Topic: attention all you metal fabricator people

[possum2082]

okay...i'm transplanting a 76 550k everything into a 73 500 frame.  the exhaust rear hanger doesn't line up and i need to make some kind of connecting piece to the 500 hanger.

two questions:

1.  what tools do you use to cut and drill into metal?  grinder, jigsaw, drill, drill press?

2.  where does everyone get the pieces of stock metal that they start with?

thank you all per usual. 

[Aaron J Williams]

When I need to cut metal I use a torch or hacksaw or sawzall or plasma cutter. For shaping I use a grinder or for bending a hammer, torch and anvil. Drilling is done with a drill or plasma cutter depending on how precise the hole must be. For a simple bracket extension I would use flat steel with a couple of holes drilled in it to go between the frame mount and the pipe mount. As to where to get the steel I save every usable piece I get when I'm hauling scrap metal for people and I use that. If I need a certain type that I don't have any of then I go to a steel yard and buy what I need from them. I hope that helps you.

[333]

You might try your local hardware store for stock.  Also, in using the above mentioned tools, you must hold the piece down firmly.  I use a vise.

[Glenn Stauffer]

Kind of depends where you live.  I live in farm country - there are tons of small welding and metal fabrication shops around here that I can go to to have things made.  Might be harder to find similar services in the city or suburbs.

[FunJimmy]

I typically only fab up in aluminum and find lots of it at the recycler.
In the event the recycler doesn't have what I'm looking for then I find a metal supermarket listed in the yellow pages.

Tool: Bandsaw, hacksaw, files, drill press, belt sander. Those are the primary tools that I use.

Good Luck

[tomkimberly]

One big word of warning, clamp down or hold in a vise any time you drill holes in sheet metal. If the drill bit catches and spins the sheet metal around, you could remove your fingers!

Tom

[Jinxracing]

2nd piece of advice: if you're using power tools, make sure the speeds are about 90% slower than you'd use cutting wood. The heat generated from high speeds will dull your cutting edges really quickly if you try to go fast. When in doubt, slow down.

[rlarkin70]

I second the local hardware store vote. I had never fabricated anything before, but I have a drill press, a dremel, a vice, a hacksaw, and a metal file.  I have made some brackets, and some side covers from sheet metal. Got the stock L brackets and sheet from the hardware store. Used a vice to bend the metal, dremel to cut and grind, and the file to finish edges. My drill press is only one speed, but I used some cutting oil. Seemed to work fine.

I second the be careful vote. Metal is sharp. I wear leather gloves, and CLAMP things to my drill press, or workbench.

Have fun, experiment.

-Ron

[LMAERO_396]

This is a good source online for metal.

http://www.metalsdepot.com/

[Sam Green Racing]

Please please don't take this as being rude but, are basic metal working skills not taught in American schools.

I reallise that some people are good with their hands and others are good in the brains department but a simple metal bracket

Sam.

[cafe750]

Please please don't take this as being rude but, are basic metal working skills not taught in American schools.

I reallise that some people are good with their hands and others are good in the brains department but a simple metal bracket

Sam.

Only if you sign up for shop, if you're lucky enough to be going to a school that still offers some sort of metal shop class. It's really sad, but there are schools that no longer offer shop classes due to insurance regulations, lack of funding, or lack of interest. I never took metal shop, just because I played in the Auto Shop....

[scondon]

Please please don't take this as being rude but, are basic metal working skills not taught in American schools.

I reallise that some people are good with their hands and others are good in the brains department but a simple metal bracket

Sam.

  Oh, so it's an American thing, eh Sam? I guess you Brits skipped English class in order to hang out in metal shop. It's called spellcheck, Sam, a handy modern tool for you Limeys with sagging grammar

and no. they didn't teach shop at my school

[troppo]

G`day possum (my god that sounds like dame edna lol)
it sounds like your metal skills and rather limited, so i would get everything in place then grab some paper or cardboard and make a template of what you need, then look at it long and hard and see how hard you think it will be to make, cutting the piece and drilling holes are simple enough, like the others said go slow and mount the piece in a vice (metal has some bloody sharp edges) then clean the piece up with a file to remove any swarf (metal shards) and take off the sharp edges. welding the piece to the frame is another matter entirely, given that its an exhaust bracket on a bike it will be prone to vibration, so my advice is to get a mate that can weld decently and offer him a 6 pack to do the job, if you dont know anyone that can weld, make sure the the section of frame is clean bare metal and take it to a shop to do for you.... make sure the exhaust is in place, that way they will be able to weld it in the exact right place
hopw this was of some help
cheers
troppo

[hymodyne]

Material: Local hardware store, Home Depot, etc.,

Tools: Good drill bits, grinder, hand file, sturdy vise.

I agree that if you are not experienced in metalwork that you should use cardboard or some other throw away media to make a model or template that can be fitted to your bike so you don't learn how to make your part at the expense of three or four attempts with metal$$. 

I also use bailing wire quite a bit on my bike, to hold parts in place so I can see how things look together. I'm putting an M4 canister on my 500K1, and I hung the muffler in place with bailing wire, adjusting the length of the wire on each end until I got the look that gave me the bike/ground clearance and angle I wanted...

hym

[possum2082]

sam, sam, sam...i don't think you're rude.  you're just still pissed off about the whole revolutionary war thing, right? 

  kidding, kidding.

no, unfortunately, shop is not a part of all schools.  i'm actually a chemistry teacher and i didn't start getting interested in working with my hands until college. 

thank you all so much for the input. 
on the shopping list:

set of metal files
vice
grinder

(more later once cleared with the mrs. possum)

[333]

You've done it now.  Where's my soapbox?

When I was a kid(late 60s), I had shop from the 7th grade.  In 8th grade, we had metal shop, where we learned welding and forging(aluminium, not handwriting).  When my kids then went to the very same schools, the only shop was in 7th grade.  And the kids weren't allowed to use the power tools.  The teacher showed the kids how to do the work by doing all the work.  The room that was the shop in the high school had all the tools covered with tarps and pushed to one side of the room and art is taught there.

Makes me sick!

[754]

My 2 cents..

I think you should check out a few books on basic metalwork from a library or online if you can.. get a bit of background before you start.

Metal work is slow and can be dangerous!! Never mind your fingers drilling sheet, you should worry just as much about slicing an arm open or riping your guts open!! Take your time and form a plan first.. carefull layout & planning yields better results.

I know there is a tendency these days to rip your bike apart as far as you can, then ask what to do or why it doesnt work on a forum..without looking at a manual!! Happens every single day on here.

 However..unlike just screwing up parts on your bike due to lack of knowledge, (suspension & brakes.. a whole other story).. you generally dont get hurt.. with metal working, you easily can.. moreso if you dont learn the basics before you start..

And dont try it when you are gOOned.. its a hobby best tried straight.. the beer is for the benchracing, not the metalwork part... have fun!!

[Steve F]

You've done it now.  Where's my soapbox?

When I was a kid(late 60s), I had shop from the 7th grade.  In 8th grade, we had metal shop, where we learned welding and forging(aluminium, not handwriting).  When my kids then went to the very same schools, the only shop was in 7th grade.  And the kids weren't allowed to use the power tools.  The teacher showed the kids how to do the work by doing all the work.  The room that was the shop in the high school had all the tools covered with tarps and pushed to one side of the room and art is taught there.

Makes me sick!

That's kinda what I went through, but we didn't have any metal shop until high school, sophomore year.  Then we were able to use the power tools.  After I graduated, the wood and metal shops were "dissolved" like 5 years later.  But I gotta say that the school district at least offered classes at a near-by trade school instead of just abandoning the "trades" altogether.  The space that used to house the shop classes were transformed into a "resources center" with the computers and a TV studio

[possum2082]

i struggle with the american education system.  most of the schools i've taught at have the mentality that all kids can be all things, i.e. any kid could be a brain surgeon.  now i think everyone should be given the chance, but we cannot forget to be realists.  i, for one, know that i cannot be a brain surgeon.  teaching kids that have no college ambition or prospect a trade is smart and responsible. 

in argentina, once kids hit 7th (or is it 8th), students either go to a trade studies program or college prep (and yes they can change their minds).  excue me while i go try to fix the edcuation system in america.  give me a few minutes. 

'climbs off of soapbox'

[Sam Green Racing]

 


























































 

Sam

[possum2082]

you're killing me, man 

[Sam Green Racing]

You're just pissed off because you've got GW Bush and we have a Queen

I'll strike a deal with you to save you buying those new tools you need.
Send me a drawing of the bracket you need and I'll make it for you.
When I need some exotic fuel to run my race bike on.....you'll be the man to mix it

Sam.

[jevfro]

It is really sad that here in the US basic shop skills are not very common anymore.  Lawyers (and the ppl who hire them) are mostly to blame.  Even at the University level now we have shut down our foundry because the level of danger involved is more than can be tolerated by our "health and safety" specialists.  It really pisses me off.  Soon we will have to trade in our scissors for ones w/ plastic blades because someone cut's themselves.  To much liability....   Can't we all just sign a waiver or something?

[Sam Green Racing]

Please please don't take this as being rude but, are basic metal working skills not taught in American schools.

I reallise that some people are good with their hands and others are good in the brains department but a simple metal bracket

Sam.

  Oh, so it's an American thing, eh Sam? I guess you Brits skipped English class in order to hang out in metal shop. It's called spellcheck, Sam, a handy modern tool for you Limeys with sagging grammar

and no. they didn't teach shop at my school

Hey Condom, be carefull slagging me off,  remember, I know where you live. It will be no problem getting some of my American friends to pay you a visit on Saturday and.......................




































cheer you on at the dyno good luck mate.

Sam.

[babyfood1217]

jevfro-

I can relate with you and all to well.  I'm at the university level, and I'm getting pretty tired of the legalities that go along with education... I could rant forever, but I won't. 

Most important tool:  your carefully thought outidea, next is safety glasses!!!!!!!

As for the bracket, I'm glad people are encouring the mock-up stage with cardboard and wire first...it pays off.  As for tools, there have been some good suggestions, but if you really want to learn and aren't in a terrible hurry, I'm going to suggest this: use hand tools and understand them before you jump right into power tools.  You'll learn so much more about how the metal moves and what the tool can do, and when power become a necessary item, you'll be that much ahead.  There are a lot of people that can go out and guy a grinder, a cut off wheel and a grinding disc, and they haven't the slightest idea what they are doing.  Hand tools respond much better than power tools do, and you never have to worry about clipping bits of your fingers off (don't ask how I know.)  Power tools can be invaluable, IF YOU UNDERSTAND THEM!  Plan thoroughly, measure twice, plan a bit more, and then cut.  Safety glasses are a must (I wasn't kidding before.)  Post your mockup pictures here, I'm sure we will critique the process as you work on it.  And even though we are here to help you, there will be an obviously large amount of time and work done where it is just you, your bike and your tools, so please, no matter what, BE CAREFUL***.






***This is think should be encouraged to/by everyone.  Saftey when working on your bike (or your kitchen cabinets) should always be first, because as often as we may dread one anothers comments on these posts, I think we would all hate to see any one of us get hurt.



-Chris