1940 SS Knucklehead: People's Champ 5 Build" - Page 3 - The Jockey Journal Board

Go Back   The Jockey Journal Board > General Discussion > The Board

Reply
 
Thread Tools Search this Thread Display Modes
Old 11-11-2016, 10:12 AM   #41
newman
Senior Member
 
Join Date: Aug 2014
Location: Buffalo, NY
Posts: 141
Default Re: 1940 SS Knuckle

Thanks for the compliments everyone.

Quote:
Originally Posted by KCgran View Post
Really nice work, ( I have trouble calling machine work fabrication, with all the math, trig and geometry associated with it ,its more science than something that can be covered by a word that also means lying!). Most of the engineers I know couldn't design any part of this and damn sure couldn't make it! You are a unique individual sir. I also am running aBridgeport mill with some runout, I've found that if I machine something down to say .25mm then make my finish cuts using high rpm climb cuts at my final value I'm usually dead on dimension. Under normal machining practices The action of the end mill tooth on the wall in front of the tooling actually pushes the end mill further into the workpiece making it undersized.
I'm curious, I don't remember ever machining stainless. Is it difficult to deal with? It tigs much easier than plain carbon steal, but I think it is harder?
Lastly, I love the stance of that turbo shovel, what's the rake and trail?
I've never heard that fabrication joke.

Machining stainless sucks. It work hardens, gums up, just generally shitty, have to cut really slow. Been doing a lot of work with 4140 and 1144 lately and it's MUCH easier to work with.

The shovel is -5 degrees, and the trail, I THINK was about 3". I'd have to dig up my old drawings to be sure and they're on an old harddrive.
newman is offline   Reply With Quote
Sponsored Links
Advertisement
 
Old 11-11-2016, 10:40 AM   #42
KCgran
Senior Member
 
Join Date: Dec 2011
Location: kentucky,USofA
Posts: 1,163
Smile Re: 1940 SS Knuckle

Quote:
Originally Posted by newman View Post
Thanks for the compliments everyone.



I've never heard that fabrication joke.

Machining stainless sucks. It work hardens, gums up, just generally shitty, have to cut really slow. Been doing a lot of work with 4140 and 1144 lately and it's MUCH easier to work with.

The shovel is -5 degrees, and the trail, I THINK was about 3". I'd have to dig up my old drawings to be sure and they're on an old harddrive.
That's cause I just made it up!
Well crap, honestly it's my daughters joke, albeit inadvertently. She was with me when someone asked me what I did at the auto plant where I work. People can't understand what I do so I just say I'm a fabricator. After I told the guy I was a fabricator at the plant she asked why did I tell him I was a liar? Problem was she was serious!
__________________
I buy all my groceries and pharmaceuticals at Circle K

Last edited by KCgran; 11-11-2016 at 10:49 AM.
KCgran is offline   Reply With Quote
Old 12-01-2016, 12:06 PM   #43
dhallilama
Senior Member
 
dhallilama's Avatar
 
Join Date: Nov 2008
Location: portland, or
Posts: 837
Default Re: 1940 SS Knuckle

unfucking believable build.

the knuck is the most insane build i've ever seen (in a great way), the other bikes are bitchin' too.
dhallilama is offline   Reply With Quote
 
Old 12-01-2016, 02:12 PM   #44
Dan Boy
Senior Member
 
Dan Boy's Avatar
 
Join Date: Sep 2009
Location: Norfolk, UK
Posts: 2,219
Default Re: 1940 SS Knuckle

Newman, your work is just amazing. I love your ingenuity and attention to detail, your welds are just fantastic and I love reading through your threads.

Great stuff, Dan.
__________________

http://www.jockeyjournal.com/forum/signaturepics/sigpic21807_5.gif

Blown Triple Build
Dan Boy is offline   Reply With Quote
Old 12-02-2016, 08:25 AM   #45
newman
Senior Member
 
Join Date: Aug 2014
Location: Buffalo, NY
Posts: 141
Default Re: 1940 SS Knuckle

So, I spent about 50 hours making a set of handlebars, and they’re not even done yet. I didn’t document a lot of the fab work, because the task was so daunting. It doesn’t even look like something that would take as long as it did, but manual machining and manual polishing really eats up a lot of time.

The first step was to make these parts. They look simple, and on a CNC they would be. Doing it on manual equipment really presented all sorts of challenges.



The right hand side one is even drilled for throttle cable pass through.




Next, I needed a 1.25” bend CLR on some 1” round. I don’t have a die for my bender that small, and I doubt anyone does… Never fear:



That’ll work. Took a few tries which was about the end of the service life for the die.



So now I am just going to jump to the complete product but there is a TON that I am skipping. The bars are actually made from 13 different pieces. There is a riser cap, upper tube, middle tube and lower solid round section. The solid round section is profiled manually and then headlight mounting bracket bosses were added. They also have a “backup ring” that takes some of the suspension load off the stem nut. The risers actually pass through the top tree and bolt to the bottom tree. There is a set screw behind the upper girder links that keeps the bars from rattling around in the top tree.

The upper portion of the bars I am not decided on yet. It’s going to be a function of tank fitment I think, but fortunately, I can almost do that at the very end of the project, allowing me to play with various ideas. So here are some pictures that I don’t really feel does the project justice, but it will get the idea across.
Riser backup ring:





Front view:





Top view:



Details:



Side view:




Another option in case I decide to run lower bars:



The profiled riser support uprights, milled and tapped for headlight mounts:





Also got some parts back from heat treat. The nuts are 1144 and HT to 54HRC, the other parts are 4140 and HT to 51HRC.



This IG video gives a bit of a better "overall feel" to the bars:

https://www.instagram.com/p/BNYLt_vl...en-by=ctnewman

Last edited by newman; 12-02-2016 at 08:52 AM.
newman is offline   Reply With Quote
Old 12-02-2016, 10:51 AM   #46
rhysmort
Senior Member
 
rhysmort's Avatar
 
Join Date: Jan 2016
Location: UK
Posts: 708
Default Re: 1940 SS Knuckle

Amazing man!

I had some bars fabbed, but I just welded mind to my top tree! simple life for me haha.
rhysmort is offline   Reply With Quote
Old 12-02-2016, 11:32 AM   #47
Lester
Senior Member
 
Lester's Avatar
 
Join Date: Nov 2012
Location: Norway
Posts: 1,482
Default Re: 1940 SS Knuckle

What amazing craftsmanship!
Thanks for sharing and in so much detail too. Keep it coming!

Lester
__________________
'62 DuoGlide Mine for 23yrs
'62 Triumph T-Bird in boxes
'63 BSA Lightning Café Racer
'75 BMW R90 stock
'83 BMW R100 commuter
'72 Triumph Bonneville Nothing special
'70s Jawa speedway DT500
'80 couple og Jap bikes too
Lester is offline   Reply With Quote
Old 12-02-2016, 02:06 PM   #48
VonWegener
Senior Member
 
VonWegener's Avatar
 
Join Date: Nov 2009
Location: Apple Valley
Posts: 2,821
Default Re: 1940 SS Knuckle

I like that everything you do is odd as hell but the outcome is always pleasing looking.
So many times we get a build thread from an excellent craftsman who has zero design taste. You combine great skills as a machinist with a keen eye for design and execution.
I am in awe of what you are doing here.
__________________
*
Have you hugged your motorcycle today?

VonWegener is offline   Reply With Quote
Old 12-02-2016, 02:38 PM   #49
newman
Senior Member
 
Join Date: Aug 2014
Location: Buffalo, NY
Posts: 141
Default Re: 1940 SS Knuckle

Thanks guys.

Hearing that people appreciate my stuff keeps me stoked to keep going, because sometimes it's hard to spend all my time in the shop or at work.
newman is offline   Reply With Quote
Old 12-05-2016, 09:01 AM   #50
newman
Senior Member
 
Join Date: Aug 2014
Location: Buffalo, NY
Posts: 141
Default Re: 1940 SS Knuckle

Decided I wanted to make my own headlight. So first I bought a cool looking lens for an old chevy. Then I drew a cad model of what I wanted the headlight to look like.



Then I modified to be constructed from pieces 3/16 thick.



Then used that cad model to make templates:



Cut out some 3/16 316SS plate to the dimensions of the template:



Then start welding. Remember to take a selfie.



Welding it in small layers helps. Remember to keep it clamped.




Let it fully cool before unclamping and rewilding:



Ultimately it was pretty good welding practice, but I got bored and started rushing.



The inside:




Time to start sanding… getting there:




Fast forward a couple hours. By no means a perfect polish, but it’s just gotta reflect light:



Clamp the lid onto the body:



And match drill/tap/cbore:



Start sanding:



Keep sanding:



Still sanding!




Now fast forward about 8 hours:









Overall I do not recommend this method of construction. I kept sanding totally through my welds, which required a lot of rewelding. Very frustrating. Next time I think I'll pay someone to hog the rough shape out of billet before sanding smooth. About a 25 hour endeavor to get to this point. Still needs mounts and a bulb holder, that's why it isn't fully polished.
newman is offline   Reply With Quote
Old 12-05-2016, 12:03 PM   #51
Ratso
Senior Member
 
Ratso's Avatar
 
Join Date: Aug 2015
Location: San Francisco
Posts: 452
Default Re: 1940 SS Knuckle

Holy jeebers. I thought it was awesome in its early, ziggurat phase. What a piece of work. You're a real craftsman and -- it must be said -- a real character.
Ratso is offline   Reply With Quote
Old 12-05-2016, 12:10 PM   #52
Dan Boy
Senior Member
 
Dan Boy's Avatar
 
Join Date: Sep 2009
Location: Norfolk, UK
Posts: 2,219
Default Re: 1940 SS Knuckle

I'll pack up my tools and clear off my bench in the morning.
__________________

http://www.jockeyjournal.com/forum/signaturepics/sigpic21807_5.gif

Blown Triple Build
Dan Boy is offline   Reply With Quote
Old 12-05-2016, 06:41 PM   #53
blown36
Junior Member
 
Join Date: Oct 2016
Location: Australia
Posts: 18
Default Re: 1940 SS Knuckle

This is going to be one of those bikes that will be famous, legendary, incredible, and a step up from anything we've ever seen! And we're lucky enough to see it get hand made right here.

Thank you and please keep the pics and commentary coming!
blown36 is offline   Reply With Quote
Old 12-06-2016, 12:38 AM   #54
JAWS
Senior Member
 
JAWS's Avatar
 
Join Date: Jul 2007
Location: Maui
Posts: 7,120
Default Re: 1940 SS Knuckle

Enough... stop. Waaaaaay to much awsesome here.

I cant handle the resentment I have towards my junk, that I have after looking at this thread.

Im ten seconds from lightin my pan on fire.
__________________
The police never think it's as funny as I do....

ROLLING DEATH

"In short, if you have engineering experience and are cautious and sensible they're fun and look great, if you're lazy and stupid, throw them on the bike and go for a ride you'll be dead the same day." -=JL=
JAWS is offline   Reply With Quote
Old 12-06-2016, 07:14 AM   #55
TigerAlex
Senior Member
 
Join Date: Feb 2008
Location: Alexandria, VA
Posts: 243
Default Re: 1940 SS Knuckle

I'll add my admiration of your work and appreciation for sharing it here. She's gorgeous so far and getting better with each installment.
Alex
TigerAlex is offline   Reply With Quote
Old 12-06-2016, 08:34 AM   #56
newman
Senior Member
 
Join Date: Aug 2014
Location: Buffalo, NY
Posts: 141
Default Re: 1940 SS Knuckle

Under normal circumstances I wouldn’t even bother posting about something as simple as a headlight support bracket, but this one has a little twist so here it is:

First I made a drawing, then using a center drill, marked a bunch of key locations on a hunk of 7GA 316SS. Using a compass and a scribe, I added the outline of the part.



Drill some holes.



Make some slots:



Now you can see why there were so many extra holes for a part that only needs two bolts. Not having a CNC forces me to use the rotary table whenever I need to circular mill something.



First slot done. Then unbolt and move to the other hole. This wouldn’t work if you needed high precision, but this is a low precision slot. Will become apparent later:



Second slot done:



Cut it out on your saw with a shitty blade:



Then get it more accurate with a sander:



Next, cut out another piece out of some thinner 316. This is 12ga or ~.100



Weld ‘em together.



Use an endmill to start a hole:



And a drill bit to finish:



That’s what he was doing…



Whenever I am worried about something not coming out right, I forget to take pictures, so what’s not shown is Z bending the part on a shitty box brake, or any of the sanding and smoothing, so here is the end result. The wire will enter the bracket, and then never be seen again.







newman is offline   Reply With Quote
Old 12-06-2016, 11:56 AM   #57
Uuh...
Senior Member
 
Uuh...'s Avatar
 
Join Date: Oct 2007
Location: Rotterdam, Netherlands
Posts: 119
Default Re: 1940 SS Knuckle

Mister Newman,

Three questions/comments:
1) What software do you use? Solidworks?
2) Do you tie your hair/beard when drilling/milling/sanding? Is good workshop practice, you know.


3) Thank you for giving us the heads up on the new trend after you release your bike to the public: the "cordless" headlight!
It (really!) looks awesome!
__________________
Build, make, create and inspire. Thinking is for when you are confronted with a problem. - Selectedgrub
Uuh... is offline   Reply With Quote
Old 12-06-2016, 12:09 PM   #58
newman
Senior Member
 
Join Date: Aug 2014
Location: Buffalo, NY
Posts: 141
Default Re: 1940 SS Knuckle

Quote:
Originally Posted by Uuh... View Post
Mister Newman,

Three questions/comments:
1) What software do you use? Solidworks?
2) Do you tie your hair/beard when drilling/milling/sanding? Is good workshop practice, you know.

3) Thank you for giving us the heads up on the new trend after you release your bike to the public: the "cordless" headlight!
It (really!) looks awesome!
1) Inventor. Mostly because that is what we use at work.

2) Yeah, although recently I dipped my hair into what was going to be a beautiful weld while trying to get a better look at it.

3) You're welcome.
newman is offline   Reply With Quote
Old 12-08-2016, 12:35 AM   #59
JAWS
Senior Member
 
JAWS's Avatar
 
Join Date: Jul 2007
Location: Maui
Posts: 7,120
Default Re: 1940 SS Knuckle

Fire, litteraly on fire....

Everything you touch is waaaay past what I could dream up. Most of it I am lost.
__________________
The police never think it's as funny as I do....

ROLLING DEATH

"In short, if you have engineering experience and are cautious and sensible they're fun and look great, if you're lazy and stupid, throw them on the bike and go for a ride you'll be dead the same day." -=JL=
JAWS is offline   Reply With Quote
Old 12-08-2016, 05:50 AM   #60
Mick93
Member
 
Mick93's Avatar
 
Join Date: May 2016
Location: wombat country
Posts: 42
Default Re: 1940 SS Knuckle

very impressive...... thanks for the updates and explanations
__________________
Allergic to Stock

pushing the limits since 67
Mick93 is offline   Reply With Quote
Reply

Thread Tools Search this Thread
Search this Thread:

Advanced Search
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is On

Forum Jump


All times are GMT -5. The time now is 02:19 AM.