A Weld Too Far

Leaving work an hour early was nice.

I rode the BMW down the HOV to Newington where my friend Denis works.  His shop had every tool and equipment item for fabrication I could think of.

First step was to cut off the old frame support.

The next step was to bend the existing hoop to give it a bit of an angle.  Unfortunately this resulted in closing the ends up and not really bending anything.

Next, we bent some smaller diameter bar to support the thin and hollow loop into the frame.  We mocked up the hoop then went and bent the bar to match the necessary angle.

A few tack welds to hold it in place

Then the MIG welding!

(insert video)

After letting it cool a bit, we thanked him profusely and headed back to the garage to get some work done!  I took a stop at Lowes to pick up 50lb of play sand.  When I pulled in, I couldn't resist parking in front of this bumblebee airhead GS

So 50lb extra on one side of a motorcycle is VERY STRANGE

Once unloaded at the garage, he made burgers and I set up the equipment for sandblasting in the yard.

A man can't live on beer alone...for long...so - Burgers :)

I then blasted the engine mounts, kickstand and fenders.

Meanwhile, Matt ground off the existing tabs and smoothed out some of the welds and loose metal pieces.

The frame was sanded again and acetone cleaned.

A little bondo filled in the cracks and small imperfections in the weld area.  He did such a great job welding the issues were mostly our own doing!

We also picked up a piece of foam to later mock up a seat design.  VERY stoked about that.

I was tired and ready to head home.  Matt was drinking and on a ladder preparing the ceiling for wires to hang parts for painting.  With 2-3 hours of drying time required before the bondo sets, it could be a late night getting primer and paint done.   Go Matt Go!!