Make your Own Sheet Metal Fork Brace - Steve Saunders Goldwing Forums
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post #1 of 46 (permalink) Old 11-22-2009, 12:53 PM Thread Starter
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Join Date: Jul 2005
Location: Baldwinsville, Just Outside of Syracuse, New York, USA
Model: 09 Gl1800
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Fork Brace made of .122” ( 3.1mm ) Stainless Steel Sheet Metal

Modern Day American Indian Craft made by your Friendly Neighborhood Indian “MOHAWK”

We just call it Injun-New-ity… Say it to yourself…. GRIN

I wrote this up so the people that want to make their own Fork Brace can make it or have someone make it for them.

These helped my Bike Handling with "Tar Snakes", and Rain Grooves and Steel Grated Bridges.

Here are the Dimensions I used for the Stainless Steel Sheet Metal Blank:
( With Metric Dimensions for our friends across the pond )

Length = 5.530” ( 140.462 mm )
Width = 2.500” ( 63.5 mm )
All Hole Centers in “X” Direction = 4.560” ( 115.824 mm )
( 4 ) outside .292” ( 7.4168 mm ) Diameter Hole Centers in “Y” Direction = 1.580” ( 40.132 mm )
( 2 ) .810” ( 20.574 mm ) Diameter Clearance Holes from .292” Mounting Holes = .790” ( 20.066 mm )

Below is a picture of the Plate with Dimensions noted.






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File Type: jpg 001-Fork-Brace-Dimensions.jpg (35.4 KB, 1473 views)

95 Aspencade, Dressed to the Nines
Live to Ride - Ride to Live
My 4th Wing with 43 Years in the Wind Now
I have owned over 50 bikes now, This is the longest I have owned only one bike.

Prior USMC Sgt. and Vietnam Vet - Platoon Sgt. and D.I.
PGR Member since 2006 - Serving Those Who Served For Us.

The Native Americans found out what happens when you don't control immigration.
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post #2 of 46 (permalink) Old 11-22-2009, 12:57 PM Thread Starter
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Join Date: Jul 2005
Location: Baldwinsville, Just Outside of Syracuse, New York, USA
Model: 09 Gl1800
Posts: 2,129
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Follow the below Steps to Mount the Fork Brace to your Bike.

First remove the Chrome Front Fork Cover by Prying up the two Socket Bolt Caps.

Now remove the two 6mm x 100mm Long bolts with a 5mm Allen Wrench.

When removing the Fork Cover be sure and not lose the two metal collars that go in the bolt holes and protect the plastic.

Now remove 3 of the 7mm x 17mm Long bolts that go through the Forks into the Fender Stay under plastic Fender.

Important Hint,
If you remove all four Bolts the Fender Stay will drop down on top of Tire and you have to remove many parts to get to
Metal Fender Stay to get bolts back into it. Not fun, Trust me.

If The Metal Fender Stay falls down there is hardly any way to get it back in position to catch the bolt threads without removing the Rear Part of Fender.

I tried Long Screw Drivers, Magnets, The Wife’s skinny hands, Cussing and all kinds of things. And I still had to remove the rear of Front Fender to put the stay back in place.

I chose the rear of front fender, as I have to work on my “Ring of Fire” lights anyway.

Now the four 7mm x 17 mm Long bolts are not long enough to hold an extra .122” thick brace, and you will find that 7mm bolts are kind of rare. I picked up some 20mm Long bolts that are not quite long enough and some 30mm long bolts that are too long.

I took two of the 30mm Long Bolts and cut the heads off to turn them into studs to hand pull the Fender Stay up to help insert the holding bolts.
For Studs even longer bolts than the 30mm length would be great.
I made them studs as you can then slip the brace over the end of studs. Pull up on stud and start one of your hold down bolts.

Pictured Below from left to right, is the Stock 17mm Long Cap Head, a 20mm Long Bolt, a 30mm Long Bolt and the 2 Studs I made to help with installation.


Attached Images
File Type: jpg 002-Stk-20mm-30mm-2Studs.JPG (58.4 KB, 1313 views)

95 Aspencade, Dressed to the Nines
Live to Ride - Ride to Live
My 4th Wing with 43 Years in the Wind Now
I have owned over 50 bikes now, This is the longest I have owned only one bike.

Prior USMC Sgt. and Vietnam Vet - Platoon Sgt. and D.I.
PGR Member since 2006 - Serving Those Who Served For Us.

The Native Americans found out what happens when you don't control immigration.
Mohawk is offline  
post #3 of 46 (permalink) Old 11-22-2009, 12:59 PM Thread Starter
Passed On, R.I.P.
 
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Join Date: Jul 2005
Location: Baldwinsville, Just Outside of Syracuse, New York, USA
Model: 09 Gl1800
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Safety Note. When you cut the heads off the bolts, Don’t be a “Neat Freak”, Leave them on the floor where they fell.
As when you pick them up, It won’t take you long to look at them.



Dem Puppy’s is HOT!!

I also Cut down 4 of the too long 30mm Long Bolts to hold the Brace through the forks into the Metal Fender Stay underneath the Fender.


I cut the Bolts thread length to around .910” long, which is about the stock length plus head thickness as shown.
I just placed the stock bolt next to 30mm long bolt and using my air cut off tool cut them down and smoothed the ends to help with thread starting.






Attached Images
File Type: jpg 003-Cut-30mm_to_910.JPG (48.4 KB, 1328 views)

95 Aspencade, Dressed to the Nines
Live to Ride - Ride to Live
My 4th Wing with 43 Years in the Wind Now
I have owned over 50 bikes now, This is the longest I have owned only one bike.

Prior USMC Sgt. and Vietnam Vet - Platoon Sgt. and D.I.
PGR Member since 2006 - Serving Those Who Served For Us.

The Native Americans found out what happens when you don't control immigration.
Mohawk is offline  
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post #4 of 46 (permalink) Old 11-22-2009, 01:00 PM Thread Starter
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Join Date: Jul 2005
Location: Baldwinsville, Just Outside of Syracuse, New York, USA
Model: 09 Gl1800
Posts: 2,129
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I have a Vise mounted on Workbench in the Work Shop but I jury Rigged this for speed.


It is just a Vise Grip Clamped to my Bike Shed Bench. Worked great for me. More “Injun-New-ity”






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File Type: jpg 004-Cut_Off_Jury_Rig.JPG (63.1 KB, 1309 views)

95 Aspencade, Dressed to the Nines
Live to Ride - Ride to Live
My 4th Wing with 43 Years in the Wind Now
I have owned over 50 bikes now, This is the longest I have owned only one bike.

Prior USMC Sgt. and Vietnam Vet - Platoon Sgt. and D.I.
PGR Member since 2006 - Serving Those Who Served For Us.

The Native Americans found out what happens when you don't control immigration.
Mohawk is offline  
post #5 of 46 (permalink) Old 11-22-2009, 01:01 PM Thread Starter
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Join Date: Jul 2005
Location: Baldwinsville, Just Outside of Syracuse, New York, USA
Model: 09 Gl1800
Posts: 2,129
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Below is a picture of the old style Brace flanked by two of the New Style Braces.


I put a radius on the corners and made the center hole .810” in diameter to clear the Fork Cover.
This larger hole will allow the Fork Cover to fit closer to Fender and be at the stock clearance position.
The old style was made from type 316 Brushed SST and the new ones are made from Type 304 SST.





Attached Images
File Type: jpg 005-Old_Style_Flanked_by_New_Style.JPG (48.5 KB, 1350 views)

95 Aspencade, Dressed to the Nines
Live to Ride - Ride to Live
My 4th Wing with 43 Years in the Wind Now
I have owned over 50 bikes now, This is the longest I have owned only one bike.

Prior USMC Sgt. and Vietnam Vet - Platoon Sgt. and D.I.
PGR Member since 2006 - Serving Those Who Served For Us.

The Native Americans found out what happens when you don't control immigration.
Mohawk is offline  
post #6 of 46 (permalink) Old 11-22-2009, 01:02 PM Thread Starter
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Join Date: Jul 2005
Location: Baldwinsville, Just Outside of Syracuse, New York, USA
Model: 09 Gl1800
Posts: 2,129
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Now with both of your newly made studs screwed in the Fender Stay, you can now remove the last stock 7x17 mounting bolt. I put my studs kitty corner, one on each fork.


Now you can see the stud protrude far enough to let you place your brace over it, Pull up stud by hand and start threading your new mounting bolts in.





Attached Images
File Type: jpg 006-30mm_Stud_Pull_UP.JPG (28.6 KB, 1321 views)

95 Aspencade, Dressed to the Nines
Live to Ride - Ride to Live
My 4th Wing with 43 Years in the Wind Now
I have owned over 50 bikes now, This is the longest I have owned only one bike.

Prior USMC Sgt. and Vietnam Vet - Platoon Sgt. and D.I.
PGR Member since 2006 - Serving Those Who Served For Us.

The Native Americans found out what happens when you don't control immigration.
Mohawk is offline  
post #7 of 46 (permalink) Old 11-22-2009, 01:03 PM Thread Starter
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Join Date: Jul 2005
Location: Baldwinsville, Just Outside of Syracuse, New York, USA
Model: 09 Gl1800
Posts: 2,129
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Below is the New Brace with the longer Bolts with a Stainless Lock Washer underneath each Bolt Head. You can take a flashlight and look under Fender to see how far the bolts go into the Fender Stay.
Perfect would be just flush with end of threads. This would protect the threads in Fender Stay from rusting or filling up with crap. You don’t want the bolts to stick much out of the Fender Stay.




Attached Images
File Type: jpg 007-New_Style_Mounted.JPG (45.7 KB, 1337 views)

95 Aspencade, Dressed to the Nines
Live to Ride - Ride to Live
My 4th Wing with 43 Years in the Wind Now
I have owned over 50 bikes now, This is the longest I have owned only one bike.

Prior USMC Sgt. and Vietnam Vet - Platoon Sgt. and D.I.
PGR Member since 2006 - Serving Those Who Served For Us.

The Native Americans found out what happens when you don't control immigration.
Mohawk is offline  
post #8 of 46 (permalink) Old 11-22-2009, 01:04 PM Thread Starter
Passed On, R.I.P.
 
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Join Date: Jul 2005
Location: Baldwinsville, Just Outside of Syracuse, New York, USA
Model: 09 Gl1800
Posts: 2,129
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Below Note that the Fork Cover that has the stock clearance gap even with New Brace underneath.

Well, This was easy and cheap.

It should also Stiffen up the Front end from that Mushy feeling when you throw the handle bars around from lock to lock in slow turns.




Attached Images
File Type: jpg 008-Stock_Fender-Gap_Still.JPG (42.5 KB, 1326 views)

95 Aspencade, Dressed to the Nines
Live to Ride - Ride to Live
My 4th Wing with 43 Years in the Wind Now
I have owned over 50 bikes now, This is the longest I have owned only one bike.

Prior USMC Sgt. and Vietnam Vet - Platoon Sgt. and D.I.
PGR Member since 2006 - Serving Those Who Served For Us.

The Native Americans found out what happens when you don't control immigration.
Mohawk is offline  
post #9 of 46 (permalink) Old 11-22-2009, 01:06 PM Thread Starter
Passed On, R.I.P.
 
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Join Date: Jul 2005
Location: Baldwinsville, Just Outside of Syracuse, New York, USA
Model: 09 Gl1800
Posts: 2,129
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Here are some extra plates that I am going to carry to the NASSIR 3 in July 2010
for the guys that show up and want them.


I hope this helps somebody to make their own Brace.


C Ya


Mohawk




Attached Images
File Type: jpg 009-New_Style_Waiting_4_A_Home.JPG (53.4 KB, 1319 views)

95 Aspencade, Dressed to the Nines
Live to Ride - Ride to Live
My 4th Wing with 43 Years in the Wind Now
I have owned over 50 bikes now, This is the longest I have owned only one bike.

Prior USMC Sgt. and Vietnam Vet - Platoon Sgt. and D.I.
PGR Member since 2006 - Serving Those Who Served For Us.

The Native Americans found out what happens when you don't control immigration.
Mohawk is offline  
post #10 of 46 (permalink) Old 12-01-2009, 03:48 AM Thread Starter
Passed On, R.I.P.
 
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Join Date: Jul 2005
Location: Baldwinsville, Just Outside of Syracuse, New York, USA
Model: 09 Gl1800
Posts: 2,129
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I have had reports back from 3 members that have installed this Stainless Fork Brace and all reported improved handling.

I only sent 6 out and I know some of the guys were waiting until winter to install the brace to try it out.

So this kinda proves the point that you don't need that massive block of aluminum mounted to do the same thing.

Matter of fact I believe that this Stainless Brace will outperform the aluminum Super Brace in side or transitional twisting forces.

Plus this is a brace anybody can make or have made for them far cheaper than the cost of the super brace.

If I hear from the other three members I will be sure and report here.

I really expect somebody to say he feels no difference.

For myself and all the figure eights and circles I do at idle, I feel a marked improvement throwing the bars from lock to lock while riding.

Mohawk

95 Aspencade, Dressed to the Nines
Live to Ride - Ride to Live
My 4th Wing with 43 Years in the Wind Now
I have owned over 50 bikes now, This is the longest I have owned only one bike.

Prior USMC Sgt. and Vietnam Vet - Platoon Sgt. and D.I.
PGR Member since 2006 - Serving Those Who Served For Us.

The Native Americans found out what happens when you don't control immigration.
Mohawk is offline  
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