tank and bars

[cornishbob]

tank is finall ready to fit

made a set of bars this morning. made to fit my arms. still need a bit of tweeking but you get the jist

[cornishbob]

got the bars and tank (almost) fitted.

bars went on a treat and are a comfy position.

tank is a bit different. bit wierd actually. the bike came with that tank all fitted but in need of a bit of tlc. which i gave it i hope but... theres always a but. on putting it back on the underneath bracket doent fit .

the holes no longer line up . the came off from being mounted  and bolted. ive not done anything to the bracket but when i offered it up yesterday the two outer holes were about a 1/16" (maybe a bit less... didnt measure) out. i didnt recall any issue disassmbling it . i;ll have to look into it but if anyone has a suggestion....

next is to fit the oil tank

[V500]

What did you use to bend the bars?

[cornishbob]

a lot of heat...a lot and a little bitty jig i made up

[cornishbob]

this is the main bit of the jig. SOOOOOOO simple

this bit can be used as is or bolted to a bigger bit of sheet depending on what i'm doing this is the bit where it all happens
just do your measuring from the centre and use a spacer or wharever according to the rad you want. i wanted a tightish bend as it was only 35 degrees
draw out what you want and a bit of triganometry you can get the lengths and angles you need.

be accurate with measuring and measure 20 times bend once. plan plan plan as once bent it stays bent.
plenty of G clamps and bits of angle (to use as stops) and a propane/butane blow lamp (mines a cheapo from B&Q) and you're ready to roll.
remember to heat just ahead of the pivot point as thats where the bending begins

i have used a solid alloy. cant tell you what it is but i have a supply from someone who knows whats what. its lighter and stronger than you might think
if you have a big boys means of heating it up you can use steel tube. you can get those springy insert things like wot plumbers use to bend copper pipe to stop it deforming.

thats about it. once you start and you're organised it doesnt take long and with care and good prep you'd be surprised how accurate you can get things

if you are using alloy use good stuff and dont cool it with water just leave it