BMW Frame Gussets

x3300 · 11-20-2010, 12:37 PM

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:

create the remaining artwork
make prototypes in paper and check the fit
make pre-production parts in steel and check the fit
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

igormortis · 11-20-2010, 11:57 PM

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.

x3300 · 11-21-2010, 12:52 PM

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

igormortis · 11-21-2010, 04:02 PM

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.

x3300 · 11-27-2010, 11:01 AM

Just an update, I uploaded a few more vector graphic files today.

http://stuff.gotdns.org/bike/orgs-bu.../gusset-design

-x3300

rediRrakaD · 11-28-2010, 09:31 AM

Geoff,
I'm in for the group buy and any help I can provide.
Let me know what I can do.
Cheers,
S.

Lornce · 12-07-2010, 02:02 PM

In.

Beemerguru · 12-08-2010, 06:08 PM

How many orders do you need to get this started...I need 2 sets

Greg in Foster City

igormortis · 12-08-2010, 09:07 PM

I'll take one set for sure.

GESII · 12-13-2010, 09:10 PM

I'm in for one set...

SlackerSteve · 12-14-2010, 05:55 AM

In.

airheadpilot · 12-14-2010, 09:14 AM

Put me down for a set.

timdog · 12-16-2010, 10:09 AM

I am interested in a set.

bgoodsoil · 12-17-2010, 10:28 PM

I'll take a set.

walkingbear · 12-18-2010, 07:45 PM

I'm in for a set

11-20-2010, 12:37 PM	#1
x3300 ^OP geoff Joined: Mar 2005 Location: San Jose, CA Oddometer: 169	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. 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: create the remaining artwork make prototypes in paper and check the fit make pre-production parts in steel and check the fit 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

11-20-2010, 11:57 PM	#2
igormortis Beastly Adventurer Joined: Dec 2006 Location: Wellington, New Zealand Oddometer: 1,082	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

11-27-2010, 11:01 AM	#5
x3300 ^OP geoff Joined: Mar 2005 Location: San Jose, CA Oddometer: 169	Just an update, I uploaded a few more vector graphic files today. http://stuff.gotdns.org/bike/orgs-bu.../gusset-design -x3300

11-28-2010, 09:31 AM	#6
rediRrakaD Whoopdie do Joined: Jan 2006 Location: Oaktown Oddometer: 440	Geoff, I'm in for the group buy and any help I can provide. Let me know what I can do. Cheers, S. __________________ RIFF RAFF Industrial Tiki Purveyor

12-07-2010, 02:02 PM	#7
Lornce Lost In Place Joined: Aug 2003 Location: Way Out There. Oddometer: 15,980	In. __________________ Across Canada on a '83 R80G/S-PD Across Canada on a '71 R50/5 My Garage Of Doom *Wear The Fox Hat*

12-08-2010, 06:08 PM	#8
Beemerguru Beemerguru...G/S guy Joined: Nov 2006 Location: Foster City, CA Oddometer: 635	How many orders do you need to get this started...I need 2 sets Greg in Foster City __________________ Greg Hutchinson BMW Club of Northern California, Ambassador, BMW MOA, Vice President Vintage BMW Club http://gregsgssite.shutterfly.com/

12-08-2010, 09:07 PM	#9
igormortis Beastly Adventurer Joined: Dec 2006 Location: Wellington, New Zealand Oddometer: 1,082	I'll take one set for sure.

12-13-2010, 09:10 PM	#10
GESII Gerry with a G Joined: May 2005 Location: Between nowhere and somewhere - Hyndman, PA Oddometer: 96	I'm in for one set...

12-14-2010, 05:55 AM	#11
SlackerSteve Homely Adventurer Joined: Feb 2008 Location: Further... Oddometer: 452	Me too! In. __________________ When you create with your brain, it is work When you create with your heart, it is craft When you create with your soul, it is art

12-14-2010, 09:14 AM	#12
airheadpilot Le Poulet du Désert Joined: Dec 2005 Location: near San Francisco Oddometer: 282	Oh what the hell... Put me down for a set. __________________ Big Ass Titties!

12-16-2010, 10:09 AM	#13
timdog a.k.a. Josh Joined: Oct 2005 Location: Troy, MI Oddometer: 553	I am interested in a set.

12-17-2010, 10:28 PM	#14
bgoodsoil Dare to be Stupid Joined: Jul 2008 Location: Atlanta, GA, USA Oddometer: 3,793	I'll take a set. __________________ '85 BMW r80G/S--Another G/S on the road--Central America on a Shoestring--Nova Scotia on a Shoestring Proud SmugMug User Support ADV: Don't give those cheap bums your discount code

12-18-2010, 07:45 PM	#15
walkingbear Beastly Adventurer Joined: Jun 2004 Location: Scottsdale AZ.. Oddometer: 2,853	I'm in I'm in for a set __________________ BMWMOA 82741 75 R90S ,83 R100RT (Baron) , 88 R100GS ,94 R1100RS (Aragorn) 2k 1150GS w/hack,05 K1200S (Gandalf)

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