T.T billet top brace for Airhead rigs

Discussion in 'Hack Vendors' started by Toaster.Tan, Nov 13, 2011.

  1. Toaster.Tan

    Toaster.Tan Toaster Rider

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    Toaster.Tan billet top brace which fits airheads from 1969-87 with telescopic forks. This will significantly improve handling and stability over the stock, thin piece of flat steel. It takes the flex out of the forks under loads. You WILL notice the difference in handling and feel more positive and planted on the front end.

    Made of 7075-T6 aircraft aluminum and machined in the USA. It's a drop-on with no special tools. It also only has 25 lbs torque on the three top caps and eliminates the need for 70 lbs per spec. A better design and clamping system.

    The three models pictured from top: /5 only,
    /5-/6-/7, GS/GS-PD. The GS model has integral clamp on the ends for the signal pod stem.

    See more photos at the weblink below.

    Thanks for checking them out.
    Stephen

    Attached Files:

    #1
  2. tony the tiger

    tony the tiger Long timer

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    Hi Stephen - I've had one of these on my /6 (solo bike) for years now, and it was an easy mod to install...

    But I think I've only seen one sidecar rig with one installed. :dunno
    #2
  3. MotoJ

    MotoJ Mobtown Hacker

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    #3
  4. Toaster.Tan

    Toaster.Tan Toaster Rider

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    The whole reason I started making them is because of the SJ brace. Two friends had them and wanted me to help install and true the forks. Both braces were out of tolerance to the bike stanchions and in different places! They were machined in Mexico out of 6065 - the lowest grade aluminum you can use for this. I found the SJ braces always crack in the same place when it fails. Not saying they all fail, just that when they do - it's always where the round end meets the top plane at a 90º angle. The design focuses the stress there and they fracture. I recommend if you have one you inspect them by spraying carb cleaner on the underside and clean that angle really good. Then look for cracks.

    Notice I have no curves on the underside and break up the angles where the end clamp meets the plane. This prevents a focused load. The ramp at the front makes it even more rigid. 7075-T6 aluminum is a LOT more expensive.

    I'm getting ready to start another run and am taking prepaid orders now. Let me know if you know anyone wants on the reserved list.

    :D

    Attached Files:

    #4
  5. Toaster.Tan

    Toaster.Tan Toaster Rider

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    That's a shame..... a side car rig REALLY benefits from this brace.


    :puke1
    #5
  6. BMWzenrider

    BMWzenrider The Road Scholar

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    I can attest to that!!!

    When I added one of these braces to my 1982 R100RT based rig (The FrankenBeemer), it was like adding power steering! :clap

    That rig had the stock forks with heavy springs and additional preload spacers as well as both the stock & SanJose double-loop lower fork braces installed.
    While all of those made small improvements, the Toaster Tan top brace made the single largest improvement to the steering of that rig.

    After installing the brace my front wheel finally felt like it was solidly connected to the handlebars, rather than having to "overwind" the bars to get the steering response that I wanted.

    If you have stock forks on an Airhead sidecar rig, you owe it to yourself to get a Toaster Tan top clamp.
    Just do it! :deal
    #6
  7. MotoJ

    MotoJ Mobtown Hacker

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    I can feel the flex in my front end, especially in left handers when I have to muscle the car around 90 dgr turns and stay in lane here in the city. There's enough flex that my stem cap nut actually starts to loosen up every couple weeks.
    Hopefully this top brace will alleviate that?



    #7
  8. brockoli

    brockoli build of cool stuff

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    That is a great looking product. The problem with sidecar use is that it still doesn't fix the amount of trail the bike has. The effort required to steer is still the same as it is with the stock top plate, it's just stiffer, less flexing and it is actually letting the wheel be pointed to where it needs to go. If you reduce the amount of effort require at the actual contact point of the tire, you eliminate the forces needed at the handle bars and it steers with ease, even with a stock top plate. The bike is not seeing near the twisting loads it would, when counter seeing solo, once the trail has been reduced. I like this product, I'm not trying to hijack the thread. If there was one that was made at the new angle that we do our trees at, it would be a win/win. Reduced effort and a more solid top clamp.
    Regards,
    Brock
    #8
  9. craydds

    craydds Long timer

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    Stephen, put my name on the list for the brace for a '75 R90S.
    #9
  10. MotoJ

    MotoJ Mobtown Hacker

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    Hey Stephen,

    Any progress updates? I sent an email and a PM but never got a reply. No hurry, just tryin' to schedule some stuff.

    Thanks
    #10
  11. wirewrkr

    wirewrkr the thread-killer

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    The SanJose clamps have been made in CALIFORNIA, USA for as long as I can remember, they farm them out to a local CNC shop who they have been using for years for all the CNC production work.
    This post is bordering on slanderous. I am actually surprised at you for saying this.
    Pretty chickenshit, in my personal opinion.
    #11
  12. Toaster.Tan

    Toaster.Tan Toaster Rider

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    WIREWRKR -
    I could have been more clear in the context, but that post is part of a longer thread. I started making braces over 12 years ago when the SJ brace had square ends and it was Chris that told me where they were made. I was referring to that time period. The design has since been changed and production moved. I stand by all other comments. I've already had this conversation on another thread and encourage you to read all the responses that go with that quote.

    A person on this forum contacted me last weekend because he had problem with his front alignment. He had a square-end SJ brace and after some 'testing' found the bores were not aligned correctly. I haven't asked permission to use his name - so won't, but the thread is easy to find with current dates.

    Bottom line is that SJ makes a brace - I make a brace. Pick one. Your choice. Leave the foul feces out of it.
    #12
  13. Toaster.Tan

    Toaster.Tan Toaster Rider

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    I sent out an update this morning to my distribution list and will send you a copy. Looks like the validation part passed fit-check and should have some coming off next weekend.

    I trailered my R100GS-PD to the machinist and left it with him as a template & fit-check for the new stuff I'm making, including top plates, multiple height risers, adjustable risers, lower ( above wheel) brace and swing arm torsion bar. Hope to have some prototypes in a couple weeks.

    Ping me off forum if interested.

    Thanks!
    #13
  14. MotoJ

    MotoJ Mobtown Hacker

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    ....on top brace production? How're things coming along? I ould use it in the snow!
    #14
  15. MotoJ

    MotoJ Mobtown Hacker

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    Bueller? Bueller?
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  16. MotoJ

    MotoJ Mobtown Hacker

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    Got my /7 brace yesterday. It's a beautiful thing. Thanks Stephen!
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  17. Toaster.Tan

    Toaster.Tan Toaster Rider

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    I just mailed out the the last of the Standard /6-7 braces and have a few in inventory. Started the /5 and Café, which should finish up this week. Then will start the GS, followed by the Mono. Busy - busy. I can still add to the orders if you want in as the machinist will go back to do 'straggler' set-ups.

    Yup, got a 98 Thunderbolt, which I have an irrational love for. It's on my lift right now getting the isolator mounts replaced, which is a weak point. Since I have to yank the whole ass end off the bike I am replacing the drive belt as the only way to do that is pull the swing arm. Sheesh..... :wink:


    Stephen :D
    #17
  18. Les_Garten

    Les_Garten Been here awhile

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    Any speculation on when the Mono braces will go out?

    Also, will the stock handlebar risers work with your Mono brace till you do the risers you mentioned?
    #18
  19. gfx

    gfx gfx

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    Is it just me, or does anyone else find that both SJ and TT braces are seriously lacking good instruction sets and information?

    From TT Instructions:

    From SJ Instructions:

    Typos and lack of information does not inspire confidence when tackling a project that includes trimming metal. Shouldn't they likely just MAKE some some new ears and include them or make them an option?

    I know this isn't rocket science, and I'm the first one to admit I'm not as mechanically inclined as many of folks on this sweet forum, but if I was a businessman, I'd probably want to appeal to a broader audience.

    I'd really like either one of these products, but in my opinion there is a lot of room for improvement for instructions. San Jose especially looks like someone had to draw one up in under 10 minutes; the most elaborate part of the instructions is the warranty.

    http://www.sjbmw.com/_documents/instructions/32_part.pdf

    https://docs.google.com/file/d/14XQ...G_ssYuOobmSqmJ7Lr2ghEd0hFqWpXwBV9E/edit?pli=1

    See here for how real instructions look:

    http://www.euromotoelectrics.com/v/...ralast installation guidelines_v7.7 11-11.pdf

    I'm not trying to put either company down, I'm just saying as a consumer I'd like a little bit more "feel good" if I'm going to drop $170 on a product.
    #19
  20. MotoJ

    MotoJ Mobtown Hacker

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    Including headlight ears for an old airhead would double or triple the price if they were new. It's just not feasible.
    Get yourself a Dremel for $45 and a cut-off attachment for another $8, scribe the top of the ears as described, clamp them down, and take your time cutting. Clean up with a sharp file. I just installed my new TT brace the other weekend. It took an afternoon, operating at a relaxed pace. Just be methodical and you won't have any problems!
    #20