Victory mc footboard-round 2-sideplate template

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Victory mc footboard-round 2-sideplate template http://www.weldingweb.com/attachment...1&d=1198295442Above is the template we made, with smaller outer holes to allow for room for an inner corner gusset fillet and bevel welds.http://www.weldingweb.com/attachment...1&d=1198295514Yesterday-Saturday, I make a plywood copy of the poster board template, taped this to both right and left mounts-to verify fit and clearances. Gee! Maybe we could just use the plywood with some lag screws into the aluminum?http://www.weldingweb.com/attachment...1&d=1198295611The left side-originally with the mount trimmed to 12 degree/side toe out—only cleared the clutch cable by 1/8”. I had to trim the back side of this left aluminum mount, to kick it out for a decent, 1/2” clearance-as shown above. Doing the same modification  to the right side to maintain symmetry-is not possible, since thistrimming would place the 3/8” aluminum plate, very, very close to the belt guard.     This difference will not be noticeable—I’m damn glad I checked this out.[There’s more symmetry gauging and checks, I’ll need to create before the fitup on the symmetry fixtures, but that’s not a biggy.....just some things, I’ll need to do, along with some fit verification on the bike frame during the welding of the plates to the mounts.]http://www.weldingweb.com/attachment...1&d=1198295764Above is the left side mount, after additional trimming to clear the clutch cable.Today, Sunday, I made and preliminary test-fitted for clearance, 2 ‘strong back’, 3/8” thick, 5/8” high, formed gussetsto bridge and strengthen the spacing between the 2 mounting hole bosses.  These will both be on the rearwardside of the bosses. There’s not enough room on the front side, for the left mount to have a gusset.....so putboth of them on the rear.           Tomorrow am:-when it’s cool and I’m frosty—I’ll weld these in place, on the mounts.-get 6” wide plate (that’s not-heavily scratched!) for the side plates. I may have the plate, bead blasted just to see ‘how much’ sanding and finishing it will need, prior to machining, since the finished parts cannot have any scratches on them. (As I’ve mentioned, the finished assemblies will be bead-blasted, just prior to powder coating.)-order the silicone pull plugs-custom sized for the mount holes for powdercoating-order additional, extra socket head cap screws for the mounts. I’ve already got hardened, sized, washers for the mounts. The stock washers appear to be soft, which isn’t acceptable.-I’ve got a bolted, hanger system devised for hanging and grounding the mounts for powdercoatingI feel at this point, that I’ve finally got a handle on how this job will proceed!Creating the mockup and symmetry fixtures, makes all the difference.This is similar to how things are done in professional aerospace engineering shops—so they tell me. Attached ImagesBlackbird