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Old 11-20-2010, 12:37 PM   #1
x3300 OP
geoff
 
Joined: Mar 2005
Location: San Jose, CA
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BMW Frame Gussets

Hi All,

As part of my project I made up a set of gussets to reinforce the frame of my BMW R100GS.

http://stuff.gotdns.org/bike/orgs-build-up/01-orgs-build-up/gussets-and-patterns.jpg

I started to make some scalable vector graphic (svg) artwork based on these so others could make their own gussets. What I have ready for release can be found here:
http://stuff.gotdns.org/bike/orgs-bu...gusset-design/
Most browsers and some paint programs can display svg files, so you may be able to print from one of those. The svg files have dimension info so with a good printer accurate templates can be printed, and these templates pasted to sheet metal stock and cut out with a band saw, cut-off tool, etc.

I stopped by the Rustworks Fabrication Shop (http://www.rustworks.com/) in San Carlos, CA this week and talked with Jesse about having some gussets cut using their CNC controlled water jet cutter. The cut quality of the steel sheet samples I saw was really good.

He said the cost is made up of some one time CNC programming fees, essentially to convert the artwork into code for their CNC controller, some per-job setup fees, some per-piece cutting fees, and material fees if you want them to supply the metal stock. He said that he could do volume orders and that the resulting set cost would be significantly less. A conservative estimate would be less than $200 per set, but most likely closer to $100.

Based on the contacts I have received it seems a number of people are interested in reinforcing their BMW frames, so, if anyone is interested in joining a group order for BMW frame gussets, or interested in helping with preparing the artwork please let me know either in this thread or in an e-mail if you prefer. We can also do optional shock absorber mounts and HPN front tank mounts.

The main things to do for the order include:
  1. create the remaining artwork
  2. make prototypes in paper and check the fit
  3. make pre-production parts in steel and check the fit
  4. make final parts and ship orders

Note that these gussets will just be pieces cut out of sheet steel. Some grinding and forming will be required to fit these to the frame during installation.

Also, this is not a money making enterprise. I'm thinking gusset costs will be shared fairly, and shipping will be world-wide and that paid for by the individual.

-x3300
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Old 11-20-2010, 11:57 PM   #2
igormortis
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Just what I've been looking for. Thanks for sharing!

I'd be keen for the vector graphics at the very least, but would most probably take advantage of a group order if you were to have the gussets water-jet cut.

Be interested in an HPN tank mount also. What about the rear mount as well?

Awesome work - thanks again.

igormortis screwed with this post 11-21-2010 at 04:02 PM
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Old 11-21-2010, 12:52 PM   #3
x3300 OP
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Quote:
Originally Posted by igormortis
What about the rear mount as well?
In the rear the HPN tank attaches to the two top main tube gussets, which will be in the set. Some way to secure the bolts is needed though.

-x3300

x3300 screwed with this post 12-15-2010 at 09:17 AM Reason: Remove laser comment
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Old 11-21-2010, 04:02 PM   #4
igormortis
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Quote:
Originally Posted by x3300
I guess laser cut sounds more impressive...
Whoops - reading and comprehension fail on my part! I actually thought water and wrote laser.
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Old 11-27-2010, 11:01 AM   #5
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Just an update, I uploaded a few more vector graphic files today.
http://stuff.gotdns.org/bike/orgs-bu.../gusset-design
-x3300
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Old 11-28-2010, 09:31 AM   #6
rediRrakaD
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Geoff,
I'm in for the group buy and any help I can provide.
Let me know what I can do.
Cheers,
S.
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Old 12-07-2010, 02:02 PM   #7
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In.


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Old 12-08-2010, 06:08 PM   #8
Beemerguru
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How many orders do you need to get this started...I need 2 sets

Greg in Foster City
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Old 12-08-2010, 09:07 PM   #9
igormortis
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I'll take one set for sure.
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Old 12-13-2010, 09:10 PM   #10
GESII
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I'm in for one set...
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Old 12-14-2010, 05:55 AM   #11
Detroit Steve
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Me too!

In.
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Old 12-14-2010, 09:14 AM   #12
airheadpilot
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Oh what the hell...

Put me down for a set.
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Old 12-16-2010, 10:09 AM   #13
timdog
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I am interested in a set.
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Old 12-17-2010, 10:28 PM   #14
bgoodsoil
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I'll take a set.
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Old 12-18-2010, 07:45 PM   #15
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I'm in

I'm in for a set
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