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That's an idea. Where could a fellow source the aluminum bosses that could be welded to the fork legs? I have all the stuff for aluminum welding...

tenni128 wrote:That's an idea. Where could a fellow source the aluminum bosses that could be welded to the fork legs? I have all the stuff for aluminum welding...

Drill and tap a piece of rod, then cut to length. Easier if you have a lathe.

True Tim, though rather than tapping them out, they could just have clearance holes for M8 bolts. However, the fork legs would need to be set up in a milling machine and have cuts made for the bosses to position in (as per the spacing on the fork brace/mudguard bridge), then welded. the alignment of the forks is critical, and for both practical and cosmetic purposes the mudguard must be at the right height and angle. I believe it would take the combined skills of a good engineering workshop, a good welder and you to get everything right. Also I have concerns that the teflon bearings in my fork lowers could be affected (K100RS 16V forks). Add to this the time to remove the existing bosses, and the fact that a custom fork is difficult to replace after wear, or an accident, it all adds up to a lot of work. I still want to do it though.
Sam

Or, you could source two bottles of whiskey, an aluminum welder and a die grinder and just get it done.

With the tight clearances inside the fork leg, I don't think you would want to be welding on it post-machining. Welding something onto a fork leg before the machining would be fine, of course.

Sorry fellows...been away.
REAL HORNS will help you save all that work you've done so far and possibly your own hide.
It's possible to blip them to "say hello", but when you need to penetrate closed windows and a thick skull, those dual Fiamms do a good job.

Good point, Jean; I'll look into it
WRT to the fork legs...I'll likely just leave them alone, if for no other reason than the fact that repeatability in the case of a crash would be more trouble than it's worth.