First section finished

Yes !!! The first section of the frame is finished !!! This section (see photo in previous blog) will hold the front wheels, steering housing and pedals. I closed the open ends of the square tubes by welding 3 mm plate in them. This will create strong corner sections that will allow for the best match of strenght and flexibility.

The welding is also improving more and more as I go. The machine is doing better now I have the settings right and everything checked and sorted. Next week I hope to have some more copper tips and another 2 rolls of wire.

The coming week I hope to start cutting the mid section tubing (bottom part) and fit it to the front. This will increase the frame quite dramatically and I need to start preparing my storage location (the ceiling or wall). It would help if I could sell the Yamaha Streetfighter so I gain some space.

Disassembly complete and sparks flying

I have completed the disassembly of the Kawasaki and the parts are up for sale. Interest is high but no actual sales yet. So I am now the proud owner of the worlds most powerful moving trolley ;) Over 200hp, so watch out Holland !!

Upon completion of the disassembly work it is finally time to start working on the frame. I have all the steel as well so it is time to start putting it together.

First step was to get the welding parameters right. I cut some short bits of tube (Square Hollow Section 25 by 1.5 mm) with which I am going to build the frame and did some welding on it. Both butt and fillet welds until the settings were right. By being able to look inside, I could see that the penetration was sufficient.

Then I started cutting the sections to length for the front section, where the front wheels will be attached. It will also hold the pedal box and the steering housing. Unfortunately I had some issues with the welding machine that screwed up the welds and I ended up cutting up the frame (only a small part).

The new frame however is progressing well now I have sorted out the welding machine. There is however quite a bit of work going into the preparation, grinding and welding. So progress is not as fast as I would like but still it is going the right way.

Once this front section is ready, the mid section is next, followed by the aft section where the engine will be installed (see above ;)

The frame is then finished and the suspension will be next. The front unequal triangles will be made from tubing, the rear swingarm as well. The rear swingarm will have a single spring/shock unit that ties into the frame and the hinges will be in line with the sprocket (eliminates chain length changes while the wheel moves up and down).

Anyway, lets first finish the frame before we start with the rest !!!