Welder World Blog

Posts Tagged ‘motorcycle’

Commercially-made motorcycles are built based on a standard jig to ensure uniformity as they come off the factory production line.  If you are a serious motorcycle enthusiast, why not build your own motorcycle? You can purchase a standard jig from some motorcycle shops.  Remember to check the jig size to ensure it can be used to build the motorcycle of your choice as each motorcycle requires a specific jig and may not be interchangeable.  Test its weld to ensure strength and durability.  Alternatively, design and create your own motorcycle frame jig.  If you’re not sure how to go about it, there are numerous instructional books and manuals with useful tips and pitfalls to avoid.  Do your homework and go through several readily available designs to understand how the jig works.  Ready jig templates are available for purchase from motorcycle accessory shops and websites.  They are normally fundamental as their designers’ intent is for the home enthusiast to try his hand at adding his own touch.  Only if you have the necessary knowledge, skills and experience, you can endeavor to create your own design from scratch.

Try and build full-scale models of the motorcycle frame jig and its components before committing the final design onto blueprint.  Building something from scratch is equivalent to a scientist attempting to make a first discovery.  Failures are inevitable but if you persevere hard enough, you’re bound to find a breakthrough.  Join the relevant discussion groups and forums to get further assistance when you reach a dead-end.  There are many experts ready to advice and share their experiences.  Edison didn’t discover the light bulb by giving up when the first few units didn’t work.

Once you have a proper blueprint of the jig at hand, you also need to design and make the components to be fitted into your customized jig.  If some can be purchased to save time and money, don’t hesitate to do so unless you are insistent on a 100% self-made machine.  As some welding work is required, it is advisable you take a welding course to learn proper techniques.  Once you have learnt the know-how, hire a welding machine.  Purchasing a welding machine may be a significant investment unless you intend to do more welding work in the future.  Alternatively, hire a professional welder to cater to all your welding needs.

Since building a motorcycle frame jig is equivalent to an artist at work, it can be a work never achieving total completion as there is always a reason to fine-tune, modify and improve as you scrutinize and ponder on it.

HOW TO PLASTIC WELD A MOTORCYCLE REAR FENDER

  Using a mini-weld model 6 airless plastic welder

Cost to replace fender-$75.14 + S/H $8.94= $84.09

Cost of repair fiber-flex= $4.00 Steel mesh .50 cents

TOTAL COST OF REPAIR $4.50

So with using a plastic welder. I was able to save $79.59

1) Work Area

Have a clean and organized work area. Well ventilated area. Remember the plastic welder is HOT. Can burn you and start a fire. Just use common sense and you’ll be fine. Set up plastic welder. (Set welder to preheat, how your doing the next step)

2) Parts that need welded

Check the parts to be welded. Identify what kind of plastic your working with. In this case it is fiber-flex plastic welding rod. I used fiber flex because it is easier to use.  I had to cover a large area. Get out the welding rods you’ll be using. Plus if you’re going to use wire mesh for added strength get that out also. We will be using wire mesh for this project. Make sure that the part is clean. ( soap and water should work) Set up part to be welded on work bench. Know how your going to weld it. Now set the plastic welder to heat setting your going to use to weld the plastic fender.

3) Plastic weld part

Lay out part to be welded. I made a V-groove in the crack and filled it with Fiber-Flex rod. Then for added support. I welded the wire mesh in. Now for the big hole. I welded the wire mesh in. I put aluminum tape on the back to help hold the mesh in place. Using the Fiber-Flex  rod begin to fill in the large void. This is time consuming. So take your time. If plastic gets too hot to work with cool it off with water, not too much because your still welding. Do the same thing to the other large hole. And for added support do the same thing to the other side of fender. Now we are done with the welding.

4) To finish the part

let plastic cool down. You can help it cool down with water. Use a spray bottle and lightly spray the welded plastic down to cool. Begin to sand the weld down. I use  60 grit sand paper then go to 180 grit sand paper. If painting part use paint made for plastic. If you would like to see pictures of this operation. Please go to kandjwarehouse.com

THANK YOU

 KANDJWAREHOUSE