Monday, December 22, 2008

Redesign of the tail section - post 2

Here's a photo log of the recent work I did on the tail end. I've got to get this frame powder-coated so I can move to the next step, putting it together. Oh, and this is the first time you get to see pictures of me.

I made a mistake and cut off too much of my tail. I also made the mistake of throwing away the tail section I cut off! Oops. I finally came up with an equal sized steel tubing to extend my tail.

I'm adding back 3 inches to the rear end. It will look better and hold all the gear that attaches to the back a lot easier.

I started with 3" sections of steel tubing, and cut out round pieces to cap the back end:
I welded them to the ends, then ground out my welds for a smooth finish:
The new tail piece with round end welded on:
Zoom of piece (OK it's boring I know):

Now I'm fitting up the piece, making sure it's aligned straight:
Now weld up the the piece:
On to the second one:
Weld it up, grind it out, and dang I'm tired:
Now, let's weld on my new brackets:
And, finally, the finished product:
And from straight on (you can see my fab techniques have massively improved):

My original brackets were all cut and bent by hand using crude tools. I'm now a member of a great place called TechShop in Menlo Park, CA. It's a DIY machine shop with much much more and has allowed me to use equipment I would otherwise never have been able to. I'm doing all my welding at home thanks to my good friend Jim Waltz. Jim has let me borrow all the welding equipment and gear that you see in the photos. Thanks Jim! Thanks also to Jessica for taking all the photos, and putting up with my testy behavior!

I've since gone over and sanded out the frame, again, removing all the marks from the over-abrasive sanding discs I was previously using. I need to just double check everything before I send it to get coated. Next week it will go in.

1 comment:

timbo1 said...

absolutely brilliant work, cant wait ot find out what you do with the motor. Mines just done a main bearing.