1975 KZ 900 , ZRX Swingarm, 89 GSXR front end

79MKII wrote:

The weld looks much better. Do you have to be careful so you don't weaken the weld?

Great idea to post your process - Thanks!

You are correct you need to be sure you do not grind into the "parent metal".

As long as you give the fillet a big radius some people argue the weld is actually stronger after filleting as it removes impurities and stress risers.

ok trying the picture again..

and again

I ahh well I have this thing about mechanical things and sloppy fits.

Probably went over board here. but I decided to install bushings in the clutch lever, you know they always be floppin around in the wind...hate that!!

I milled the top and bottom of the lever, then bored it out.

Then made two bushings to fit .... and BAM...no more slop!!

I think there is something wrong with me....

Heres what they look like installed....

Very cool! I guess there's something wrong with me too since I like it! :laugh:

tk11b40 wrote:

79MKII wrote:

The weld looks much better. Do you have to be careful so you don't weaken the weld?

Great idea to post your process - Thanks!

You are correct you need to be sure you do not grind into the "parent metal".

As long as you give the fillet a big radius some people argue the weld is actually stronger after filleting as it removes impurities and stress risers.

It is already a fillet weld as you have it drawn your sanding is radiusing the weld. Sanding will make the weld stronger, and depending on the loading to be seen by the weld it would effect how much of a radius you do versus leaving more material behind in a true fillet.

As mentioned sanding the weld down eliminates notches in the weld that would be a likely place for a crack to start. If your weld has cracks in it already, you need to grind it out and re-weld.

Other than that, the swing arm looks great. I've been trying to find something like your that lets me keep the stock rim and shocks without using giant spacers.

Oh boy...Clearly went overboard on the clutch lever and perch. Here is a photo of the finished product.

Bushings.
Bolts drilled out to make them lighter.
Mirror boss milled off and blended to look stock.
Lightening holes drilled into the perch.
Powder coated.
Lever is polished.

Yes there is something wrong with me.:blink:

ok pisture was too big here it is..

Front view....:laugh:

It looks pretty trick man!

Thank you..

Back in Washington now working on the swing arm.

Bladda bladda..

Blending and sanding sanding and blending and blending and sanding and blending and sanding and blending....

My buddies keep reminding me I have been working on this thing for 7 years...

sanding and blending and blending and sanding....

and polishing...

and silly clutch lever ideas....

:laugh: