Tuesday, February 24, 2009

Tail Redesign Part 4

I fabbed up the tail light bracket today and am very pleased with the results.

I first started with a cardboard template to get a feel for layout and look:

I then worked a piece of 1/16 aluminum and came up with this:

This is using my new flare LED brake lights I ordered from England.
And on the bike from a couple of angles:

Alas, everything is not quite right yet. The bracket/endpiece is a perfect fit, I mean so perfect. But the only problem is:
Those stupid welds are in the way of the end-piece fitting flush up against the lower cross piece! I didn't plan the weld location all that great. OOPS. So now I either remove the welds (bad idea), space out the end-piece using rubber or another metal piece, or modify the end-piece so it doesn't fit all the way to the round frame (ugly). I think I'm going to space the bracket out slightly.

I've still got to drill the mounting holes and of course, anodize the aluminum piece. I've set up a homebrew anodizing rig and have been getting excellent results on test pieces so far. More about my anodizing setup on another post.



RazorsEdge2112 said...

Looking great so far! Those lights are quite nice. OOPS on that weld issue. Is there much stress on that cross-piece? Maybe dremeling off that side of the weld wouldn't be so bad?

Excellent work!

Eric said...

Great stuff man. I'm enjoying watching your progress. I have a 1991 Suzuki VX800 and I've been doing the opposite of you in a way. I'm setting everything back to stock, and replacing old parts with new OEM pieces. Much of this is due to a lack of equipment and tools.

Kudos on all the hard work. I'm sure this will be majorly impressive bike once you are finished...hell it is already. :)

Stephen F. said...

RazorsEdge: Thanks! Not much stress on the cross piece. It's really for bolting on bodywork, lights, license plate etc. I ended up grinding down the welds slightly, now I just need to dab some paint to prevent rust on the exposed steel.