BMW Frame Gussets

Discussion in 'Vendors' started by x3300, Nov 20, 2010.

  1. x3300

    x3300 geoff

    Joined:
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    Hi All,

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

    <a href="http://stuff.gotdns.org/bike/orgs-build-up/01-orgs-build-up/gussets-and-patterns.jpg" target="_blank"><img src="http://stuff.gotdns.org/bike/orgs-build-up/01-orgs-build-up/gussets-and-patterns-sm.jpg" border="0" alt="http://stuff.gotdns.org/bike/orgs-build-up/01-orgs-build-up/gussets-and-patterns.jpg"></a>

    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:


    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
    #1
  2. igormortis

    igormortis Long timer

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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.
    #2
  3. x3300

    x3300 geoff

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    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
    #3
  4. igormortis

    igormortis Long timer

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    Whoops - reading and comprehension fail on my part! I actually thought water and wrote laser. :D
    #4
  5. x3300

    x3300 geoff

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    #5
  6. rediRrakaD

    rediRrakaD Whoopdie do

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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.
    #6
  7. Lornce

    Lornce Lost In Place

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    In.


    :lurk
    #7
  8. Beemerguru

    Beemerguru Beemerguru...G/S guy

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

    Greg in Foster City
    #8
  9. igormortis

    igormortis Long timer

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    I'll take one set for sure.
    #9
  10. GESII

    GESII Gerry with a G

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    Between nowhere and somewhere - Hyndman, PA
    I'm in for one set...
    #10
  11. Detroit Steve

    Detroit Steve Homely Adventurer

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    Further...
    In.
    #11
  12. airheadpilot

    airheadpilot Le Poulet du D├ęsert

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    Put me down for a set.
    #12
  13. timdog

    timdog a.k.a. Josh

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    I am interested in a set.
    #13
  14. bgoodsoil

    bgoodsoil Dare to be Stupid

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    I'll take a set.
    #14
  15. walkingbear

    walkingbear Long timer

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    I'm in for a set
    #15
  16. x3300

    x3300 geoff

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    Hi All,

    Its great there's so much interest. Tell your friends!

    I created drawings for the remaining parts and updated some of the existing drawings today. I reduced the drawing size from A4, so printing to US Letter size paper should work better.

    I'll try to get all the parts printed out on paper this week, but I don't know if I'll be able to do much more until after the New Year.

    -x3300
    #16
  17. Beemerguru

    Beemerguru Beemerguru...G/S guy

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    I need 2 sets...welder and powder coat guys are waiting.

    Happy Holidays.
    #17
  18. x3300

    x3300 geoff

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    Beemerguru, as I told you in a private e-mail, I won't meet your schedule, and so you should make your own. Sorry if I wasn't clear about it.

    -x3300
    #18
  19. x3300

    x3300 geoff

    Joined:
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    Oddometer:
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    San Jose, CA
    Hi All,

    Just an update, I got all the cardboard template fittings done and the drawings updated. Some rework was needed for the down tube plate and the front main tube parts. I'm calling these drawings Revision 1. They are close to what will work, but I guess the down tube plate would need some grinding in the front to get it to fit in its place when made of steel. Next is step #3, make steel prototypes, in my list. I've already bought the material and am working on getting the CNC data files and other things prepared.

    I moved the svg files to their own directory on the server: http://stuff.gotdns.org/bike/orgs-build-up/gusset-design/svg/. Note that if you intend to use the files please check the licensing terms in the file COPYING on the server.

    -x3300
    #19
  20. matteo

    matteo HPM

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    If it's not too late I'd like to put in a request as well. I can pick them up. No shipping required. Thanks for you effort in doing this.
    #20