Victory mc footboard-round 4-sideplates

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Victory mc footboard-round 4-sideplatesRevised Plate TemplateI set the original plate template we made, against the bolt mount, to verify a bunch of things. It was about 1/2” too tall and not flared wide enough to cover the saw edge of the bolt mount. Below is the relative, now fixed plate position—from dimensions transferred over from the steel mount-mock-up fixture, foot board drop/angle, etc. The same curving detail was transferred to this new template. The 2 outer holes are now 1.125 diameter.http://www.weldingweb.com/attachment...1&d=1198297682The flat bottom of the template, is resting on 1.875 and 2.000 high blocking. This approximates the 1.5 degree pitch uP angle of the steel mock-up. This is good, since I now have easily created, fixed bottom datum points to rest the machined plates on, for welding fitup.    Prior to fitup of the plates to the bolt mounts, the clevis castings will be welded and finished on both plates. This fitup will be done with the foot boards in the clevis—so they run parallel to the bottom, straight edge of the plate. The clevis castings were not made dead square—but this will be compensated for in the welding fitup of the clevis castings to the plate.Side Plates-are 6061-T6, .375 aluminum plate. I was able to visually inspect a plate remnant, for heavy scratching, prior to having this blank sheared to 16” X 19”. Below, the plate is coated with marking pen ink, and a right/left side outlined, carbide scribed from the revised template. I located the outlines in areas with the least scratching. The long sides of the side plates run in line with the rolling grain of this plate. The outlines were sawn on vertical bandsaw, allowing about 1/32” for edge cleanup back to the scribed outline.http://www.weldingweb.com/attachment...1&d=1198297988Below is the outer face (show-side) of the r/h side plate, and the inner face (no-show side) of the l/h side plate.The inner faces of both plates have a groove (that will be covered by the welded bolt mount) to identifythe inner face.  This groove is in the red circle. The 1.125 and 1.375 diameter holes were machined with Hougen Slug-Cutters. These cutters produce a 90 microinch finish, just as cut. Try that with a twist drill. No ragged drill breakout, huge torque reactions, drill wandering, etc.    The right side plate has been polished with the coarse grade of Carborundum FibraTex, 3M abrasive pads on a 4 1/2” angle grinder. For this job, sanding with grit discs, just creates more work and scratches to remove with the polishing pads—even on the sawn edges. One needs to have clean hands and repeatedly wash/wipe down the parts-prior to polishing, then after, and clean again before each operation.http://www.weldingweb.com/attachment...1&d=1198298144Below is a test sample plate I made up, with a 1/4” hanging hole, then polished the edge and one face for a bead blast and subsequent powdercoat sample. At this point, I needed to verify that the polishing pads and marks left from them, would still create a matte finish. I polish in 2 right angle directions using very light-almost no pressure, to minimize scratching.Had the powdercoater bead blast this-first. The blasting creates a nice, no-scratch, matte finish, in little time. The bead blasting also creates an excellent ‘tooth’ profile for the power coat to lock onto—just like the heavy sandblasting I have them do, on steel parts.Discussed this job, again, with the powder coat foreman:    -wash assemblies with lacquer thinner, blow off, then wash and blow off with aluminum etchant    -beadblast, then wash with aluminum etchant that I’ll supply, wipe and blow dry    -For the best durable finish—he recco’s:        -prime        -paint with Vulcan black—this is a semi-gloss black        -topcoat with clear coatThe clearcoat is harder and more durable against road damage than coating with high gloss black. This is the system they use to powdercoat wheels.*******Anyway, he’ll have the sample part below, coated with Vulcan black then clear coated, to show you. It’ll cost me a suitcase of beer.http://www.weldingweb.com/attachment...1&d=1198298565Continued in round 5 Attached ImagesBlackbird