Righto, I got some bucks (almost) finished for the bike over the last two days and shot and posted some videos for the private community member’s Metalworking 2 course to go with it.
I started with the fender, and simply bent out some welding wire into the shapes I liked. Then tack welded them together with the MIG. All the work on the fender here took about 90 minutes – it’s not that long a process. Remember, we had the centre line already in place, so the job was to blend that centre line with the rest of the bike’s structure. And of course, if you don’t like how it looks, just chop and change it.
I got a start on the tank buck, and this one I’m making in both timber and wireframe for the purposes of the Metalworking 2 course. Using Medium Density Fibreboard (MDF) that I had lying around, I traced the centreline wire that I made earlier and cut it out. This I placed on a base board, and used welding wire to form the bottom profile of the tank. I aimed to make it the same width as the rear frame rails – 275mm.
Cutting out one side, you can trace over some folded card and trim the card to the line. When you unfold the card, you’ll have a perfectly symmetrical base which can be transferred to the board.
Trim and sand, then glue and screw the centre rib to the base. The stations on my buck are located at the highest point on the centreline (station 1), the widest part of the tank (station 2) and an arbitrary location towards the read (station 3).
Trim those stations and glue up. This buck will need some fine tuning and sanding but its sitting on the bike in the following shots so I’m starting to get a better picture of it now: