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Old 07-08-2012, 09:55 AM   #676
kirkster70 OP
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Next up: I trace around the light and tag with a Sharpie.



Using a port-a-band, I cut off the majority of the metal.



Then I use a grinder to radius the corners. I do my final welds while in the vise.



Then I give her some more lovin' with the grinder.



More of the same.





Back on the bike for another look.



I'm liking it.



Well, that didn't turn out too bad. Now for the hard part.

Next up: making a hood over the light for protection, and then using sheet metal to box everything in and to attempt to make it look stock by concealing the OEM mounting area. That should keep me busy for a bit.



A piece of 3/16" x 1 1/2" flat bar goes into the home made brake. I abuse this thing, and it takes it like a pro.



I try to match the angle by eye.



I can work with that.



Now for the radius across the top. I tweak away in the brake's top brace.



I keep checking for fit. It's getting there.



After cutting both ends, I've lost my leverage. Now I use a piece of sprinkler pipe in a vise and a ball peen hammer for fine-tuning.



I can live with that.



Zap-zap. I hear bacon.



A little dressing up on the corners with the grinder, and not too shabby. Hello? Arlen Ness? Can I work for you yet?

kirkster70 screwed with this post 07-08-2012 at 02:39 PM
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Old 07-08-2012, 02:07 PM   #677
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I install 2 rubber gromets; 1 for wiring, 1 for the front mount so that the whole assy. is rubber mounted. I cut another small piece of flat bar for the front mount.



I drill through the front mounting plate, root through my metric bolt junk bin, cut the head off an M10, and weld both sides. I grind the top smooth for clearance, Clarence.

I will wear stick gloves a lot of times just to be able to handle the pieces faster. Chop chop!



Plate snugged down.



I measure, lay out, clamp, then cut with a cutting wheel in a grinder. This is 16 gauge scrap. It was inside a shipping crate for wheels to roll on. Me like scrap.



Make the BRP heavier? Why not. I may need a new rear shock by time I'm finished.



I set my machine for 18 ga. and make a series of tacks after lining everything up.



I take a step back and contemplate my next move. I'm going to try something creative next to make XR owners scratch their heads when they see it. Is that stock?

kirkster70 screwed with this post 07-08-2012 at 02:43 PM
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Old 07-08-2012, 06:33 PM   #678
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I decided to try to get a bit fancy by giving it some shape.



And I tapered some of the width out of it.



Automotive masking paper, tape, and a dark crayon makes a pattern.



R side cut out and tacked in. My garage helper comes along for a brake check! Thanks, little buddy!



Hide your wife, hide your kids - here comes the flying doorstop.

I'm going to do some more tomorrow. One thing's for sure - this doorstop kicked my butt today! I've been messing with this ALL DAY.
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Old 07-08-2012, 07:39 PM   #679
JimVonBaden
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Awesome!

Great to see you back and posting man! One day I really will come up and see you!

Jim
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Old 07-08-2012, 09:11 PM   #680
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Old 07-09-2012, 05:37 AM   #681
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Originally Posted by 100mpg View Post
Kirk, that is ... or should I say, will be an historic piece! After WWIIIIII they will unearth that mask and wonder if it came from space! That is really cool, I wish I had the space and tools to do that. I might have said that a few times already though...
Bravo. Hand paint it...
Don't paint it and it will look like this in a few years. My first art welding project:


You can do a lot of things with an old farm diesel tank, cutting torch, mig welder, and a grinder. And time, lots of time. The wifey wanted a birdbath

And a side view where you can see that the depth goes from a knife edge to about 3" thick.


OK, sorry. Thread hi-jack over. Just wanted to warn you that sculpting with metal can be highly addictive.
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Old 07-09-2012, 07:04 AM   #682
JimVonBaden
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Originally Posted by josjor View Post
Don't paint it and it will look like this in a few years. My first art welding project:


You can do a lot of things with an old farm diesel tank, cutting torch, mig welder, and a grinder. And time, lots of time. The wifey wanted a birdbath

And a side view where you can see that the depth goes from a knife edge to about 3" thick.


OK, sorry. Thread hi-jack over. Just wanted to warn you that sculpting with metal can be highly addictive.
That is awesome! More than just welding skills there. You have the eye!

Jim
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Old 07-09-2012, 07:21 AM   #683
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Its funny ya know, I always pictured you as an older guy...

Hey I gotta laugh at my own jokes, no one else does!

Quote:
Originally Posted by kirkster70 View Post
BUT, I think you have to change the name of this thread from "Rookie wanna be welder starting to make some cool things" to "Expert fabricator builds everything!"
Have you built any bridges or skyscrapers you're not telling us about?
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Old 07-09-2012, 12:31 PM   #684
kirkster70 OP
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Awesome!

Great to see you back and posting man! One day I really will come up and see you!

Jim
Thanks, Jim!

The everlasting scrap pile is at your disposal. Let me know when you'd like to pay a visit.

- Kirk
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Old 07-09-2012, 12:33 PM   #685
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Quote:
Originally Posted by josjor View Post
Don't paint it and it will look like this in a few years. My first art welding project:


You can do a lot of things with an old farm diesel tank, cutting torch, mig welder, and a grinder. And time, lots of time. The wifey wanted a birdbath

And a side view where you can see that the depth goes from a knife edge to about 3" thick.


OK, sorry. Thread hi-jack over. Just wanted to warn you that sculpting with metal can be highly addictive.
Absolutely BEAUTIFUL!!!!!!!!!! Please, hijack all you want anytime you want!!!! NICE!!!!!!!!
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Old 07-09-2012, 12:36 PM   #686
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Originally Posted by 100mpg View Post
Its funny ya know, I always pictured you as an older guy...

Hey I gotta laugh at my own jokes, no one else does!



BUT, I think you have to change the name of this thread from "Rookie wanna be welder starting to make some cool things" to "Expert fabricator builds everything!"
Have you built any bridges or skyscrapers you're not telling us about?

I do look young, don't I? I'm always getting splinters in my feet somehow.



Thanks, buddy!

No expert here. Just a lucky guy with nice playtoys, scrap, and some freetime.
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Old 07-09-2012, 12:51 PM   #687
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Back to the grind. Literally. Yes, the bad jokes continue.



All tacked together. Viewed from the underside.



Looks like something from Mad Max.



I have my MIG set for 18ga, and I just begin leapfrogging tacks to spread out the heat to prevent warping. Once all is a solid weld, I grind most of it away.



All the while I am looking at my creation, I'm thinking - this thing looks like a boat anchor. Let's try to make it look visually lighter while in actuality make it heavier. Holes! Now it matches the tractor! Suh-weet! A hole saw does the trick.



I sleeve it with a piece of E.M.T. (electrical conduit) I cut the EMT with a cutting wheel since neither side is a square cut.



After welding, I grind the outside with a flap wheel and the inside with a die grinder. I like it! This step really didn't take that much longer to do.



I told you XR owners would be scratching their heads. Huh? What is that?



If one hole is good, two has to be twice as good. What the heck. Why not.



Well, it's different. Different is good. Same is boring. - at least to me anyway.



That's all for now. I need to dress up a couple areas with the die grinder, and then shoot some paint. Then I can finalize my wiring and get her ready for inspection.
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Old 07-09-2012, 06:11 PM   #688
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After a good bit of bonding time with my grinder, it's finally ready for paint.



I wish I would have dug around a bit and made it out of aluminum now. I like the unfinished look. Maybe I'll paint it silver to match the frame.



Paint will have to wait until next break. I've got 2 days worth of grinding dust and scattered tools to clean up. Besides, I couldn't stand to see the bike sit for another day. I buttoned her up, and my garage helper and I had some fun in the back yard.



That tiny little part whupped my butt!
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Old 07-09-2012, 07:20 PM   #689
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Damn that thing is bombproof! Looks awesome, great job
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Old 07-09-2012, 07:25 PM   #690
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