Topic: How Do I Cut Handle Bar Clamps Off Triple Tree?

[no718.com]

I'm trying to achieve the pic below. It's the top triple tree from a 750 with the clamps cut off and smoothed. It would make my front end look cleaner now that I've added clipons.

I've never worked with metal b4 so I don't know what saw or tools to approach this with. Do I use a grinder to smooth it out afterwards? Could use the advice. I'm new to getting my hands dirty so please be as specific and detailed as possible. Much appreciated . . .

[Bodi]

A hacksaw will get them off, you want a vise to hold the part while sawing. Leave some excess material on the triple tree side. Then you file off the excess and try to match the curve of the main piece. Get a decent size (at least 10 inch) medium bastard half-round file plus a similar size smooth file, the bastard removes metal quickly but leaves scars while the smooth can leave a very nice finish in skilled hands. Next use wet/dry paper (you use it wet, under running water is best) to smooth it to whatever finish you want. Start with about 250 grit and then 400, 600 should be used for a really nice paintable finish. If you want bare mirror finish alloy then it takes a lot more effort!
You may find voids in the metal after cutting off bits. You can fill these with JB-Weld or equivalent for painting.

[no718.com]

Bodi,

Thank you very much. I'll go at her soon. I'll post pics of finished product . . .

[750K8 Kev]

Bodi,

Thank you very much. I'll go at her soon. I'll post pics of finished product . . .

I look foward to the pics, I plan on trying the same thing after I finish up my wiring.

[eosmontana]

i did mine with a cutting wheel and flap disks to smooth it the rest of the way out... then progressive grits of sand paper.... then a buffing wheel to shine it up.

[THE DUDE]

that looks great!!   

[Slams77]

+1 on the Flap Disks.  I cut the clamps off with a coping saw then used a 40 grit flap disk to blend the triple tree.  When it was as even as I could get it I went over it with various grits of wet/dry sand paper.

[no718.com]

Wow those both look great!

[750K8 Kev]

Wow guys they look awesome!

[Kong]

Those are really nice, both jobs.  I was wondering on the holes that remain after the towers have been cut off. I notice on Slam's tree the four holes are evenly square and look very nice and I notice on EOSMontan's that the holes were opened up into one large hole on each side.  Can each of you tell me how much of your effort had to go into making the holes symmetrical or did they rough grind out to fairly close to their finished shape?  It just looks to me like casting irregularities might make it very difficult to get those holes looking good.  Also, it seems to me I saw one build in which the indicator lights were later mounted in those holes, which really looked good.

[Toxic]

+1 on the Flap Disks.  I cut the clamps off with a coping saw then used a 40 grit flap disk to blend the triple tree.  When it was as even as I could get it I went over it with various grits of wet/dry sand paper.

WOW!!!  need more details on your bike. If you went to that much detail on your triple tree, I have to see the rest of it.

How did you get the contour around the speedo?

[JS550]

I just brought in a top clamp to do this today. I wanna switch to clip ons. Those look great.

[q2418130103p]

Angle grinder (with cut-off disk) to cut off the big chunk, then 40 grit grinder to smooth it out.  If you are going to paint it then you need to sand it out with some progresively finer paper, the paint you use would probabl determine the final grit you need to use.  If you decide to polish then you need to sand with progressivley finer paper until around 600 grit or so, then you can start using polishing compounds.  I have a good article about it if you are interested.

[Slams77]

Those are really nice, both jobs.  I was wondering on the holes that remain after the towers have been cut off. I notice on Slam's tree the four holes are evenly square and look very nice and I notice on EOSMontan's that the holes were opened up into one large hole on each side.  Can each of you tell me how much of your effort had to go into making the holes symmetrical or did they rough grind out to fairly close to their finished shape?  It just looks to me like casting irregularities might make it very difficult to get those holes looking good.  Also, it seems to me I saw one build in which the indicator lights were later mounted in those holes, which really looked good.

It took some patience to make everything as even as possible but being that the aluminum is soft, I was able to use a file and rasp set (flat to make the square and round for the edges) and a needle file set (to smooth it out after I achieved the shape) I picked up at harbor freight.  I then went over the inside with wet dry sand paper until the edges were smooth.

[Slams77]

+1 on the Flap Disks.  I cut the clamps off with a coping saw then used a 40 grit flap disk to blend the triple tree.  When it was as even as I could get it I went over it with various grits of wet/dry sand paper.

WOW!!!  need more details on your bike. If you went to that much detail on your triple tree, I have to see the rest of it.

How did you get the contour around the speedo?

Thanks, it has been very slow work in progress and is partially disassembled at this time.  As it sits though, I have bobbed the front fender, fabricated a speedo and indicator light bracket, headlight ears (courtesy of “Do The Ton”) and fabricated an LED indicator light gauge cluster.  I am also running clip-ons a Manx style seat, and will eventually swap out the brakes and suspension.  The contour around the speedo was made by using a sanding drum kit (also from harbor freight) I hooked up to my drill press.  I attached a ¾” piece of wood with a hole drilled out a little bigger than the sanding drum so that I could adjust the depth and to be able to slide the triple tree along it without fear of scratching it up.  I sanded a little at a time until the speedo rested flush against the triple tree, then smoothed it with wet dry sand paper. 

[KingCustomCycles.com]

I can only add that a wood jaw vise will protect the soft aluminum casting.  NICE WORK!