Thread: 2/3 scale Brough Superior

Originally Posted by DaveTTC

The holes in the tank, will you use strips pvc pipe to fill and creeate the concave curve there?

Dave TTC
Turning Wood Into Art

To me it looks like the back of the recess (across the end of the tunnel) and the sides are fairly flat.
There seems to be a curve on either side that joins them.

t12.jpg

I'm pretty keen to get the tank back in one piece.
So as soon as I've got the triple trees made and I know exactly what clearance is needed in the recessed area,
I'll make a former out of MDF, PVC and Filler, then take a fiberglass cast from that.
Hopefully I can blend it into the front of the tank without to many hassles!.

Cheers
Trev.

Originally Posted by Repliconics

I had a bit of good luck and found some old pipe and square section steel in the bush behind the shed.
I think there's a good start to a set of forks in them.

I knew Tassie was good for growing timber but pipe and square steel?
Loving the build Trevor.

Craig

Originally Posted by CAG

I knew Tassie was good for growing timber but pipe and square steel?
Loving the build Trevor.

Craig

You'd be surprised what can turn-up in the Tassie bush!.

I've got some more done on the steering.
Finished off make the rest of the plates and parts for the lower bracket on the steering throat.
Then I cut a temporary one for the top.

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In fact it's all pretty temporary at the minute, it's only held together with so glue and bodyfiller.

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What I'm after at the moment is finding out just how big the recess in the tanks needs to be!.
The width is looking pretty good although it could do with being a little deeper at the top.
That would give me a bit more rotation in the steering.

So I'll cut a bit more from the top, and if it's all looking good get started on making a former so I can fill in the recess.
Once that's done I can get started on building the forks for real!.

Cheers
Trev.

Looking really good Trev.

I like the metal work you have done. Very nice

Charlie

I was about to start working on an overly complicated former to use in making the fiberglass cover for the recess in the front of the tank.
About then I spotted one of Tayne's empty Nutri-Grain boxes and came up with a much easier way of doing things.

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All I needed to do was cut out the shape from the cardboard box and glue it in place.
After that just glass over the top of it and jobs done!.

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Then I fixed it in place and formed the bracing plate at the top of the recess, with some more fiberglass and filler.

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It's all looking a bit rough at the moment, but with a clean up and a couple of resin coats than some primer it should be sweet.
Pretty happy with it all so far, there's enough clearance in the recess that the forks will have a good turning radius.

Now I need to find someone in town with a 5/8 drill bit, I tried the hardware store this morning but it was a little to hefty for their range!.

Cheers
Trev.

Trev,s tank,
Iron man tuff.
Just one question was that all done before or after breakfast?

Cheers Matt

Originally Posted by Simplicity

Trev,s tank,
Iron man tuff.
Just one question was that all done before or after breakfast?

Cheers Matt

Knowing Trev probably before

That is looking GREAT, but
When you fill it with gas won't the Nutri-Grain clog up the filter?

Maybe I should've gone with All-Bran, isn't that supposed to keep the pipes clean!.

Cheers
Trev.

All sounds a bit flaky to me

Your right Ray it's all getting just a little corny!.

I solved the problem with not having a 5/8 drill bit.
There's an Engineering joint not far from my place, just outside of town.
"Damn I Love Small Town's" you walk in the door say G'day Mate explain what the problem is, and walk out with what you need for the job.
You can't get much better than that!.

Cheers
Trev.

Things may not look much different than the other day, but it's all been welded up!.

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It took quite sometime to weld all ten pieces of the brace at the bottom of the steering throat together.
Each of the parts needed to be plug welded a piece at a time.
Then the forks are welded in place top and bottom of the brace.

IMG_8089.jpg IMG_8091.jpg

As you can see the forks look fairly thin at the moment, but they need to be laminated into shape.
When finished they'll have a taper from the brace down to their base.

The clearance to the tank is fine and the angle of the forks looks good.

It's great to have that job done.

Cheers
Trev.

It's really coming together now Trev, Top Stuff

Charlie

I started working on the first of the tapers for the forks early this morning.
I've got a fair bit done but ran out of bodyfiller so I'll need to wait until tomorrow to get some more.

I'm using pretty much the same method to give the forks the appearance of being tapered as I did when I built the Harley.
Only this time I've added a layer of fiberglass as well.

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First I laminated strips of 3mm MDF onto the tube and used bodyfiller to take up the gaps.
Then I sanded it down making the rough appearance of a tapered fork.
A layer of fiberglass was next.
It makes an unholy mess, but I think it's well worth the effort.

Back in the day when I built the Harley I only used MDF and filler.
It worked well at the time but after six years or so the laminations started to open.
Hopefully this time with the glass added that shouldn't be a problem.

IMG_8158.jpg

You can see in the last two photos I've started to clean it all up and form the taper.
It will need quite a bit more work to get the finished shape but it a good start.

Just as a footnote: The Castle forks made by Brough and fitted to the bike I'm building are almost dead ringers for the Harley forks of the time.

Cheers
Trev.