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This a post that I have been asked to make by many forum members. At last I have got around to it.
I have done it in the form of a PDF which can be downloaded from here
https://motochassis.com/FileDump/Frame%20making.pdf
Here are a few photos as a teaser.
Attachment 31360 Attachment 31361 Attachment 31362 Click image for full size.
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Thanks tonyfoale! We've added your Motorcycle Frame Fabrication to our Motorcycle category,
as well as to your builder page: tonyfoale's Homemade Tools. Your receipt:
<div id="blocks"> <div class="block b1 pngfix"> <div class="bimg"> <div> <a href="https://www.homemadetools.net/homemade-motorcycle-frame-fabrication"> <img src="/uploads/226725/homemade-motorcycle-frame-fabrication.jpeg"/> </a> </div> </div> <div class="head pngfix"></div> <div class="left pngfix"></div> <div class="right pngfix"></div> <div class="blockover b1 pngfix"> <div class="title"> <a href="https://www.homemadetools.net/homemade-motorcycle-frame-fabrication">Motorcycle Frame Fabrication</a> <span> by <a href="https://www.homemadetools.net/builder/tonyfoale">tonyfoale</a></span> </div> <div class="tags">tags: <a href='https://www.homemadetools.net/tag/motorcycle'>motorcycle</a>, <a href='https://www.homemadetools.net/tag/frame'>frame</a> </div> </div> </div> </div>
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Fascinating build log Tony, your attention to detail is inspiring. Looking forward to seeing more of your new engine build,
Alan,Quote:
Originally Posted by olderdan
Not much progress on the engine. It was a long hot summer, too hot to spend much time in the workshop. So I tried to stay cool working in my office, catching up on some software upgrades and some workshop related programming and electronic gizmos, as well as preparing a new version of the book.
A year or two ago I bought a 1 micron linear encoder for a cam profile measuring device. it didn't get a lot of use, how many cams does one need to measure? I thought that the addition of an LCD display would let me turn the encoder and its black box into a general purpose accurate comparator. When used for cams there is no need for the display because the data is shunted off to a PC for analysis. I added a switch to change functions from one to the other. Here are some pix.
Attachment 31379 Attachment 31380 Attachment 31381 Click images for full size.
Always curious about brazing. For the life of me, I don't see how it's as strong as welding. Sure is pretty, though.Quote:
Originally Posted by tonyfoale
Steveofthenw,
As Tony explains in his document, brazing has some advantages for fatigue and vibration dampening, as well as not taking so much heat into the tube.
While it isn't as strong as a steel filler metal would be for Oxy-Acet or TIG welding, the weld bead can be larger which helps add additional material to make up for the lower strength, and because it is a lower temperature there is less chance of burning through the thin-wall tubing and lessening distortion, which is pretty critical on a racing bike.
If you have a torch, pick up some flux coated brazing rod and give it a try... it is more like soldering than welding though as you tend to heat the filler metal and puddle it on rather than making a puddle on the base material and dipping into the puddle.
You can use Oxy Acetylene or Oxy Propane or the electric arc on the TIG welder.
Plus, Brazing is just fun welding as well!
Altho I just like welding... especially Tig, and Brazing, and MIG and stick. Not so much on flux core because of all the spatter.
Thanks to Tony for posting that nice write-up, quite helpful for anyone building a frame and would like to minimize distortion and maintain accuracy. Lots of good building practices and helpful tips and tricks.
For tube notching, I prefer to use my abrasive tube notcher, and second choice would be the end milling operation. Hole saws are my last choice... rough cut and hard to creep up on the fit. I have used hole saws on large tubes for fitting 2x3 square up to 2" round with 1/4" wall thickness.
It is the strength of the structure that is important, do not get bogged down with the strength of an individual weld.Quote:
Originally Posted by steveofthenw
This is great, thanks Tony!
Hi Tony, yes I have been aware of the high temperature in Spain & Portugal this year. I once bought a villa in Almeria with the idea of moving there, circumstances at home delayed that for too long so I sold it. The way things turned out I think it was for the best, I do miss the Spanish way of life however but the idea of lounging poolside all day would drive me nuts, I have to have a workshop to keep me sane.Quote:
Originally Posted by tonyfoale
Lounging by the poolside is not a part of my routine, I do not even have a pool. It is not really the spanish way of life either, it is more like the way of life of the northern europeans who move or holiday here. Geriatrics with nothing else to do.Quote:
Originally Posted by olderdan
BTW. the Almeria race track is my all time favourite track.
Congratulations tonyfoale - your Motorcycle Chassis Fabrication Method and Tools are the Homemade Tool of the Week!
Great work! This was another busy week and difficult to win, but this was a clear winner this week.
Some more nice tools from this week:
Pulley Making Setup by liberal
Lathe Slotter by Me2
Welding Gun Spool Modification by Frank S
Stainless Pipe Bender by Let'sLearnSomething
QCTP by celsoari
Pipe and Tubing Welding Jig by Kwandotechnic
Drum Sander by Christofix
Starrett Hole Attachment Adapter by bobneumann
Belt Grinder by Making Stuff
Welding Cart Wheel Modification by Captainleeward
Scrapers by Salix84
Float Lock Vise by Retro Steam Tech
Water Pump by Mr.DK DIY
Thin Wood Slicing Jig by Make Things
Furnace Burner by SculptyWorks
12V Soldering Iron by mariost
tonyfoale - We've added your tool entry to our All Homemade Tool of the Week winners post, and you'll be receiving a $25 online gift card, in your choice of Amazon, PayPal, or bitcoin. Please PM me your current email address and award choice and I'll get it sent over right away.
More importantly, this is your 10th Homemade Tool of the Week win! I've just added the golden wrench-on-pedestal graphic to the awards showcase in your postbit, visible underneath your avatar.
:rocker: :clapping: :thumbsup: :bow:https://www.homemadetools.net/forum/...OfTheWeek1.png:bow: :thumbsup: :clapping: :rocker:
You join these four other 10-time winners: rossbotics, mklotz, Vyacheslav.Nevolya, and Tuomas. Congratulations again and good job :thumbsup:
Here are all 10 of your Homemade Tool of the Week winning tools:
<div id="blocks"> <div class="block b1 pngfix"> <div class="bimg"> <div> <a href="https://www.homemadetools.net/forum/home-made-horizontal-milling-machine-55333#post81620"> <img src="/uploads/162905/homemade-horizontal-milling-machine-2.jpeg"/> </a> </div> </div> <div class="head pngfix"></div> <div class="left pngfix"></div> <div class="right pngfix"></div> <div class="blockover b1 pngfix"> <div class="title"> <a href="https://www.homemadetools.net/forum/home-made-horizontal-milling-machine-55333#post81620">Horizontal Milling Machine</a> <span> by <a href="https://www.homemadetools.net/builder/tonyfoale">tonyfoale</a></span> </div> <div class="tags">tags: <a href='https://www.homemadetools.net/tag/mill'>mill</a> </div> </div> </div> <div class="block b1 pngfix"> <div class="bimg"> <div> <a href="https://www.homemadetools.net/forum/grinding-machine-drum-brakes-55587#post82147"> <img src="/uploads/162657/homemade-drum-brake-grinder.jpeg"/> </a> </div> </div> <div class="head pngfix"></div> <div class="left pngfix"></div> <div class="right pngfix"></div> <div class="blockover b1 pngfix"> <div class="title"> <a href="https://www.homemadetools.net/forum/grinding-machine-drum-brakes-55587#post82147">Drum Brake Grinder</a> <span> by <a href="https://www.homemadetools.net/builder/tonyfoale">tonyfoale</a></span> </div> <div class="tags">tags: <a href='https://www.homemadetools.net/tag/grinder'>grinder</a>, <a href='https://www.homemadetools.net/tag/brake-drums'>brake drums</a> </div> </div> </div> <div class="block b1 pngfix"> <div class="bimg"> <div> <a href="https://www.homemadetools.net/forum/shock-dyno-shock-absorber-dynamometer-56478#post83755"> <img src="/uploads/163993/homemade-shock-absorber-dynamometer.jpeg"/> </a> </div> </div> <div class="head pngfix"></div> <div class="left pngfix"></div> <div class="right pngfix"></div> <div class="blockover b1 pngfix"> <div class="title"> <a href="https://www.homemadetools.net/forum/shock-dyno-shock-absorber-dynamometer-56478#post83755">Shock Absorber Dynamometer</a> <span> by <a href="https://www.homemadetools.net/builder/tonyfoale">tonyfoale</a></span> </div> <div class="tags">tags: <a href='https://www.homemadetools.net/tag/suspension'>suspension</a>, <a href='https://www.homemadetools.net/tag/measurement'>measurement</a> </div> </div> </div> <div class="block b1 pngfix"> <div class="bimg"> <div> <a href="https://www.homemadetools.net/forum/valve-holding-measuring-collet-58294#post87183"> <img src="/uploads/166061/homemade-valve-holding-collet.jpeg"/> </a> </div> </div> <div class="head pngfix"></div> <div class="left pngfix"></div> <div class="right pngfix"></div> <div class="blockover b1 pngfix"> <div class="title"> <a href="https://www.homemadetools.net/forum/valve-holding-measuring-collet-58294#post87183">Valve Holding Collet</a> <span> by <a href="https://www.homemadetools.net/builder/tonyfoale">tonyfoale</a></span> </div> <div class="tags">tags: <a href='https://www.homemadetools.net/tag/valve'>valve</a>, <a href='https://www.homemadetools.net/tag/holder'>holder</a>, <a href='https://www.homemadetools.net/tag/collet'>collet</a> </div> </div> </div> <div class="block b1 pngfix"> <div class="bimg"> <div> <a href="https://www.homemadetools.net/homemade-laser-aligner"> <img src="/uploads/168729/homemade-laser-aligner.jpeg"/> </a> </div> </div> <div class="head pngfix"></div> <div class="left pngfix"></div> <div class="right pngfix"></div> <div class="blockover b1 pngfix"> <div class="title"> <a href="https://www.homemadetools.net/homemade-laser-aligner">Laser Aligner</a> <span> by <a href="https://www.homemadetools.net/builder/tonyfoale">tonyfoale</a></span> </div> <div class="tags">tags: <a href='https://www.homemadetools.net/tag/alignment'>alignment</a>, <a href='https://www.homemadetools.net/tag/laser'>laser</a> </div> </div> </div> <div class="block b1 pngfix"> <div class="bimg"> <div> <a href="https://www.homemadetools.net/forum/double-edged-fly-cutter-63995#post100445"> <img src="/uploads/205514/homemade-double-edge-fly-cutter.jpeg"/> </a> </div> </div> <div class="head pngfix"></div> <div class="left pngfix"></div> <div class="right pngfix"></div> <div class="blockover b1 pngfix"> <div class="title"> <a href="https://www.homemadetools.net/forum/double-edged-fly-cutter-63995#post100445">Double Edge Fly Cutter</a> <span> by <a href="https://www.homemadetools.net/builder/tonyfoale">tonyfoale</a></span> </div> <div class="tags">tags: <a href='https://www.homemadetools.net/tag/flange'>flange</a>, <a href='https://www.homemadetools.net/tag/fly-cutter'>fly cutter</a> </div> </div> </div> <div class="block b1 pngfix"> <div class="bimg"> <div> <a href="https://www.homemadetools.net/forum/homemade-vertical-bandsaw-66678#post108045"> <img src="/uploads/211089/homemade-vertical-bandsaw-5.jpeg"/> </a> </div> </div> <div class="head pngfix"></div> <div class="left pngfix"></div> <div class="right pngfix"></div> <div class="blockover b1 pngfix"> <div class="title"> <a href="https://www.homemadetools.net/forum/homemade-vertical-bandsaw-66678#post108045">Vertical Bandsaw</a> <span> by <a href="https://www.homemadetools.net/builder/tonyfoale">tonyfoale</a></span> </div> <div class="tags">tags: <a href='https://www.homemadetools.net/tag/bandsaw'>bandsaw</a> </div> </div> </div> <div class="block b1 pngfix"> <div class="bimg"> <div> <a href="https://www.homemadetools.net/forum/diy-surface-grinder-67127#post109600"> <img src="/uploads/212251/homemade-surface-grinder-11.jpeg"/> </a> </div> </div> <div class="head pngfix"></div> <div class="left pngfix"></div> <div class="right pngfix"></div> <div class="blockover b1 pngfix"> <div class="title"> <a href="https://www.homemadetools.net/forum/diy-surface-grinder-67127#post109600">Surface Grinder</a> <span> by <a href="https://www.homemadetools.net/builder/tonyfoale">tonyfoale</a></span> </div> <div class="tags">tags: <a href='https://www.homemadetools.net/tag/grinder'>grinder</a>, <a href='https://www.homemadetools.net/tag/surface'>surface</a> </div> </div> </div> <div class="block b1 pngfix"> <div class="bimg"> <div> <a href="https://www.homemadetools.net/forum/radius-gauge-reverse-engineering-70673#post123621"> <img src="/uploads/219843/homemade-radius-gauge-3.jpeg"/> </a> </div> </div> <div class="head pngfix"></div> <div class="left pngfix"></div> <div class="right pngfix"></div> <div class="blockover b1 pngfix"> <div class="title"> <a href="https://www.homemadetools.net/forum/radius-gauge-reverse-engineering-70673#post123621">Radius Gauge</a> <span> by <a href="https://www.homemadetools.net/builder/tonyfoale">tonyfoale</a></span> </div> <div class="tags">tags: <a href='https://www.homemadetools.net/tag/gauge'>gauge</a>, <a href='https://www.homemadetools.net/tag/radius'>radius</a> </div> </div> </div> <div class="block b1 pngfix"> <div class="bimg"> <div> <a href="https://www.homemadetools.net/forum/making-motorcycle-chassis-what-tools-75470#post142830"> <img src="/uploads/226725/homemade-motorcycle-frame-fabrication.jpeg"/> </a> </div> </div> <div class="head pngfix"></div> <div class="left pngfix"></div> <div class="right pngfix"></div> <div class="blockover b1 pngfix"> <div class="title"> <a href="https://www.homemadetools.net/forum/making-motorcycle-chassis-what-tools-75470#post142830">Motorcycle Frame Fabrication</a> <span> by <a href="https://www.homemadetools.net/builder/tonyfoale">tonyfoale</a></span> </div> <div class="tags">tags: <a href='https://www.homemadetools.net/tag/motorcycle'>motorcycle</a>, <a href='https://www.homemadetools.net/tag/frame'>frame</a> </div> </div> </div> </div>
Well deserved Tony, may you get much pleasured use of your new golden wrench.
Thanks for sharing your detailed build Tony. A work of art in its simplicity of design. And to win was the cherry on top. Well done.
Those wheels and drum brakes look very similar to the ones on my 1974 Ducati 350 Desmo cafe racer. By todays standards those brakes were awful when pushed hard with a lot of fade.
Those brakes were magnesium Fontanas. There were several other lookalikes but none up to the same standard. Properly ground drum with the linings turned to fit with Ferodo green linings and fade was not much trouble except in long races on busy tracks.Quote:
Originally Posted by albertq
just a few things I noticed..1 that's going to be hard n the butt. add some cushion to the bars for your butt...2 it must be a very short race as the thing will run out of fuel fast,Im not sure I would want to fill the bars with fuel, but some have done that...3 add a muffler or you will be like me...4 a little wiring might be nice to have if you need to switch it off when you get t a corner and it don't want to slow down,4 add a little paint unless it's stainless... 5 as always don't get hurt or caught or arrested. And make sure it's on video. as always again. Keep up the great work.!! yes it looks awesome those are just a few observations from somebody that doesn't seem to do much any more..!! I have parts for my motorcycle and 4 wheeler, but no desire to do it....the car stuff has worn me out and the brain is starting to fade. but I love looking at your handy work !!!
Just for fun here are a few more pix but somewhat more recent.
Attachment 48555 Attachment 48556 click on images for full size
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The first one. Early 1970s
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