Ducati Wheel Speed Sensor Bracket

I have recently been asked to manufacture 1 off replacement Ducati wheel speed sensor bracket.

The original one was manufactured as 2 separate pieces and then welded together. This had been knocked and bent.

I managed to straighten this out, nick through the existing weld and re-weld around 3 sides to”repair” the original.

Knowing that this original design may have a weakness where the joint between the 2 parts are only able to be welded on 3 sides, I machined the item as a single part, using a manual lathe and mill.

The material I used was HE30 Aluminium, or  what is now commonly known as “6082 grade alloy” or “T6″.

Particulars of this grade of material is ideal for this application – “Alloy 6082 is a medium strength alloy with excellent corrosion resistance. Alloy 6082 has the highest strength of the 6000 series alloy. Due to the higher strength of Alloy 6082 it has replaced Alloy 6061 in many applications. Alloy 6082 is typically used in highly stressed applications, Trusses, Bridges, Cranes, Transport applications, Ore Skips, Beer Barrels, Milk churns”. (taken from http://www.aircraftmaterials.com/data/aluminium/6082.html 30/9/2013).

A more typical application for this grade is aircraft parts, billet alloy slab yokes, fork clamps, handlebar risers.

20130919_20480920130919_204822

Above image shows 1 piece sensor bracket, machined from billet T6 Alloy, etch primed and painted silver

————————————————————————————————————————————————-

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

Stainless Steel Oval tube frame Mountain Bike Frame

I decided that I had to sort out my bike, I have had it several years and it was getting past its best.

The head bearings were worn and needed replacement.

The Tyres were well worn and a puncture put an end to it, so I stripped it into bits!

Once stripped, I decided I was going to play with the frame, I chopped and changed it and realised, actually I didn’t like it at all.

Frame ended up in the skip and the only piece kept was the shock mount.

IMG-20130821-00781

As luck would have it I had a spare piece of oval stainless steel tube in the rack,just enough to complete a new frame set up.

Below shows the first set up I made with the standard rear frame fitted to check alignment.

IMG-20130821-00782

A couple of small modifications and I ended up with something I thought might suffice.

Below shows my attempt at a mountain bike frame set up.

IMG-20130822-00783

Picture below shows the frame once polished and painted head stock and seat postIMG-20130826-00784 IMG-20130826-00785

Although the frame polished up ok, I am not over happy with the welding nor the joint set up, as you can see below the TIG welding is not perfect. If I had spent a bit more time scalloping the tubes and wrap then the fit up would have been better and hence welding much more even. Ok for me but I would have re-done it again much better for a customer.

IMG-20130826-00786

Picture below shows the original fork set with leaking forks

IMG-20130826-00787

I brought a new set at a bargain price off the good old Ebay.

Unfortunately once delivered I realised that the stem sizes were different, original was 1″ and new one was 11/8″.

Only way round this was a little more precision cutting and welding and half an hour later and

the stems were swapped over.

IMG-20130826-00788

Along with a few new items purchased through reputable companies on Ebay, I built the bike back up.

bike

Now I have built it and set the brakes and gear sets up, I don’t know if I like it?

Rides ok, I have put more road orientated tyres on it but, think perhaps I should have brought a carbon frame and made up an aluminium rear frame, a set of top and bottom yokes and gone the whole hog.

bike1

So, I may be open to offers on the above?

The bike is suitable for anyone above about 5,5″ up to 6.5″, the wheels are 26″, shimano brake and gear change units, shimano gear shifters and dual shock set up.

See additional finished images below

20130929_163329 20130929_163338 20130929_163357 20130929_163406 20130929_163414 20130929_163423 20130929_163434 20130929_163449 20130929_163503

————————————————————————————————————————————————-

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

Ford Capri 2.8 Fuel Tank Replacement in Aluminium

Its pretty typical with the age of many Capri`s still either on the road or in garages being repaired or restored, that their steel fuel tank is showing signs of corrosion and maybe even perforation.

In this instance  we had been asked to replicate a Ford Capri 2.8 injection fuel tank as the old steel one was too badly corroded.

Fuel tanks were typically pressed or stamped out of sheet metal and flange welded in the days of Ford Capri manufacture. Many fuel tanks were simply “hung” from the chassis or floor pan and suffered with corrosion due to the rear wheels kicking up water, road dirt and the likes onto the mounted fuel tank. Many tanks now days are manufactured from plastics and hence do not suffer with corrosion like the Steel Capri tanks.

Obviously in some instances repair is possible. This usually means stripping the tank, removing any risk of explosion by means of emptying the fuel tank, pressure washing out and then purging and filling the tank with” inert” gas before cutting / patching / welding / repairing the tank.

Over the years I have seen many tanks repaired with “chemical metal”, which eventually still “seep” fuel, not ideal.

So if you are needing repair or replacement of your Ford Capri fuel tank, you know where to come.

20140118_093902

20140118_165238

Above – bottom pressings and ends tacked up, fuel swirl pot, pick up and return

Image showing top of tank ready for pressure testing


Completed tank with breather pipes fitted and filler flange taped off to stop dirt

getting into tank

Polished and cleaned up.

Any Capri experts will notice the fuel pump mounted on the wrong end of the tank ! oops

Does help if I weld the bottom to the top section of the tank in the correct orientation.

In this instance I ended up cutting the top section off, remaking and re-welding / re-testing.

Wont be making that same mistake again !

For all tank repairs and custom manufacture to suit your requirements, please contact us as below.

————————————————————————————————————————————————-

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