1940 SS Knucklehead: People's Champ 5 Build" - Page 14 - The Jockey Journal Board

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Old 05-08-2017, 10:41 AM   #261
newman
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Default Re: 1940 SS Knucklehead: People's Champ 5 Build"

Then it was time to make some brake linkage. All I used to make this was an angle grinder, a drill press and a bandsaw.







Then I made some more pieces… here’s a bit more detail, should be pretty self explanatory.













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Old 05-08-2017, 10:41 AM   #262
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Default Re: 1940 SS Knucklehead: People's Champ 5 Build"







Then welded those parts on a part I made on the lathe, blended the welds and polished them:





I wanted some unique clevises, so I had to make those as well. Here’s how I did that. Turn OD



Use grooving tool to profile



Sand smooth



4 pieces done



Then put in the mill in the rotary table and slot and drill.

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Old 05-08-2017, 10:41 AM   #263
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Default Re: 1940 SS Knucklehead: People's Champ 5 Build"

The last step I didn’t take photos for, but I put the part back into the lathe and profiled the rest of it with the groover and sander. And this is how the parts looked when done and “installed”



Then I had to make mounts for the master cylinder and the pivot linkage. I did the math to have the end result of the braking force be equal to that of my sportster, which is comfortable to me,
based on leverage ratios, master size, caliper pot size, etc. Fab tip: it’s often helpful to fab small brackets and things while they are still attached to the stock which is helpful for clamping, drilling, sanding polishing, etc. Also, protip 2: don’t smash your thumb while changing brakepads on your car.



Here’s a video of the actuation of the master:

https://www.instagram.com/p/BTvYai1F...en-by=ctnewman

After that it was time to build a front portion of the front pipe. I had a midsection cast off a 3d printed wax model, bolted that to the frame, then built a pipe from 304 using vband flanges to mount
it. I had to make the flanges but used an off the shelf clamp.
Here are several shots of the exhaust.













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Old 05-08-2017, 10:42 AM   #264
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Default Re: 1940 SS Knucklehead: People's Champ 5 Build"

And here’s a tool I made to make cutting tubing easier and more accurate. First, set the angle and lock it down.



Then add the hold down ring and clamp that down. The whole plate slides in the miter groove of the saw and you get perfectly radial cuts every time.



You need one for every CLR tube you have, and every diameter, but since I really only build Harley exhausts, I made 1.75 OD X 2,3,4,6 CLR. I need to make a 1.75CLR still.

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Old 05-08-2017, 11:12 AM   #265
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Default Re: 1940 SS Knucklehead: People's Champ 5 Build"

As usual a fascinating post. Your desire for uniqueness and then the execution of your ideas is beyond anything I have ever seen.
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Old 05-08-2017, 11:44 AM   #266
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Default Re: 1940 SS Knucklehead: People's Champ 5 Build"

As always man, it's a pleasure to see your stuff! that's seriously skinny, watch those drains when you ride may fall in the gaps!
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Old 05-08-2017, 12:12 PM   #267
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Default Re: 1940 SS Knucklehead: People's Champ 5 Build"

The breakdown with what you get after each step of the process (layout, bandsaw, grind, polish) is fantastic.

And that trick of putting washers over the flat bit when shaping the arms is genius!
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Old 05-08-2017, 03:50 PM   #268
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Default Re: 1940 SS Knucklehead: People's Champ 5 Build"

Genius, period.
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Old 05-09-2017, 02:47 AM   #269
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Default Re: 1940 SS Knucklehead: People's Champ 5 Build"

Beautiful.
Will the mag go in more? or thats the spot?
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Old 05-09-2017, 10:28 AM   #270
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Default Re: 1940 SS Knucklehead: People's Champ 5 Build"

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Beautiful.
Will the mag go in more? or thats the spot?
I'm assuming he's going for a side-mounted mag to save shaving the regulator boss off (what is now) a very rare set of cases.
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Old 05-09-2017, 02:23 PM   #271
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Default Re: 1940 SS Knucklehead: People's Champ 5 Build"

This is correct. The relay boss is in good shape so I didn't want to hack it up.
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Old 05-09-2017, 02:29 PM   #272
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Default Re: 1940 SS Knucklehead: People's Champ 5 Build"

Made a top motor mount. Nothing fancy here. I wasn't feeling exceptionally inspired when I was designing it.







Used 1/8 filler rod which made blending the welds a lot simpler than the welds on the foot control bracket. Also made a fixture to hold everything true because I knew I was going to be putting a lot of heat into it. It pulled a little bit, but it pulled evenly, so I will probably have to run a .030 shim behind the center bolt.



Fit well. There will not be an issue with the rocker tins interfering...





Then got it polished up. Polish only took 3 hours which isn't bad.







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Old 05-09-2017, 08:19 PM   #273
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Default Re: 1940 SS Knucklehead: People's Champ 5 Build"

I think I'm gonna have to make the trip from AUS to Born Free just to see this bike. Fuck the detail and skill is awesome.
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Old 05-10-2017, 09:41 PM   #274
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Default Re: 1940 SS Knucklehead: People's Champ 5 Build"

What kind of saw blade is that? My experience with stainless is you have to cut it with a carbide cutting wheel or tooling?
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Old 05-10-2017, 09:53 PM   #275
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Default Re: 1940 SS Knucklehead: People's Champ 5 Build"

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What kind of saw blade is that? My experience with stainless is you have to cut it with a carbide cutting wheel or tooling?
I can't speak for Newman, but I use Lenox Bi-metal blades for aluminum, stainless, and CRS.
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Old 05-11-2017, 07:18 AM   #276
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Default Re: 1940 SS Knucklehead: People's Champ 5 Build"

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What kind of saw blade is that? My experience with stainless is you have to cut it with a carbide cutting wheel or tooling?
Quote:
Originally Posted by HD48FL View Post
I can't speak for Newman, but I use Lenox Bi-metal blades for aluminum, stainless, and CRS.
I use Lenox as well. Specifically:

Lenox DIEMASTER 2 Bi-Metal Band Saw Blades 3/8 x.025 14/18V

They last a really long time.

I get them from bandsawbladesdirect.com
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Old 05-11-2017, 11:18 AM   #277
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Default Re: 1940 SS Knucklehead: People's Champ 5 Build"

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I use Lenox as well. Specifically:

Lenox DIEMASTER 2 Bi-Metal Band Saw Blades 3/8 x.025 14/18V

They last a really long time.

I get them from bandsawbladesdirect.com
+3 probably the best blades about. They last for a literal age. Worth every penny.
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Old 05-11-2017, 11:28 AM   #278
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Default Re: 1940 SS Knucklehead: People's Champ 5 Build"

Quote:
Originally Posted by newman View Post
I use Lenox as well. Specifically:

Lenox DIEMASTER 2 Bi-Metal Band Saw Blades 3/8 x.025 14/18V

They last a really long time.

I get them from bandsawbladesdirect.com
+3 probably the best blades about. They last for a literal age. Worth every penny.
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Old 05-11-2017, 04:52 PM   #279
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Default Re: 1940 SS Knucklehead: People's Champ 5 Build"

your fabrication skills are awesome
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Old 05-11-2017, 08:01 PM   #280
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Default Re: 1940 SS Knucklehead: People's Champ 5 Build"

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Made a top motor mount. Nothing fancy here.
With everything else so far over the top, a "mildly" kustom motor mount won't go unappreciated. I like it.
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