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How to fabricate an illegal tag bracket.

Discussion in 'How-To' started by gearsmithy, Oct 19, 2009.

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  1. pauldeepsea

    pauldeepsea Well-Known Member

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    Thats really some good work. Wish I had the time and talent. Not afraid to get the hands dirty by any means just never had any real mechanics in the family. Learned alot by screwing things up and from the all the great people on this forum to take the time out of their busy schedules to help a brother out. Great job and keep those how to's coming!!
     
  2. waykool

    waykool Banned

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    I liked it GS. Good Job!
     
  3. gearsmithy

    gearsmithy Active Member

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    Thanks guys. I'm almost to the point in my build where I need to make some bars. A friend of mine gave me a tubing bender as get well present but I'm thinking I'll make these without it and show you guys how to properly prep, jig, and bend tubing without access to a bender. This will be VERY old school and somewhat time intensive but you'll see the process to make bars for under $50 - very portable to big dog (actually these will be way more complicated than replicating the big dog bars so you should get some value of it too). Stay tuned, might take me a while since I'm looking for another job though.
     
  4. lee

    lee Well-Known Member

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    I've been thinking about doing this so I'll look forward to that
     
  5. gearsmithy

    gearsmithy Active Member

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    It's really not that hard, bars are one of the simplest things to fabricate. The tough part is getting them symetrical and if you can do it without slugging/sleeving then you can do it without welding.

    The process is pretty simple:
    1. take a welding rod, bend it the shape of the handlebars that you want to produce
    2. transfer your bend radius(s) to a wooden jig with a strip of sheetmetal on the outside surface
    3. Bake a bunch of sand in the oven to remove all moisture
    4. cap the ends of the tube and fill it with the water-free sand (keeps the tubing from kinking).
    5. clamp it to your jig, heat it up with a torch, and bend to shape.
    6. The rest is details that will depend on your application (i.e. using riser spuds vs. risers)
    5. slugging for grip and controls etc..
     
  6. lee

    lee Well-Known Member

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    sounds good to me :2thumbs:

    I was thinking along the lines are sharper, squarer angles. Cut, mitre and weld. Very interested to see what you come up with though.
     
  7. gearsmithy

    gearsmithy Active Member

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    these will be a modern take on the old mustache bars of yore, which I think can be tricky to fabricate (lots of compound sweeping curves). It will be fun though, I've been kicking around the idea of shit-canning my EHC and making some new bars for the ridgeback for a while, just haven't found the time yet.
     
  8. RRRUFF

    RRRUFF Well-Known Member

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    Great work!:2thumbs::cheers:
     
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