In this episode we'll install a set of forward controls on this triumph motorcycle.
Hey folks, I'm Custom Cez for Roma Custom Bike and I welcome you back for this motorcycle
fabrication video: the installation of some custom forward controls on a Triumph boneville.
By the end of this project we'll have made this…
A custom support made from scratch that we'll use to install the forward controls…
While we are at it we'll move the original brake pump…
And we'll bleed and re-set the brake hydraulic system.
It will be a heck of a job, so stick around to the end!
As you can see we have already modified this bike quite a bit, starting from the lowering
of the seat and restyling of the entire tail of the bike.
My girl is right next to her to keep morals up before surgery.
Let's start by understanding exactly what we'll do:
What we have is a universal forward controls kit we bought a while back, but to make it
work we have to fabricate some sort of bracket that will position the foot pegs in the right
place.
We'll use these four bolts, set by the factory for "I don't know what", to connect
our structure to the frame and make it rigid enough.
I can visualize the project by gesturing but for you guys…
I've prepared some visual aid…
The factory brake control is here… but we want it here… so, along with it, we'll
also need to move the pump and the oil reservoir that here you can see in its original position.
The same on the other side, the shift control needs to go from here… to here.
Using only some round and flat stock and a bit of creativity you can achieve some pretty
amazing results, everything of course, in full Roma Custom Bike style.
Being this a quite elaborate project I've summoned the great Polsky Rage!
He's great welding and metal shaping skills will be extremely valuable for this project.
While I get to work removing the brake pump we'll need to relocate along with the lever…
Polsky Rage begins evaluating how to fabricate the plate that will support the entire structure.
After getting all the necessary measures he starts drilling the mounting holes on the
drill press.
He starts with a smaller drill bit and increases the size until he reaches the desired diameter
hole.
As soon as we put it on the bike to check the alignment we realize that it needs to
be further out not to interfere with the frames down tubes.
This piece of 10 centimeter stock is just the right thickness we need and its strong
enough to guaranty structural support.
A couple of spot weld will ensure they stay in place while we work on them.
Drilling through this thick stock is turning out to be a lot for my small drill press,
but Polsky has his own way to refrigerate the drill bit… nothing works better than
good old beer.
You never stop learning in life!!!
Now that we have a solid base to build on, we can start building what until now have
been only air sculpting and wishful thinking.
It's time to get this stuff done for real.
And it doesn't get any realer than 18 millimeters thick round stock and 8 millimeters thick
flat stock.
I think that even with the long reach we are going for the structure will be plenty strong.
After deciding how far out we want to place the controls, Polsky Rage cuts down the round
stock to size… and he welds them together.
He brought them already bent because in his work shop he has a bigger vise needed to bend
them at 90 degrees.
Not knowing how we would actually use them he left them long.
Now that we know a bit more about our structure he can cut them to size and weld them so to
form something like a letter C.
Those of you that have watched this series for a while know that in the shop we have
both a TIG and a MIG welder, but for this project be decided to go for stick welding
to prove that even with cheaper equipment you can achieve good results.
After a bit of cleanup of the welds the bars are ready.
I mark up the middle of both the bars… and the plate, so that we can align them together.
With the help of a big magnet and a level we make sure everything is in position to
spot weld it in place.
Pain is part of the fabrication process, how they say: "no pain, no gain" or "stop
burning my mother effing arm bro!"
Anyway… after the first tack weld we still have a bit of movement to play with and adjust
things before the next tacks.
The same process went into the second support.
Before continuing with the work I have some pretty amazing news to tell you.
Starting in September we will launch the new DIY web series called "Roland Master Maker".
With the valuable support of Roland DG Mid Europe that have given me free access to their
equipment, from the printers to the mills, and to their knowledge and support base, in
each episode I'll explore DIY manufacturing projects that span outside of the motorcycle
realm.
This will allow me to document projects of larger interest bat that retain that "Roma
Custom Bike" spirit.
So don't forget to subscribe and click the little bell so that you'll receive a notification
as soon as I'll post a new video.
Thank you Roland for this great opportunity and a special thank s goes to you guys for
helping me get to this point!
Now, let's get back to work.
Now that we have something tangible to look at I need to check if we are going the right
way or we need to adjust things around, so I jump on the bike and see if the position
is ok or if there is something in the way or reaching the foot pegs.
It seems ok.
We try to figure out how are we going to fabricate the surface onto witch the foot pegs will
bolt onto and Polsky Rage suggests we weld the plate between the upper and lower support
and then give it a diagonal cut to finish it off.
For the brake side we decided to use the plate to support both the control and the brake
pump, we just don't know how yet… hehehe
So, we take everything a part and we are right back into the shop.
To better execute Polsky's idea, He decides to remove the top support to weld the plates
in and there is nothing better than slow motion to watch a spark shower!
Very hypnotic guys!!!
But I'll tell you, welding in slow mo looks good too!
All right, that's it for the slow-mo brake!
Let's get back to work!
Polsky Rage begins welding the first plate.
The project itself is not that complex, but the difficulties arise when it comes to precision
and alignment.
So to make sure the result will be top notch, he checks the level of each piece many times
before welding.
Didn't I tell you that this guy's skills would have come in handy or what?
Once satisfied with how things are, Polsky cuts out the extra material and, using a grinder,
he shapes the cut so that it follows the curvature of the bend.
The same is done for the brake side with the exeption of the shape of the plate that will
need to hold the brake pump and the oil reservoir.
Polsky gets all artistic in this side too and shapes the plates to fit in with the contour
of the round stock.
Every detail is so important for the final result!
Even in a simple project attention to detail is what can really take it to the next level.
Now that the plates are in place we can weld back on the top C bar.
The double tube design is both for strength and rigidity and to match the double tube
design we did under the seat when we lowered it.
Once again: details.
They are important!
The structure finds its way back onto the bike and after drilling he hole for the actual
foot peg we try to figure out how are we going to secure the brake pump.
It has to be roughly here…
Initially we wanted to extend the plate to support the pump… but Polsky thinks it will
look better if we extended the round stock.
It will give it a cleaner look and it will place the pump in the right spot.
Once we made the decision the part is back in the shop for welding.
Easy peasy for the great Polsky Rage!
The beauty of post-production is that with a blink of an eye the part is back on the
bike and while Polsky works…
I sjow my level of maturity… hahaha We check the pump's position one more time
and we can finish it up.
Two screws welded directly on the fame will make the pump very easy to install and service.
We take some measurements because we are repurposing the original brake link but it needs to be
shortened and re threaded.
Everything is coming together and it seems to work good!
Good!
Now we need to find a spot for the oil reservoir and while our camera operator is busy taking
this astonishing floral time lapse, very beautiful, we have already figured out where and how
to put it.
But we can document the finishing touches.
Last assembly for the brake system,,, I hope, and everything seems to work.
Keyword "seems"…
But I have to say that we are kicking ass…
Polsky Rage is a true master of fabrication.
Now that the brake side is done we need to take care of the shifter side, but for that,
along with the painting and the finishing touches that include the bleeding of the brakes,
you'll have to wait for part two of this episode.
I'd like to invite you to subscribe to the channel, click the like button and to check
out the other videos of the series.
I'm Custom Cez for Roma Custom Bike and I'll see you next time.
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