Alloy cutting
 

Hi DD people,

I'm trying to build my own brackets to fit standard SSie rearsets to the Monster. So I've bought that:

http://cgi.ebay.co.uk/ws/eBayISAPI.d...tem=7558489994

Now my problem is I don't really now how to cut it like I'd like to :lol:

I've tried with that tool



But I can't cut it in a straight line. I've also that thing in my garage



but I'm not sure the result will be nice... :D

Any idea? How would you do it?

Draw your pattern on the metal and take it to the nearest metal fabricators and get them to do it for you,explaining whats important,should cost pennies.

use the hacksaw draw a line to follow
take you time and dont loose ya rag , try and do it all in one session and practice makes perfect then break the file out to trim the rought bits

then decide its not good enough and spend even more cash on the real thing

Jig saw is best use a course blade.

Hi guys, i,m currently building a DD bike for next year and am going the same way. The firm that i got the ally sheet from told me to squirt some parrafin on the jig-saw blade while cutting it, stops the blade wearing down. Have'nt tried it yet but he's sure it'll work.

Don't use a grinder Tonio, you can't see the sparks with aluminium and you will damage the heat treatment with the heat it produces.
If you don't take Dave G's very good advice then do the following,

Using a scriber, carefully mark out where you want to cut to.
Now use a hacksaw with a fresh blade to cut just outside the line, really close though. Use plenty of lubricant whilst doing this (WD40 or paraffin).
Once it's cut out, clean the lube off and mount it in a vice with some card packing or similar to prevent damage to the surface of the part, and then carefully file down to your scribe lines.
Use progressively finer files and finish off with wet'n'dry sandpaper to remove scratches from your cut lines.
Put a very slight chamfer on your edges and jobs done.
This will take absolutely ages but if you are careful you can create some very nice work :)

Ideal tool would be a jig saw with the proper Aluminium blade in it.Go through like a knife in butter. Be careful and protect your eyes . 4D

Get the marked out items to me Tonio and i'll do them on the bandsaw at work, same as I did mine.
If you use a 916 style rear brake mount off the engine cases adapting rearsets becomes easier.
As allloy is a soft material compared to some do not use a grinder. Its best to use a coarse cutting blade and a proper cutting fluid. As Fordie says a Jigsaw with the right blade will do the job.
Also use a coarse file when dressing the edges.

And get a good quality paint.........it covers up all the mistakes...the thicker the better!!!!!! I should know ;):D

Tonio 600
u2u me with what you want made as long as its not to big I may be able to help.:saint:

Is half inch thick ally gunna be strong enough? or are you building a new deltabox frame?

:o:lol:

I did it :D :D :D

I bought some new blades for my hacksaw, and it took me 4 hours to cut 2 brackets of the size of a small English sandwich. The result's not bad at all. When I have time I will polish them.

I'm very happy with that because they look tough, and I think in case of a crash I will just have to replace the SSie rearsets, which should be very cheap...

Anyway, thanks all for your help. I'm sure the result would have been much better done by anybody else, but I'm quite proud of me because I did them. I think that's the first time I build something for my bike (ok, except this http://www.ducatisportingclub.com/xm...6728#pid151284 :lol: :lol: ).