1. The forum software will be upgraded on Saturday (April 4). During this time the site may be down for a period of time to make the change. Thanks for your patience as we do the work!
    Dismiss Notice

Shortbow

Discussion in 'BUILT FROM SCRATCH' started by tjwilson, Oct 15, 2019.

  1. tjwilson

    tjwilson Pro Member

    Joined:
    Jan 15, 2016
    Messages:
    509
    Rear Brake Revisited #2

    Thanks again @HuffnPuff for the suggestion on changing the calipers. This is what I ended up with. Couldn't find SLX brakes with a right lever without waiting for over a month on delivery. Decided on Deore XL calipers and Base Deore levers. As far as I can tell all I gave up was "adjustment on the fly" at a cost just over half of the XL levers.

    01_newBrakeSystem.jpg

    Here's how the routing worked out.

    02_sideviewOpt01.jpg

    Mounting with an adapter looks pretty straightforward.

    03_detailOpt01.jpg

    However... the size and shape of the XL caliper is just different enough from the first caliper that mounting at the top of the disc is now possible. If I modify the seat support brackets, rotate the caliper a little from pictured, and create post mounts the hose routing cleans up even more. Just need to decide which way to go. To me either looks better than the previous routings.

    04_sideviewOpt02.jpg

    05_detailOpt02.jpg
     
  2. léocwc

    léocwc

    Joined:
    Jan 22, 2017
    Messages:
    294
    this will be incredible:eek:
     
    tjwilson likes this.
  3. kingfish254

    kingfish254 CHECK OUT MY SALE THREAD FOR COOL STUFF! Pro Member

    Joined:
    Aug 31, 2009
    Messages:
    25,775
    Location:
    Historic Savannah
    Just catching up on this masterpiece.
    Please tell me you are going to cross the finish line in time???????
     
    tjwilson likes this.
  4. tjwilson

    tjwilson Pro Member

    Joined:
    Jan 15, 2016
    Messages:
    509
    Thanks. Nope, not going to cross in time unfortunately. I have no idea how build-off time goes so fast! Will get it done eventually.
     
  5. MattiThundrrr

    MattiThundrrr

    Joined:
    Jul 16, 2019
    Messages:
    1,624
    Location:
    America's Friendly Hat
    Regardless of the competition, this is a winner!
     
    tjwilson and sandman like this.
  6. tjwilson

    tjwilson Pro Member

    Joined:
    Jan 15, 2016
    Messages:
    509
    Back to the Seat

    After firming up the direction for the brakes a bit more it's time to get back to the seat. Next step was to modify the template to create a pattern for the seat pan. Basically removing what will be padding from the starting template dimensions and figuring out how to fabricate that in metal. The entire time I was doing that I kept hearing the observations @OddJob had made a little while back. Here's the heart of it:

    All it was going to cost me was a couple file folders, tape and time to chase down his idea and, I knew I couldn't go any further until I did. Thanks again @OddJob. I was thoroughly convinced in the first design. You helped me see it with fresh eyes and I think the overall look is *much* better for the change.

    Seat - First Design

    01_seat01overview.jpg

    02_seat01detail.jpg

    Seat - Second Design

    03_seat02overview.jpg

    04_seat02detail.jpg
     
    Chad T, OddJob, RustyGold and 6 others like this.
  7. The Renaissance Man

    The Renaissance Man __CERTIFIED DIVER__ (Open Water & Open Dumpster)

    Joined:
    Nov 24, 2012
    Messages:
    7,887
    Location:
    The Tropics of Alabama
    Better.
     
    tjwilson likes this.
  8. OddJob

    OddJob

    Joined:
    Mar 26, 2012
    Messages:
    6,759
    Location:
    Maplewood, MN
    Just catching up here now, TJ. I like what you've done with the profile of the seat. Adding that curve to it really ties in well with your other forms / shapes that are created by your custom tube designs.
     
    tjwilson and Dr. Tankenstein like this.
  9. tjwilson

    tjwilson Pro Member

    Joined:
    Jan 15, 2016
    Messages:
    509
    Seat Pan

    Finally getting back to an update... first image shows a comparison of the pan and seat templates.

    01_panAndSeatTemplates.jpg

    Cutting and bending.

    02_layout.jpg

    03_metalCut.jpg

    04_panInitialForming.jpg

    Pan top and template.

    05_panAndTemplate.jpg

    Bending, welding and trimming the sides.

    06_panAndSides.jpg

    07_panSideClamped.jpg

    08_weldup.jpg

    09_weldsCleanedup.jpg

    10_cleandAndTrimmed.jpg

    Additional side shaping and test fit of the pan.

    11_testFit01.jpg

    13_testFit03.jpg

    12_testFit02.jpg
     
  10. tjwilson

    tjwilson Pro Member

    Joined:
    Jan 15, 2016
    Messages:
    509
    Seat Stem Attachment and Rear Light/Reflector Housing Template

    Trying something different with this seat. Rather than having a full inner pan I'm making two separate pieces. One at the front that includes the stem attachment, one at the back that incorporates a housing for either a reflector or light. Haven't decided which yet. I should be able to drill a hole into the rear piece to save a little weight once I decide on the reflector/light placement.

    01_stemAttachTemplate.jpg

    02_stemAttachAndPan.jpg

    03_stemDetail.jpg

    04_tailLightHousingTemplate.jpg

    05_tailLightHousingTemplate.jpg

    06_tailLightHousingTemplate.jpg
     
    RustyGold and Scrap Wolf like this.
  11. tjwilson

    tjwilson Pro Member

    Joined:
    Jan 15, 2016
    Messages:
    509
    Rear Light/Reflector Housing (continued)

    07_tailLightCut01.jpg

    08_tailLightCut02.jpg

    09_tailLightHousingPieces.jpg

    10_preWeldup.jpg

    11_postWeldup01.jpg

    12_postWeldup02.jpg

    13_postWeldup03.jpg

    14_housingRearView.jpg

    15_panAttachments01.jpg

    16_panAttachments02.jpg
     
  12. Scrap Wolf

    Scrap Wolf

    Joined:
    Sep 9, 2015
    Messages:
    46
    Location:
    Amsterdam
    Yes! 3 project updates in a row


    Sent from my iPhone using Tapatalk Pro
     
    tjwilson likes this.
  13. Rat Rod

    Rat Rod Owner & Founder Head Honcho Moderator

    Joined:
    Dec 31, 1969
    Messages:
    18,319
    Location:
    Texas
    :43::43::43::43::43::43::43::43::43:
     
    tjwilson likes this.
  14. MattiThundrrr

    MattiThundrrr

    Joined:
    Jul 16, 2019
    Messages:
    1,624
    Location:
    America's Friendly Hat
    That tail socket is awesome!
     
    tjwilson likes this.
  15. tjwilson

    tjwilson Pro Member

    Joined:
    Jan 15, 2016
    Messages:
    509
    Seat Covering

    Found a chunk of neoprene and some 1/4 inch foam. Good deal at $5 total for both pieces! The neoprene was messy to form but worked out great. The 1/4 inch foam either needed to be more dense or doubled up. Didn't smooth out some of the pan imperfections as much as I would have liked. Especially with a relatively thin vinyl top cover. I'll see how it wears in but I suspect there will be a recover with denser top foam at some point. On the plus side, this turned out to be the most comfortable seat I've built to date.

    01_neopreneAndFoam.jpg

    02_shape01.jpg

    03_shape02.jpg

    04_shape03.jpg

    05_shape04.jpg

    06_shape05.jpg

    07_readyQTRinchFoam.jpg

    08_qtrInchFoam.jpg

    11_topFinished.jpg

    09_bottomVinyl.jpg

    10_btmFinished.jpg
     
    Chad T, RustyGold and Scrap Wolf like this.
  16. tjwilson

    tjwilson Pro Member

    Joined:
    Jan 15, 2016
    Messages:
    509
    Overview Shots with Seat

    With the seat on and a break in the weather I was able to get a test ride in. No brakes or gears so it was a slow ride. The overall handling feels real nice. I've been concerned about the bend in the seat support and how that would hold up to the weight of a rider. I've even purchased thicker wall tubing to re-do it if I need to. So far so good. We'll see how it handles a more vigorous test ride soon enough.

    01_seatDriveSide.jpg

    02_seatNonDriveSide.jpg

    03_seatRear3QTR.jpg

    04_driveSide.jpg

    05_nonDriveSide.jpg

    06_driveSideElevated.jpg
     
  17. tjwilson

    tjwilson Pro Member

    Joined:
    Jan 15, 2016
    Messages:
    509
    Seat Recover

    The longer I looked at the seat the more issues I saw that needed to be fixed. Didn't help that once the seat started to look to me like a giant carrot stuck on top I couldn't get it out of my head! Might regret the color change but had to do something. Been more indecisive with this build than any previously.

    Pulled apart the seat. I initially used hot glue to attach the cover to the pan. Heating the edges with a hair drier made taking it off easier. Added a second layer of the 1/4 inch foam with 3M Super 77 spray. The foam I used had a smooth side and an open cell side. I reversed the top layer of foam, smooth side to smooth side. I was then able to sand and shape the cell side. I then used a thicker vinyl than the original orange. I'm happier with the current results... for now anyway. :)

    01_firstCoverRemoved.jpg

    02_additionalPadding.jpg

    Comparison of the original seat and the new recover.

    03_seatBeforeAfter_01.jpg

    04_seatBeforeAfter_02.jpg

    05_seatBeforeAfter_03.jpg

    Also finished up a little polishing of the reflector housing and stem attachment.

    06_seatDetails01.jpg

    07_seatDetails02.jpg
     
  18. tjwilson

    tjwilson Pro Member

    Joined:
    Jan 15, 2016
    Messages:
    509
    Another Round of Overview Shots with Recovered Seat

    01_overview.jpg

    02_overview.jpg

    03_overview.jpg

    04_overview.jpg
     
  19. Scrap Wolf

    Scrap Wolf

    Joined:
    Sep 9, 2015
    Messages:
    46
    Location:
    Amsterdam
    Do like the new version better.


    Sent from my iPhone using Tapatalk Pro
     
    LukeTheJoker and tjwilson like this.
  20. tjwilson

    tjwilson Pro Member

    Joined:
    Jan 15, 2016
    Messages:
    509
    Handlebar Smoothing, Blending and Polishing

    01_bars.jpg

    02_bars.jpg

    03_bars.jpg
     

Share This Page