Motorcycle – Cafe Racer, Polished Aluminium Dash Assembly

Lovely little job here, drawings were supplied by customer which we duly transferred to a 2d cad program ready for loading onto the laser machine in order to cut the main parts from 10mm thick aluminium.

Laser cut parts

Laser cut parts

Once parts had been laser cut, I had a very good friend drop them on his cnc mill, and counter bore the back of the cut holes, smaller ones were for various warning lights and needed to be recessed to allow for the fixing nut, the large clock apertures counter bored to allow the rolled aluminium clock tubes to sit neatly into them.

Trial assembly

Trial assembly

The clock bodies / drums were fabricated from 1.5mm thick ns4 aluminium sheet, cut, rolled and tig welded together, re-rolled and checked for size against the recess diameter in the back face and also the bottom discs.

Clock bodies rolled, welded and checked fro size

Clock bodies rolled, welded and checked for size, polishing begins

Once all parts were manufactured a mammoth polishing effort commenced

Showing underside of assembly

Showing underside of assembly

Several grades of soap and mops were used in the polishing process, even wet and dry grades were used on the face to try and remove as many marks as possible. Its always handy to have a good polishing motor as the mops can really drag the spindle speed down. Ideally you want to be polishing at about 2800 rpm, with good quality mops and soaps to get a good finish. Its important to start with a rough sisal fast cutting and hard polishing mop, they are particularly useful for first stage polishing on all metals including aluminium, brass, copper and steels. These will remove light marks left from preparation and are usually used with Brown metal polishing compound on soft metals or Black metal polishing compound on steels.

After a couple hours polishing

After a couple hours polishing

Stitched polishing mops are versatile cutting and polishing mops for general polishing but are less aggressive than sisal polishing mops. Stitched polishing mops are ideal for use on aluminium, copper, brass and steel and can be used with -Brown, Blue, Black, Green or white polishing soaps.

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Ready for soft loose leaf final polishing mop. The most popular type of finishing mop, loose fold polishing mops can be used with Blue, White, Pink and Jewellers Rouge polishing compounds. Loose fold polishing mops are manufactured from 100% white soft cotton, with no hard pieces.

Finally polished and ready to pack up and despatch to customer

Finally polished and ready to pack up and despatch to customer

After polishing with mops and soaps I always use a good metal polish to bring up a bit better and add a lustre to the parts.

Hopefully soon have a picture once fitted to the bike.

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For all your Custom Car & Motorcycle Parts Manufacture and Welding / Repairs
SEE –
www.flashcustoms.co.uk
Don`t forget to email or call us for all your custom made 1 off bespoke items.

Alloy welding / repairs, custom parts, Welding Instruction.

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Dax Cobra Polished Stainless Brake and Clutch Reservoir Tank

Mirror finished stainless steel fluid tank manufactured from customers drawing in 1.5mm thick material. Initially we was sent a drawing to price the job, following on from agreeing a price, we was supplied with a plastic fluid level screw cap which we had to machine a stainless threaded neck to match. Brake Header Tank Once the thread was established a nicely machined stainless threaded neck was spun up on the lathe. This needed a little fettling to ensure that there was no “rags” (sharp edges) which would cut into the plastic sensor cap. laser parts Next job was to draw up on 2d cad the individual panels required to make up this small tank and send the dxf (drawing exchange files) to our laser cutter for nesting and cutting. You notice that the panels are cut with plastic film on them, this helps keep a nice clean panel finish and reduces the risk of damage to the outer face of the material during processing. tacked up tank Above you can see the panels all tacked up ready for welding, this end panel was slotted and then drilled and tapped in 4 places to accept an m4 counter sunk socket head to hold down a clear plastic end panel with a cnc machined o ring groove to seal. PartsThe image above shows the tank tig welded and ready for the fittings to be tacked in position. Polished prior to adding fittingsSorry dodgy picture above that shows the main tank ready for polishing after welding and prior to adding fittings.

 
Cap threaded neck positioned

Cap threaded neck positioned

Considering a bit more polishing before welding neck in position

Considering a bit more polishing before welding neck in position

Take off stubs for clutch and brakes welded in

Take off stubs for clutch and brakes welded in

I machined the stubs up for this tank, welded them on and sent the customer a picture as I thought they looked too long, customers opinion was the same and so out they come. Cut them down and re-welded them in position and they looked so much better.

Cut down take off stubs ready for a fiddly polish again with the die grinder and felt mops

Cut down take off stubs ready for a fiddly polish again with the die grinder and felt mops

Stubs now look far more in proportion to size of tank. You can also see I have changed the end plate and added stubs for a level view tube as a better option to slotted end panel and perspex viewing window.

Sometimes until you actually make things you cant always see what looks good / bad / oversized etc, some things are down to skill, knowledge and experience others simply down to aesthetics and proportions.

Once fully welded, blended, polished, tested and checked this little “shiny” bit as on its way to a new home on a Dax Cobra replica – quality kit usually.

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For all your Custom Car & Motorcycle Parts Manufacture and Welding / Repairs
SEE –
www.flashcustoms.co.uk
Don`t forget to email or call us for all your custom made 1 off bespoke items.

Alloy welding / repairs, custom parts, Welding Instruction.

Thanks for reading our blog – we hope this has been of use to you.
Recommended sites
FLASH CUSTOMS – Specialist Custom Car & Motorcycle Parts
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Honda CBR1000F Sump Chop

Modifying a motorcycle sump for use in a Kit Car

Original CBR1000  alloy sump

Original CBR1000 alloy sump

As you can see above the original sump has already had some repairs to it. This leads me to believe that it has had some crash damage. Potentially an issue which will mean I need to do a crack detection test before modifying this sump to check for any surface or hairline cracks.

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Above image shows the inside of the sump including the original oil pick up pipe and baffle pot – which again needs to be modified (see later).

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Less oil pick up, showing original repair.

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Taking depth measurements to ensure an accurate chop, using a rule set across the mating flange and then drop a rule to the bottom.

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Sharp permanent marker clamped to engineers square in order to mark an a rough cut line around the lowest part of the sump.

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Again showing horizontal cut line. Anything above this will be scrapped and a loss of oil capacity will occur.

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Ouch ! No turning back now, bottom 25mm cut off.

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Rough card template mock up of new base giving an idea of overall size and position of additional area to make up some of the lost capacity + some.

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New 4mm thick aluminium base plate cut out and positioned on base of sump.

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Pen line depicts area of new sump profile, increasing oil capacity back to slightly more than original.

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Sump cut down and now showing holes cut out to allow flow of oil into and out of additional wing, this is to reduce oil “dead spots” where the oil does not get pumped around the engine.

New sump base and extra wing

New sump base and extra wing

Showing new sump base plate and extended wing & new machined drain plug fitted.

New base plate

New base plate

Inside view of chopped down sump.

Chopped down oil pick up

Chopped down oil pick up

Here you can see that the original oil pick up / filter gauze and baffle assembly, chopped down to reduce height to suit new sump.

Sump showing position of modified pick up

Sump showing position of modified pick up

Showing modified pick up sitting in position in sump bowl

Welded sump plate and oil pick up

Welded sump plate and oil pick up

Completed parts after leak testing, ready to pack up and send off to customer.

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For all your Custom Car & Motorcycle Parts Manufacture and Welding / Repairs
SEE –
www.flashcustoms.co.uk
Don`t forget to email or call us for all your custom made 1 off bespoke items.

Alloy welding / repairs, custom parts, Welding Instruction.

Thanks for reading our blog – we hope this has been of use to you.
Recommended sites
FLASH CUSTOMS – Specialist Custom Car & Motorcycle Parts
Automotive LED Lights – Car & Motorcycle LED Lighting Solutions
Loaded Wallet – Discount and cash back offers
Cash Back – Cash Back & Money Saving offers