Topic: 500/550 rearset cast

[wolf550]

a long time post showed some triangle rearsets that I had made for my 500 frame that worked really well I decided to take sean barney up on some he had stored away.

[wolf550]

these were the Cognito heavy steel. I went ahead and started building them up about a mm on both sides and the edge.

[wolf550]

the material used was a material that was from broken carbs and that 350 top triple that was aluminum and (magnesium maybe). not sure but when I previously used the material it was super hard to try and drill or sand down unlike just aluminum. this was a cover made with it and it has yet to be finished after sanding.

[wolf550]

it reminds me when I sand jade it just takes so long.

[wolf550]

after casting you can see the same browning as on the cover

[wolf550]

it took all day to drill and grind the holes and excess aluminum from the exterior but I made it.

[wolf550]

Ill probably buy some better drill bits that are the exact size as the foot peg and engine rod that these attach to because dilling using a smaller bit and them using a tungsten carbide grinding bit to open more took too long. I had alot of wandering even though I was going slow with it.

[wolf550]

next comes the stanind and jump test so we shall see.

[seanbarney41]

Hi Wolf, do you have pegs and levers that you intend to use with these?

[Kevin]

It's really cool that you are capable of doing this


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[wolf550]

Hi Wolf, do you have pegs and levers that you intend to use with these?

hey sean I do not and I did not think of that when I drilled out the hole for the lever. I assume now that it is for there levers.
I will have to see what it out there.

for my other rearsets I used steel dragon customs levers that were on another 550 I bought back in cali

[wolf550]

It's really cool that you are capable of doing this


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thanks kevin it is so cool that the irs wants more of a piece than they are already getting so I am going to have to get my own business going to start getting some back

[wolf550]

I was able to turn up that rearset bracket I used on the frankenstein bike.
you can see how much more bracket there is compared to these.
also they were only 1/4 inch thick
you could jump all day on these with no worries

[wolf550]

had some time while the storm blew in to work on the second rearsets. I found an old set of pegs I used on the frankenstein bike before switching to the steeldragon set.

[wolf550]

the bolts measured 7.91mm. if memory serves me correct I was able to stand on these with the triangle rearset brackets. another thing with the test I am unsure about is the right side bracket being able to support weight using the tab that the bolt goes in to adjust the rear brake lever. is it enough for a persons weight you think.

[wolf550]

I think it would be a good idea to make two C brackets for each side so they are both on frame bolts like in the cognito pic. being that I have already drilled the first brackets with a bigger hole I am going to throw these back into the crucible for another go around on them and also make two more C bracket for you sean.

now all this is well but I still have to see how it goes with the stand and jump test. we shall see.

[wolf550]

gotta figure out why it keeps switching to black and white

[grcamna2]

I like the look of the strength you've built into those parts wolf;I think when you mixed-in those different parts helps.

[wolf550]

I like the look of the strength you've built into those parts wolf;I think when you mixed-in those different parts helps.

thanks grcamna2 if I knew the correct mixture for some of these hybrid metal forms I would give them a try. right now Im working on some nordic gold that consist of 80% copper, 10% aluminum, 5% tin and 5% zinc

[wolf550]

I don’t think strength would be much of an issue since these brackets don’t really get the same abuse as a kickstart lever would. As long as they support standing weight you should be fine.  A decent-sized washed on the backside to displace the stress would be helpful.

As for drilling the holes, buy a reamer. You can get them in exact decimal sizes. When using it to size a hole, never reverse the bit to extract it; always leave it running in the cut direction and retract the bit. Otherwise you will dull it immediately. A small chamfering bit front and rear to center the reamer will make a very professional result.

thanks calj737 it is good to know these things when working on new stuff. it is a shame that frank is no longer around as he would give me these tips and tricks since I never did any of the middle school or high school shop classes. luckily there are plenty of forum members who have the knowledge and know how to aid in these fun adventures.

[seanbarney41]

I wonder why Cognito ever made that non-C brake side bracket?  Is it needed to work with just the K or F?  And all the hole sizes were designed to use Tarrozi universal pegs and levers, so if Tarrozi pegs and levers are not used, hole size may need to be adjusted accordingly.

[wolf550]

had time to finally recast some C brackets came out good.
depending on how these hold up, I like the look of the raask where they become thicker towards the levers
I might do some extra building up on thickness to see how it goes

[wolf550]

went ahead and melted the first set and recast two C brackets. I went to try them out but encountered a setback. the swingarm bolt is too short. so I figure I will set it up on the right side and give it the full weight. if it doesnt hold them onto plan B.

[wolf550]

a nice cool day by the water here. since the bolt openings were both on the right side I started there and hit a bump so with the C clamp it does not want to go on. it hits the tab the rear brake lever bolt stop goes into. this had me puzzled because I saw on the cognito site the bracket was on there. I kept looking at it a little bit more and from the looks of it it does not have the tab or the the rear brake lever shaft they are both cut off. then i realized the rear peg was not there either and then I just pulled back and said to myself well that is a chopped up modified frame.

I went back to original plan with the half C clamp bone bracket and put it on there when I did It just looked off now, not because the cut out where the tab is but the hole towards the rear. the bracket sits higher than the C bracket does making the position of the leg higher. I could not find any pic of these out there on a bike to see if this was right so I looked at it some more. I decided to scrounged around the garage and found a bolt that I purchsed when I had to have a license plate on the front in california and put it in the shaft hole and then put the bracket back on.  I finally decided to flip it and yes that is it, the bracket does not sit on the tab but under it and the hole is for some other part that bolts into the hole of the bracket. it just lines up. the next part would be adding washers or a thick washer to the peg shaft so all would line up or you would just grind off that little nub the oem foot peg rests up against or remove the area of the bracket to accomodate the nub. the other thing bugging me was it is hitting the exhaust. I dont think these work with it. maybe a 4 in 1  or 4 in 2 i have.

well after all that and the swingarm shaft removed I looked at the left side. I put the C bracket on the foot peg shaft and lined up the top hole of the bracket with swingarm hole and it hits the exhaust too. its right on there. I know its hot going to move but it is on the top exhaust. next thing is just like the other side is that nub. I would need to add a washer to line it up.

so what I am getting from these brackets is just more stuff to think about.
I think these brackets would be good if you are modifying your bike to your likings like i did on my frankenstein bike but for the oem side not so much.
I guess that is why cognito decide to upgrade to the fancy triangle ones.

this was a good treat to my brain to work on but I might just have to revamp the bracket I made for the frankenstein bike.

[wolf550]

with the triangle bracket cognito defintely fixed all the problems these C brackets give