Victory mc footboard-round 7-gnarly-looking parts

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Victory mc footboard-round 7-gnarly-looking parts*******I had an epiphany today, now better understanding ‘why’ some folks are surprised at the amountof time/cost/hassle, I may quote for things that--to them appear to be so wholly easy,no-brainer items, when all that I need to do, is to design, fixture, fabricate, test fit and surface finish, creatingall the required elements of form, fit and function.            My Epiphany:  It only takes Orange County Choppers or Jesse James, a 30 minute show--to do anything!    My answer: That’s ‘why’ they’re T-V stars and I’m not!Fit, fit-up, verify fits, finish weld sideplate & gussets to mounts-8-31-07Right side welding, etc. was completed 8-30-07:http://www.weldingweb.com/attachment...1&d=1198314771Gusset joints were deeply beveled, cast mount was bevel groove-deeply, on both sides, with sequential welding/tacking, grinding out tacks, grinding in more bevel, etc., etc.Inside periphery of gusset to casting was welded, then overlaid 3-4 times, for rather massive weld beads. Gusset welding was performed prior to finish, deep penetration welding of the casting to sideplate joints, to minimize weld distortion.     Root, filler and show-side blending passes used Eutectic and Rockmount rod, $2/stick. It’s the highest strength level, really clean stuff to use, for fussy things. The high-buck rod also helps when encountering this sub-surface porosity, which the castings have been noted to have.    [It’s not evident in these pics, but ‘yours truly’, truly spent goodly time, fitting these gussets, to help create sanding paths that would blend; and allowing for ‘where’ blending welding passes would be done, to help the sanding and finishing.]http://www.weldingweb.com/attachment...1&d=1198314638Rear side of mount above-The red boxes show the connection joint between the stiffener plate of the bolt mount and the gusset spanning from this joint, strong-backing the casting, then joined to the side plate. This adds torsional strength to the assembly. The front and rear gusseting on the right side mount, is shorter than the left side mount, for clearance to the belt drive cover.It’s a pity, these gussets couldn’t be longer, like the left side ones are, shown below:http://www.weldingweb.com/attachment...1&d=1198315278http://www.weldingweb.com/attachment...1&d=1198314988Above is the front view of the left side mount. The innercutout clears the battery by 3/16”.*******Finish Discussion & Tips******1-From the test samples and the actual powder coating, using the coarse 3M fibratexpad is just too abrasive, leaving slight lines and paths. I ended up doing a goodly bit of final finishing with a brand new, air DA, big assortment of new bobs and small flap wheels up to 240 grit. 2-Try out finishing methods-first, before plunging in to do the real thing.Continued in round 8 Attached ImagesLast edited by dave powelson; 12-22-2007 at 04:39 AM.Blackbird
Reply:They do all the hard work during the commercials