Turpakäräjät @ Ullan Pakari - 29th of May 2024 - Riihimäki, Finland

 Couple photos more from May and Turpakäräjät. Take a look 😎

Ford Roadster

Lahti Hela Ride-In Bike Show X - 25th of May 2024 - Lahti, Finland

 Photos from 10th Lahti Hela Ride-In Bike Show held at the end of May in Lahti. Take a look 😎

Harley-Davidson M8

Turpakäräjät @ Ullan Pakari - 10th of August 2022 - Riihimäki, Finland

 Couple more photos from sunny August. Take a look 😎

'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

'91 Honda CBR600F PC25 - Part 4 - Custom brackets for round headlight

I've had a 8 inch round headlight lying around which I bought originally for my '87 Yamaha RD350LC F2 project but never got time to install it before selling the bike. I had headlight also for sale for a while after that but no one was interested to buy it so it just stayed untouched in my shelf waiting for another suitable project.

8 inch round headlight

Regarding this build I haven't decided any specific style go with but I wanted test how a round headlight would look in front of my CBR600F. It was also good time to do that while I have front fairings removed. I've made earlier similar type of brackets for '72 Suzuki T250J and used them as a reference for these ones too. I made subtle changes and updated dimensions to suite better '99 Honda CBR900RR SC33 front forks I swapped last time. I still need to design and fabricate a stopper for the headlight to keep it from tilting while driving. I'm not 100 percent sure how to make it yet so it will have to wait for the future. There's also things like what kind of gauges I will use to think about.

Assembly drawing

Layout drawing with main dimensions

After making part drawings for collars and plates it didn't take much effort to start fabricating them out of sheets of stainless steel. It's not the easiest material to work with since it tends to wear out drill bits and warp easily with heat. I didn't end up using many power tools other than electric drill and Dremel this occasion so it took a bit longer to finish them. Quickest way of course would have been to get them cut with laser or water jet cutter.

Part drawing for collars

I cut out blanks for collars with a plate shear
and then marked holes and rounds to corners

I started by drilling holes...

... and then rounded all corners with a file and sanding block

I used an affordable sheet metal bending machine
to bend edges of collars and rest by hand against forks

I finished outer surfaces of collars with a scotch brite wheel

Part drawing for plates

Sketched outlines of plates with pencil
and used washers as templates for round corners...

I started by drilling holes,..

...then cut both plates out with a hand saw
and finished edges with file and sander

I used a vise brake for bending...

...and checked angle of bends with digital angle finder

Last step was to clean plates with scotch brite wheel

Parts for headlight brackets

Headlight installed