I kicked around the hardware store looking for something to use to mount my steel filler panel for my Worksman bike. No luck. So, I figured I'd make my own. I bought 2, 130-165mm (6" worm gear clamp) duct clamps. I was able to make 6 clamps from the 2 I bought at about .50 cents each. And here is how to make them...
Cut off the worm gear and slotted ends, put in about 5/8" of the clamp squared in the vise, bend it 90*.
The frame diameter is 1" so I used a pair of forks that had a 1" diameter tube. Set the tube center and as you push the tube toward the vise as you bend the clamp around the tube.
Remove the clamp and finish bending it around the tube by hand until it meets the other end of the clamp.
Put the clamp back in the vise squared then I added a piece of steel material equal to the thickness of my filler panel, center the tube back into the clamp, and while pushing towards the vise tighten the vise until the clamp is tight around the tube.
Take it out, match it with the other end, mark it, cut it, mark and drill your holes and there you have a perfect fit clamp.
Now if you need to you can trim any excess off after you mock them up. That is why I suggest making the tabs 5/8".
Cut off the worm gear and slotted ends, put in about 5/8" of the clamp squared in the vise, bend it 90*.
The frame diameter is 1" so I used a pair of forks that had a 1" diameter tube. Set the tube center and as you push the tube toward the vise as you bend the clamp around the tube.
Remove the clamp and finish bending it around the tube by hand until it meets the other end of the clamp.
Put the clamp back in the vise squared then I added a piece of steel material equal to the thickness of my filler panel, center the tube back into the clamp, and while pushing towards the vise tighten the vise until the clamp is tight around the tube.
Take it out, match it with the other end, mark it, cut it, mark and drill your holes and there you have a perfect fit clamp.
Now if you need to you can trim any excess off after you mock them up. That is why I suggest making the tabs 5/8".
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