Victory mc footboard-round 3-strongback bolt mounts

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Victory mc footboard-round 3-strongback bolt mounts Below, 3/8” x 5/8” aluminum flat was cut lengthwise with the grain then sanded and formed to fit the curve of the casting. Bevels for welding on the top and bottom of the gussets, where applicable. The fitup shown at the left, uses .030 of brass shim, to elevate the bottom of the gusset plate, aBOVE...the bottom of the 2 mount hole bosses. These ‘strong backs’, short in height as they must be for assembly clearances, still will provide an approximate 50% increase in deformation strength between the 2 mounting holes. (The center, 8 X 1.25mm tapped hole is for attaching the front of the saddle bag bar.)http://www.weldingweb.com/attachment...1&d=1198296349Welding of the fillets and groove welds, was performed with lots of TIG torch preheating, then getting some parent fusion and melting deep in the joint, prior to adding filler rod. Welds were overlaid, 2-4 times, fairing out the puddles and smoothing the tops with pulsing action; which this Thermo-Dynamics GTSW 300, is quite adept at.    These castings exhibit scattered porosity, lots of small, uniform porosity (.005 approx. dia.), just sub-surface (about .005-.010 depth), which is to be expected for this quality level of casting. This small porosity was only evident, in the lightly faired out, pulsed, weld blend areas that ran over the casting surfaces.To help alleviate this porosity on weld puddle surfaces, I tried a new technique:    -cook out any big ones    -once things look ‘cooked-out’, then slowly fade torch power setting back to high frequency ‘run’.     This is not high frequency start, it’s past the start, and is still transmitting some heat.    -This apparently helps the weld puddle chilling, producing little to none of .005 or smaller surface porosity. No ‘deep’ porosity was seen in making the root passes, so these welds have integrity as good as the casting metallurgy will allow. http://www.weldingweb.com/attachment...1&d=1198297044Above, is top view of both mounts. The mount on the left, is the right side mount. The upper edge of this gusset plate needed relieving to clear the edge of the fender, when test-fitting the parts. Both mounts will fit the bike and clear the front saddlebag mount, and the fender edges. I checked this repeatedly, to make it happen.    The tops of the gusset plates are beLOW the tops of the center tapped hole, for proper clearance. The lower mounting hole bosses were ground, sanded and checked for flat/flush clearance with the new, hardened washers that will be used for final assembly. The designer and fabricator apparently puts some thought and detail into this work.http://www.weldingweb.com/attachment...1&d=1198296710Above are rear, non-show frame mounting sides, as sanded and welded.http://www.weldingweb.com/attachment...1&d=1198296523Above are the sides which face the fender edge-towards the rear of the bike.Bead-blasting the mounts will provide a matte finish, with the powder coating hiding sand and polish marks. I used various cartridge rolls in a high speed air grinder, for much of the detailing, then buffing the larger surfaces with 3M Fibertex pad.Continued in round 4 Attached ImagesBlackbird