[help] Working with bike materials

Discussion in 'Motorbike Technical Discussion' started by sean_q_, Jun 29, 2010.

  1. sean_q_

    sean_q_ Guest

    Hi, I'm a newbie with only moderate mechanical skills
    and resources. I'm restoring a bent '05 Triumph Thruxton
    and fixing up a '94 Magna V45 with a sidecar.

    As usual, I need to modify some materials (rarely does
    anything I have, buy or scrounge ever bolt right on
    without some futzing and tweaking).

    (1) I have a wraps-back-around-behind-the-signal-lights windshield
    which I need to drill holes in and trim the bottom extensions
    (which collide with the Magna's radiator). However I've found
    windshield material to be very brittle when trying to cut it --
    what's the best way to drill and saw through it? (And smooth
    it afterwards, such as with a file etc?)

    (2) I needed some hard-to-find headlight supports for the Thruxton
    and finally found a pair of chromed muffler support brackets which
    (almost) work. They're basically a long metal bar bent into an open
    ring at one end which (with a slightly larger diameter) would fit
    around my over-the-fork sleeves. An already existing hole
    at the other end fits the headlight's mounting screws.
    Near the ring there's another bend but at too large an angle.
    So I need to expand the ring part and reduce the bend angle.
    How do I go about this whilst leaving the chrome intact?
    I may also have to drill holes through the straight parts.
    Is this possible without causing the chrome to peel away?

    (3) The Thruxton's gas tank has a dent as if the Jolly Green Giant
    punched it. However the dent's contours are all smooth; ie no creases
    or sharp bends. Some Google research found a clever gadget called
    a Ding King designed to fix dents by pulling them out with a glued
    suction cup. Has anyone here ever used one and is it worth trying
    or am I likely to do more harm than good and would I be better
    off taking it to a pro?

    TIA for any help,
    cc rec.motorcycles
    sean_q_, Jun 29, 2010
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  2. sean_q_

    frijoli Guest

    I don't have any specific help, other than joining this
    Triumph site to find parts and advice.

    frijoli, Jun 29, 2010
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  3. sean_q_

    ` Guest

    As I said previously, this is a naive idea.

    The muffler clamps you're talking about were designed to be loaded in
    a vertical plane and you're talking about changing the plane of
    loading from a hanging load to a cantilever load.

    The clamps will probably crack from supporting a cantilever load.

    Furthermore, chroming the mild steel that the brackets were made of
    results in hydrogen embrittlement.

    That's what happens when hydrogen gas bubbles infiltrate tiny cracks
    in the steel being chrome plated.

    To avoid breakage after chrome plating, aftermarket companies who give
    a shit will bake the hydrogen out of the parts in an oven, or they
    will store the parts on the shelf for months before selling them.

    Last of all, there is a problem with hole diameter versus edge

    There should be a minimum of half a hole of steel between the edge of
    the material and any hole you drill in it.

    A muffler clamp that was designed to be loaded vertically probably has
    more than half a hole diameter of material between the edge of the
    hole and the end of the muffler clamp.

    Any additional holes you would drill in the muffler clamps would have
    to meet the edge distance rule cited above to avoid cracking for that
    `, Jul 3, 2010
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