Today's kitchen
Chuey recently asked about the creative process. What part does it play ? Here's my example ...
I had sketched a design for a pair of brackets that would hold foot-pegs and controls:
But there was a problem
There are two lugs welded to each side of the frame behind the swing-arm pivot
intended to secure those brackets.
The clearance between the two upper lugs and the swing-arm is insufficient for a fastener.
My thought solution was to tap threads into the lugs
such that nuts would not be needed to secure the brackets.
Another problem
The I.D. of the lugs will allow an M8 fastener to slip through,
but is a bit too large to tap M10 threads securely.
... M12 would leave too little 'meat' remaining on the lugs.
The creative process, a.k.a. the solution
A "Time-Sert" is usually used to repair lost threads
but should work perfectly in my situation of an irregularly sized bore.
The process of installing a Time-Sert involves boring the I.D.,
counterboring a slightly larger diameter to fix the 'lip' of the Time-Sert,
tapping threads to secure the Sert, and threading the Sert into place.
The K.I.S.S. principle and the creative process
Well, hell's bells, the foot pegs and controls pivot on a shaft that ends in a 10 mm-1.5 thread !
Why not eliminate the bracket all together and bolt the assembly directly to the frame:
Light-weight alloy plates will next be fabricated to fit between the frame and the foot-controls,
fixed at both the upper and lower lugs.
Essentially one plate will function as a muffler bracket on the shift-side,
and the other as a fixture for the rear brake cable on the brake-side.
To secure these plates, the upper lugs will also be 'Serted' to accommodate 10 mm -1.5 screws.
The pegs are tested jump up & down solid, as sturdy as the factory bits, and ergonomically correct.
Next on the list was a linkage for the shifter.
Solid stainless rod was on hand in the garage from a past project, and so it was cut, bent,
the diameter of the ends reduced appropriately, and then tapped with M6-1.0 threads ...
stock issue BMW clevises were used.
A simple affair and not very creative, I'm afraid. The K.I.S.S. principle rules after all:
