Dirt Bike Bracket Pattern Making

[Jigantor]

Dirt bikes are constantly taking dirt samples.
Every time they bite the dirt something gets bent.
Most of the time it is number plate brackets.
The owner dusts himself off and bends the bracket back to its original shape.
After a few sessions fatigue tells the owner it is time to say hi to their local welder.

Ji

[Jigantor]

When the bracket brakes it is always lost so it is difficult to know exactly what was there.
If your lucky you will know someone with a similar model that does not mind you getting some dimensions of the original.

First I mark up the corners or edges.
Then I place some photocopy paper over the top and just rub it with my fingers.
Don't wash your hands as the dirt makes it easy to see all the edges and folds.
Once there is a rough out line I start cutting the paper down to size.

Ji

[Jigantor]

Then I place the cut out over some more photocopy paper and trace all the edges and folds. I add in the turn down flanges and curved section.
To draw the curved area I just use a washer.
Once the drawing is complete I photocopy it and cut out the pattern.
Fold down all the edges and place over the original bracket.
If all has gone well "I hope" it should fit perfectly.
There will be small differences when the folding starts but at this stage at least you have something to go off.

Very happy with the new pattern.
The reason I don't use the original cut out is because I like to keep a pattern in the draw for next time.

Now the pattern can be glued to a steel plate for fabrication.

Ji

[Jigantor]

Life is a bit easier when you have a pattern and certainly faster when you don't have to think.

Ji

[Jigantor]

Fold on the dotted line.

Ji

[Jigantor]

To make the double fold I needed to cut out the overlap.
Then the last fold and hey presto ready for a test fit.
Very happy.

Ready for the TIG.

Ji

[NoogaD]

Dude, it's not exactly the same. Terrible job. Kidding. Skills, man.

[Jigantor]

Drill hole and clamp on the backing nut.
These bikes had square shaped backing nuts not hex.

Ji

[Jigantor]

I then TIG welded up the over lap areas I cut out.

Ji

[Jigantor]

I then wire brushed the bracket and test fit the M6 screw.
Looks pretty good certainly as good as the factory job.

I now have to make a jig to hold it in place on the frame and it can be welded on.

Ji

[cncmachinist]

sweet what you charge for these brackets mine about to go on my bike cool showing the process start to finish i see so much AL used in your projects i started wondering if did any steel at all but this a sweet project

[Jigantor]

Hi CNC,
I charge $75.00 for a bracket.
Most people just buy another bike frame and cut the bracket they need off it and then sell the frame.
This leads to frames without any brackets or not the original brackets.

Ji

[NoogaD]

How long does it take you to make one of these brackets? $75/hr is not to shabby. At my rate, $75/3 days is not feasible.

[Jigantor]

Hi NoogaD,
I took me about two hours to make this one.
So I made a loss on this one but now I have the pattern I can make one anytime I like for a client any where in the world.
I would say I could make one in around 1.5 hours now.
The problem is that people will not pay to much for this type of repair. If you charge to much then they just use a mate with a MIG to weld on a 1/2" plate that they grind to shape and tap a thread into, or as previously stated they just cut the bracket off another parts frame.

Ji

[gordsgarage]

Nice work Ji! Shows what careful planning and perfect execution can accomplish.

Gord