Showing posts with label DIY. Show all posts
Showing posts with label DIY. Show all posts

Sunday, 31 May 2020

'73 Suzuki GT250 - Part 13 - MX footpegs and custom brackets

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.

Footpeg assembly

Pair of IMS Pro Series footpegs
for '99-01 Kawasaki KX125/250 (#293112-4)

Pair of pins, 10x49.5 (#92043-1564)
and springs, step (#92144-1951)

Dimension drawing of M8 frame inserts

Inserts were turned in a lathe out of 18 mm steel round bar

Dimension drawing for parts of footpeg brackets

Preview of cut drawing for parts of footpeg brackets

NC-code for water jet cutting

Water jet cutter


Exterior...

...and interior of sand blasting cabinet

Blank after sand blasting

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.

Centering pedestal drilling machine with a countersink drill bit

Drilling with 8 mm...

...and 10 mm drill bits

Finishing with deburring tool

Chamfers done with belt sander


Securing parts together with a welding magnet

Outer corner tacked

Bracket fixed to a vice

Final bead

Footpeg fitted to bracket to help welding of the other side...

...and fixed to a vice

Both corners tacked...

...and welded after removing footpeg


Tools for drilling holes to frame for M8 inserts

Positions of right side holes marked...

...and drilled

Inserts positioned using bracket,
pieces of wooden planks and two clamps

Tacked in place...

...and fully welded

Right side footpeg assembly mocked up

Both footpegs in place

Cleaning areas near weld bead with Dremel

Drilling holes to 9 mm

Deburring

Footpeg brackets...

...and footpegs sand blasted and ready for powder coating later

Tuesday, 25 October 2016

'73 Suzuki GT250 - Part 4 - Removal of broken swingarm bearings/bushings

I might have teased you in my last post that I was going to show how I fitted that aluminum '79-80 Suzuki RM250 swingarm to my '73 GT250K. But before we do so I wanted to write a little post on how to easily remove old swingarm bearings/bushings with simple tools, which you can find from almost every garage. 

Here's a little backstory about the swingarm. A while ago I bought a swingarm from '80s RM/PE250 through a want to buy add, which I had written to one Finnish classic motocross forum. It didn't take long to receive an answer for my it. Seller of this swingarm was from southern Finland which meant that I had to purchase it without seen it first. He send me a few pictures of it but nothing too detailed. Once I received the shipment I noticed that it had broken bearings or some sort of bushings inside the bearing housings. For a while I had to figure out how to get them out of there. In the end the solution was pretty simple.

'79-80 Suzuki RM/PE 250 swingarm

Broken swingarm bearing/bushing.

Bearing housings in this swingarm have 27 mm diameter. This meant that I could use M8 fender washers (24 mm outer diameter) to pull both of the bearings/bushings out. I had to grind few of the washers to make them narrower. This helped to slide them through one of the bearings/bushings and set them behind one of them. After that was accomplished it was easy to pull bearings out with a long M8 bolt and 27 mm socket.

Long M8 bolt, nut and fender washers.
Narrowing few of the washers helps to slide them through 
bearings and inside the bearing housing. Use them to get the 
first bearing out of the way.

27 mm and 13 mm sockets, small ratchet and open/ring spanner.

DIY puller.

Ready to pull.

Bearing almost out.

Job done.

Broken bearings/bushings out of the way.