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Or take some measurements, have a local machine shop spin you out a couple stepped slugs to your spec then just cut the garbage out and redo it clean. Be less work and you know what you got when done.
Stepped slugs is my preference but didn't think I could do it now. It means cutting the backbone doesn't it or could I bend / flex it up enough to fit the stepped slugs in?
Last I did was 70's sporty frame, did a 2" stretch in the front legs I made slugs for, stepped part was 5/8" each end so they were 3-1/8" overall. Clamped the frame to a heavy bench then used a small floor jack to tweak open the frame enough to get them in. Frame's will flex a good bit then a couple of 2" ratchet straps to pull it in and squared up tacking the slugs as you go. Few smack's with the heavy hammer and a hardwood block to fine tune it if needed. Chop out that huge gusset you have to rework anyway shouldn't be any issues moving it enough to pop them in.
Done 3 like that over the years. I have used a torch to heat the frame where it meets the Y joint under the seat area but that was a 4" stretch, got a neck rake too so everything got massaged, hot wrench was only way.
Trick is beveling the slug shoulders & frame tubes so the weld gets a good burn in the the clean up so it looks right again. Tig is best for this even if you have to farm it out once you get it all tacked in place.
Last edited by TwiZted Biker; Oct 15, 2022 at 05:11 PM.
Thank you thats how I'll do it, it'll make it a clean repair.
Checked the frame for straightness as per the shop manual, its out an 1/8th on the rear axle clips which is still in spec but I'd like to tweak it and get it on the money. The front is off about as much in the same direction so its a bit of a banana going down the road.
Best thing you can do with this kinda project is heavy workbench bolted down you can clamp or weld to hold the frame solid while getting privitive with it. Takes loads of bad language out of the job. Trip to a scrap yard or surplus place may find something.
New front end arrived. 20 over, 3 degree rake, measures 39" from the underside of the lower tree to the axle. A few of the details on this bike that had to be one way and nothing else would do is the style of springer front end, had to be like a modified original, a king and queen seat is a must and a tall sissybar.
The springer is from Samwel in the Netherlands. I looked into several and busted ***** about specific construction details and I was satisfied with what Samwel had to say. I like that they use forgings like oem (claim to have the original dies) and that they strive to make exact copies but offer them in several lengths and cosmetic combinations to suit the build. I was happy with just black but liked the chrome springs. I may change my mind and chrome the front end but that can happen whenever, if it happens.
Cut the legs off to eliminate the cobbled up area and Im glad we did. The extended legs were butt welded, the new legs are solid slugs with 1" on both ends extending into the tubes. Going to verify straightness, tweak as required then weld the slugs on.
Now everyone knows what I look like!
Kidding, thats not me, I probably have 30 years on that kid.
How you going to weld them in? And nice job on the tubes, proper work there.
Thanks. Going to plug weld in the sides like they do to sidecar loops or the legs in the neck from the factory then weld the seams shut and grind them smooth.
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