'73 Suzuki GT250 - Part 15 - Sidestand

Once I got my GT250 on its wheels it was time to fabricate a sidestand for it which allowed me to not keep it on a mechanic stand all the time. I wanted to use bar and spring from a sidestand I had kept from one of previous my bikes and utilize stock mount on the GT250 frame. This way I only needed to fabricate a bracket in between them. 

Assembly of sidestand bracket

Dimensions for plate

Dimensions for blank

Piece of flat bar bent with a press brake

Bolt holes drilled and edge trimmed

Holes for pin and bar drilled and profile of edge cut

Dimensions for pin

I didn't have 10 mm round bar so I utilized a piece
from a long enough M10 bolt to make the pin

Pin welded to the plate

Dimensions for support plate

Support plate tacked to the plate

First mock up

Bar was bit too long so it had to be shortened

I also reinforced stock sidestand mount on the frame which I had previously hacked after cutting unnecessary parts from the frame such as stock footpeg mounts.

Starting point

Unnecessary pieces cut off

Piece of square tube...

...tacked..

...and welded to stock sidestand mount

Bottom side ground flat and edge profiled

'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