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To put the taper in the springer legs, inside dimension calculations were made to reduce the bottom end to a 3/4" diameter round hole. Then pie slices were laid out from bottom to top. Using the cutting guide, the pie slices were cut and removed allowing the front and back halves to be pulled together forming the taper. The cuts were then v-ground to allow for 100% weld penetration.
The fork assembly was then clamped to the h-beam fixture that was used for the frame, and spot welds were made in equal and opposite positions. Then final welds were made in the same manner going from one side to the other to minimize warpage. All was allowed to cool before removing from the fixture. Machining the fork leg pivots and springer pivots was completed and readied for installation. The fork and these peices were clamped to the fixture in the same manner and held in line with pins for welding. |
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The rocker plates were torch cut from 1/2" plate, ground, and cleaned. The axel holes were drilled, and the pivot holes were drilled and reamed to receive raced needle bearings. While the fork assembly was set up for the pivot ends to be welded in, the spring plate was also welded onto the upper legs. 3/4" od .120 wall tubing was cut for the springer legs. These peices were silver soldered together. The springer rods were made from 1/2" tgp stock. Bushings were made from Delrin. Spring seats were made from motor block expansion plugs. Replacement springs were ordered for an HD Springer. Everything went together beautifully, and other than final finish, the springer is ready to go. |
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