Front end is finished and all fabrication is done!
In this episode we tackle designing and completing the front rack to hold the front bin in place. Last time I left you guys with the beginnings of the front rack but only it as a shelf. This time we put on a vertical rack as a means of attaching and also resting either the front bin or anything else you'd want to strap to and carry with the front rack.
I wasn't really happy with how the right angle was looking at the very front so I cut the two corners off and had to weld them in a way that they looked more pointed towards the front of the bike. This is strictly an aesthetic choice as it doesn't really have any bearing on the cargo capacity. I do think it looks a lot better and flows more with the rest of the bike's look.
After I got that all welded up I moved on to the rear brake. This was a bit more difficult to fab than the front because the area I was working with was much tighter in tolerances. First the disc did not clear the frame, but all that I needed was about two millimeters of clearance. I tried just squeezing the frame rail with a giant clamp and then I tried a vise, and even though this frame is aluminum it wouldn't budge at all. I eventually laid the bike down on its side and took a railroad spike and hammered a dent in it just enough for the disc to clear and all was golden. I thought I had lined everything up correctly but after the first weld-up I realized that I had positioned one of the mount points just slightly too far out of range for adjustment. Unfortunately this meant I had to remove the nut I was using as a mount point and then move it ever so slightly to one side to centralize the caliper over the disc. Once I got that off, it wasn't too hard to move it where I needed it, I spent a bit more time making sure it was just right.
The front brakes were fully welded out and even though I started with them aligned very well, after welding things warped a bit. This was fine as all I needed to do to fix it was blowtorch it and bend it slightly back into position, after that it worked very well. The rear brakes now also worked as I had fixed the alignment issue with those as well, so I was fully done with the brakes and they worked!
Lastly I needed a more permanent mount for the controller. I could place the controller in many different spots, including very tidily in the battery box, however I have some plans to possibly future proof this build and I'll get into that in a later episode. For now I mounted it centrally under the seat which is pretty cool because all the wiring goes directly into the battery box and you won't really be able to see any of the controller wiring, it looks very clean.
At this point all of the fabrication is finished and I can move on to starting the aesthetic transformations!
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⛧ \\ Table of Contents: \\ ⛧
00:00 - Front End Fab
06:28 - Rear Brake Shenanigans
09:11 - Front and Rear Brake Install
12:01 - Controller Mount + Fabrication is Done!
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