Australian Streamliner Bike Build

[Rex Schimmer]

I too drill a 1/8 pilot hole in the tube and also have made a drill guide to ensure squareness and that the hole is in the center of the tube but then I use a Blair hole saw, which will cut a hole that is about .005 inches larger than the stated size. Very accurate and you can actually do a hole through a tube by drilling the pilot hole through the tube, both sides, and then using the Blair hole saw, which has a 1/8 diameter center guide, cut one side remove the slug and then reach thought the new hole, get the center guide into the pilot hole on the other side and cut the other side hole from the inside of the tube. The Blair saws are expensive but I think they are well worth the investment.

Rex

[Glen]

I have a few drill jigs and use a lot of counter sinks and counter bores. I also have some very expensive aircraft hole saws up to 3" All have different pilots that really help with proper guiding thru tubing with pilot holes drilled thru the tubing, cut slow and good cutting oil.

[twodear]

I didn't see where Jon was needing to make a hole in sheet metal bit since the question came up...if a ragged hole by a hole saw wasn't acceptable, a set of instrument hole punches would be just the ticket. Expensive but quick.

[manta22]

2D;

We call them "chassis punches" here. Greenlee has made them for years. They were originally made to punch holes in radio chassis for tube sockets, etc.

They are OK but they do leave a bit of flaring in the panel-- it isn't completely flat any more. Of course you can get out the rubber mallet and knock it flat. Using a chassis punch on very thin stuff such as 0.020" aluminum causes problems; the clearance in the dies necessary to punch holes in thicker stuff makes them pull the material rather than shear it cleanly. I do use my chassis punches now and then for moderate- sized holes.

Regards, Neil  Tucson, AZ

[Jon]

Thanks for pointing out easy it would have been with a hole saw, proper brain fart there.......

Went down this am to weld up the front suspension rocker support/headstock and realised it looked like it fell off the top of an ugly tree and hit every stick on the way down, cut it off and started again.

Pretty happy with the third attempt, very happy to have the front and back wheel both attached to the frame eventually.







Start on the steering now.

Cheers
jon

[Jon]

Is there something wrong with you if your happy to weld in a tee shirt so you can cover your tyre with your welding jacket?

[4-barrel Mike]

No Harbor Freight in Australia?  http://www.harborfreight.com/catalogsearch/result?q=welding+blanket

Enjoying this build.

Mike

[wobblywalrus]

That is a good decision, Jon.  You will grow back, sort of, if some hot metal gets on you.  The tire would be permanently damaged.

[Jon]

Thanks guys.
No Harbour Freight in Aus Mike, there's a private guy a few blocks from me that does me a pretty good deal.
I'm glad your enjoying the build diary, sometimes I wonder if it's a bit too simple to be of much interest.

My thoughts exactly Bo, back to work tomorrow, others will be showing off their beach tan, I can show them my TIG tan.

Started on the floor today, first section is flat:


Outer sections are curved, just marked of the wide end at 20mm   (3/4") intervals and put a slight crimp from there to the point:


Most of this skinning will be almost flush on the inside so if I'm rattling around a bit I'm leaning on flat panels rather than barwork.

Tonight:


Sorry about the crap lighting.
jon

[salt27]

I'm glad your enjoying the build diary, sometimes I wonder if it's a bit too simple to be of much interest.

jon

I can't speak for others but this build is not too simple for me.

Keep on posting!

   Don

[Dr Goggles]

I'm glad your enjoying the build diary, sometimes I wonder if it's a bit too simple to be of much interest.
jon

I can't speak for others but this build is not too simple for me.
Keep on posting!
Don

Well, we've pretty much not the thick end of this nailed down then. Jon, a year or so ago Don actually managed to trick me into doing something (sitting on the ground while he took a picture of me) , so that's me and him who enjoy the thread but like I said there's Don, and there 's the guy he fooled...

Are you being immodest?....... between the cagey and the unhinged there are few doing this (Bike liners) and documenting it properly. That gives me hope for a couple of reasons. One is that anyone who skims over your build diary with the faintest thought that they might want to do something similar will get a pretty quick idea that they have some serious reading to do, two is that you have assembled a pretty hard headed and experienced email list that puts you at the centre of an info cabal that means just a casual email enquiry from a stranger can be answered with a certain authority because the people that matter are only one or two degrees of separation away. You're doin just fine, and we're all lovin it.....................

[salt27]

That darn Gus took the picture, watch out for him, he is ruthless.

There he is front and center, look at that evil grin.


   Don

[Dr Goggles]

Never said he wasn't smart or ruthless( after all he can weld with his backside)........which makes me think you must have one hell of a smart wife Don, and I'm guessin she's a looker too....

[Jon]

Thanks guys
I look at some of the other builds going on, a mada$$ supercharged flat Cad that looks like he's going to tip the can, Robfreys rocket ship, an aero quality Mid engine, a Mowog that has a degree in engine science and I post another bent tube or piece of tin.

I'm enjoying it anyway.
jon

[tauruck]

That Tig tan will pay dividends. It's looking good, your build. We haven't seen the tan though.