Victory mc footboard-round 6-clearance & p-coat sample

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Victory mc footboard-round 6-clearance & p-coat sampleSunday, 8-19-07Avoiding design mistakes—The designer makes certain that form, function and fit—willdo just that, providing assembly tool access, appropriate bolt, nut, screw and washerclearances and clearance to any moving parts.     (Including the Victory m/c’s belt guard, on top of that moving swing arm!)....Whoa! [I mull over things as a project continues...’check this’.....’re-check that’...’what about that’, especially when the design is not fixed prior to starting the job. Worry-wart, Dave worries like an old-woman, worry wart. Make all the fun you wish- doesn’t bother me, doing that, keeps me from getting blind-sided, keeps the ball rolling, with minimum, un-planned, excitement. Writing up what I’m doing, as it occurs, also helps one t-h-i-n-k.] Just how much uP travel does the guard have at the bolt mount location?The mono spring-shock mount, apparently has an internal bump stop. However, the cast swing arm has a central raised portion, which has 1.062 clearanceto a mating depression in the rear fender. This is approximately in the same plane as the bolt mounts. This kills my initial hope, that I could fab one nice, big faired gusset plate tying in the side plate to the bolt mount casting. I taped a spacer of 1.125 thickness to the top of the belt guard, plus took clearance measurements on the front and rear of the right side bolt mount:    Front = .437  (deducting the 1.125 clearance)    Rear =   .937        “           “      “         “http://www.weldingweb.com/attachment...1&d=1198304360(the RED CIRCLE is this front gusset height area)http://www.weldingweb.com/attachment...1&d=1198305284(the RED CIRCLE is the rear gusset height area)I’m fabricating both front and rear gusset plates, to accommodate this clearance required. Distributing the torque and stress of the side plate through the length of these bolt mount castings is needed to give the casting a fighting chance to withstand the loading it will see.    Use posterboard templates, then saw cut 3/8” plate, grind and carbide reliefs, bevel angles, clearances, checking the gusset piece on the bike, back to the bench, back to the bike.The left side, doesn’t have clearance problems, other than the lower corner of the battery. I’m planning to put front and rear gussets on that, as well. The left side will have taller, bigger gussets than the right side—but I don’t think exact symmetry is an issue, at this point.Nobody notices such things.1-We checked the available clearance under the right side mountwith Vic bouncing hard on the seat. The max. up movement of thearm, is what this internal depression of the fender to swing armcasting measures—1.062. I’m using a value of 1.125.****NOTE TO CUSTOMER---The mono spring of the swing arm—should neverbe compressed any more than it currently is—due to this belt guardto the underside of the right side bolt mount. It has an adjustable,tabbed nut.             Sample Test plate problems2-Sanchez powdercoating hollered at me, Monday a.m.--regardingthe sample test plate I’d given them to coat-Thursday. They’d coated and baked the Vulcan black over the matte bead blasted finish.....and the plate was now showing sanding marks thatjust are not visible after the matte bead blast.3-Redid the test plate, using 60g then 100 g with a new electric orbital sander (a DeWalt-since the head on my Makita exploded last week). These things do a nice job—just don’t let them rev-up if they’re not in contact with the work. When finishinga sanding pass, then lightly raise some of the soft velcro-faced pad, to avoid heavier circle marks as it slows down and stops.http://www.weldingweb.com/attachment...1&d=1198304838Above is the 100g plate as sent to powdercoating, today-Tuesday am, 8-21-07.I’m testing the finish produced, by lightly dusting the sanded surface with LACQUER PRIMER. If you don’t see marks thru the lacquer---then, you don’t have marks.This dries in several minutes, can be washed off with lacquer thinner-quickly, and hopefully will serve as a final finish check, prior to bead blast, etch and powdercoating.It’s going to be several days, before they can shoot this part, due to their scheduling. I need to redo both side plates, prior to the gusset fab and welding. I want to make sure-this finishing method will suffice prior to plunging ahead. Just for good measure, I figure I’ll do a final finishing at 150 g, regardless.4-The new ss clevis pins, washers and cotter pins, for the foot board clevis, came in today. The pins are same body dia. As the Rivco clip-pins and things fit.The ss cotter pins are a tad long, so I ordered the shortest (1/2” nominal) length today. I’ve spent a good $50 to correct Rivco’s stupid screwup—between these new parts and my initial ordering of metric ss retaining rings.Continued in part 7 Attached ImagesBlackbird