steel round bar |
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| Dimension drawing for parts of footpeg brackets |
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| Preview of cut drawing for parts of footpeg brackets |
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| NC-code for water jet cutting |
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| Water jet cutter |
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| Exterior... |
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| ...and interior of sand blasting cabinet |
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| Blank after sand blasting |
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| Pieces separated with a hand saw |
Since water jet cutter tends to leave chamfers to holes I decided to make them bit smaller and drill them to right size after cutting. I did that in two stages. First time to 8 mm and after mocking up and welding M8 inserts to frame to 9 mm. 8 mm holes allowed me to center inserts perfectly to brackets. They would have been too tight for M8 bolts after painting so I decided to drill them afterwards to 1 mm oversize. I will powder coat both footpegs and brackets later once I have all the other parts such as side stand etc. ready for that as well.
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| Centering pedestal drilling machine with a countersink drill bit |
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| Drilling with 8 mm... |
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| ...and 10 mm drill bits |
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| Finishing with deburring tool |
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| Chamfers done with belt sander |
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| Securing parts together with a welding magnet |
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| Outer corner tacked |
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| Bracket fixed to a vice |
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| Final bead |
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| Footpeg fitted to bracket to help welding of the other side... |
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| ...and fixed to a vice |
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| Both corners tacked... |
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| ...and welded after removing footpeg |
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| Tools for drilling holes to frame for M8 inserts |
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| Positions of right side holes marked... |
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| ...and drilled |
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Inserts positioned using bracket,
pieces of wooden planks and two clamps |
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| Tacked in place... |
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| ...and fully welded |
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| Right side footpeg assembly mocked up |
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| Both footpegs in place |
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| Cleaning areas near weld bead with Dremel |
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| Drilling holes to 9 mm |
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| Deburring |
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| Footpeg brackets... |
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| ...and footpegs sand blasted and ready for powder coating later |
