Odd Jobs

Have been making slow progress ticking things off the list.

Previously I had the electrical components rattling round inside and had tried to stop this by filling the spare space with rags - less than ideal! So now I decided to make something a bit more secure. There are basically three main components to secure - the fuse box, boyer box, and starter solenoid.

Basically I started by jamming the boyer box and solenoid as far out of the way as possible, I welded a little threaded bung inside the electrics box (with some difficulty!)



Then I fabbed up a little bracket to hold the boyer box in place. In practice I will line it with rubber to help with vibration.



Both items fixed inside, on the same mounting point, nicely tucked in the back corner;



This left lots of room for the fuse box, and it needs lots of room, as its quite tall, and when you have got all the wires connected it makes it wide too! For this I drilled some holes in the bottom of the tank, and turned up some spacers so that the fuse box would sit up high.



So I haven't actually tried wiring it all up yet, but I'm hoping that those changes will help. I also drilled a few discreet holes in the actual frame for running wires through, rather than having zip ties every six inches. But I forgot to take a picture of them.

Next on the list was the steering lock. As the triumph tank is so wide, the top of the forks currently just clash when on full lock. After a bit of testing I decided that some 2mm spacers would be appropriate and I welded them onto the frame.





Last off was to weld up the threaded connections that I had tacked in earlier for the exhaust mounts.







That pretty much concludes all of the fabrication jobs left on the bike. At the moments its all stripped down ready for the next process which will be finishing. Painting, polishing, plating. Before that though things need cleaning up (groan!) so my first job is to take as much as possible for blasting, and then it can be sorted for painting or plating.

Battery box lid

Here is the electrics box as it stands;



Didnt think that there would be much in here, hence the small lid... but I was wrong! And its difficult getting your fingers in amongst all the wiring. So I chopped it out a bit;



Made a much larger lid to fit it. Originally I had welded a little 'lip' in that the lid could sit on so it would be all nice and countersunk, but this time I just made it sit on top... alot easier!



On the bike...



Im going to add a handle, and also mount the internal components to it. Such as the starter solenoid, boyer box, and fuse box. As before they just rattled around and I stuffed the box with padding to try and stop this. Will hopefully make a much neater wiring setup.

Keep ticking things off...

Right, after some fiddling about I decided to make another lid for the battery. Mainly because it would be a fiddly pain in the arse to fasten the leads through the existing lid, but also because I didn't make it deep enough to cover the battery at the back (duh!). So I decided that the best way to fasten the leads through the lid was to avoid it all together, and just give the lid a big enough overhang so the wires can sit under it.

The new lid;







Ta-da! Shouldn't have any problem wiring that up now so I can tick it off the list.

Next up was re-mounting the exhausts. The current set up is poor because the mounting holes are in the wrong place, and also its a real pain in the arse to get fixing in because of the curvature of the exhaust itself. So I decided to mount them in a similar location, but with a vertical tab that mounts to a threaded connection on the frame.

Existing mounts (baaad boooo!!)



Threaded connections tacked in place in the frame



The tabs I made from 3mm steel. I just drilled a large hole for now;



Tacked in place on the bike;



The zip tie you can see is holding the exhaust in position.

Welded up;



When I put the exhausts back onto the bike after welding, the holes didn't line up with the fixing holes on the frame. But I had predicted this happening and made the brackets with plenty of meat so that after a quick grind with the Dremel they fit fine.

Unfortunately my phone ran out of battery at that point so I couldn't take any final pics of it mounted  :(

Battery box lid

Ive been making a lid for the battery box. If you remember I had made a shell for it to sit in but the top of the battery was still exposed. As a bit of a last minute rush-job, my dad covered some cardboard in black tape and we strapped it over the batter to act as a lid.



So I thought it time to make something a bit more finished. I used some 1.5mm sheet to make a lid that had enough clearance for insulation.

Im skipping a bit here but welded and flapper disc'd up;



I have a thin sheet of rubber that I picked up at a show and cut some for the inside;



Obviously as the contacts are on the top of the battery, we dont want it shorting with the box!

I left some extra little flaps of rubber for weather protection;



Just need to figure something out with the connections now, as I cant fit them to the battery as I did previously lol! Need to screw in some sort of extension so that I can fasten the cables securely.

Facey-B

I've finally succumb to popular social media and made a HVC page for facebook (yay!) because im proper down with all the kids and that.

Word.

https://www.facebook.com/holmevalleycustoms