A shot of my solution to what I feared, was a vulnerable (and under-engineered) area for this large, down-tube bike;
the front engine mount. The engine was originally designed to clamp around a solid tube, putting a relatively minor amount of stress on the two (small diameter) mounting bolts. But, with a "hanging-front-mount", a tremendous amount of load is delegated to those two small bolts, (and an aluminum case). Perhaps, they would hold up. ("minimal-mounts" are certainly being used) Maybe I'm
"Captain Overkill", but I began trying to design a mount with more support (and with the help of JB Steel Stick epoxy putty) it evolved into what you see below.
I opted for a "beefy" 3/16" thick steel plate, (2.75" wide X 3.5" long) bent in one place (20 degrees) so both 5/16" U-bolts would be at right angles to the down tube. Here, you can see the engine side of the plate with two bolts, which will act as re-bar for JB Weld, Steel Epoxy Putty which will fill the intended, half round void.
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Now, you can see that the JB Weld epoxy putty has cured after tamping it in the half-round void, with the plate bolted on. (The putty insures a perfect fit) Also visible is the after thought of also installing JB Weld support tabs (also molded around one "re-bar bolt" each. Any surface I didn't want the JB Epoxy to stick to, I waxed.
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The plate installed. Now, you can imagine how much support the JB Weld gives. It takes on the roll of the solid down-tube. It's a pretty simple solution and $6,
well spent.
I finished fiber-glassing (with epoxy AB resin) yesterday. Very happy with the way it turned out. I used the 4 layers of 6oz. cloth, bought at Lowes. (The resin came from Polymer Composites, Inc, from Ontario, Ca) I glassed the tank, (4 layers of cloth) in one session, which was very tricky, as I was always working with very sticky surfaces. (Think, a very thick honey) But, I found if I kept working on another side, the wet side would cure just enough that I could finish the tank in one operation. What I liked about doing it that way, is that rather than having to keep rolling out resin, (with a roller that I didn't have) I'd just lay on another glass cloth piece and the resin would just soak into it.... Very cooperative! (Notice, the sticky tank is supported on thin aluminum supports as I worked on it giving it little surface to stick to)
This morning, man....
that tank is HARD!! The Caswell, will be next, after I melt the foam out.
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After cleaning resin off of my hands, just around midnight, I finished my all aluminum "baffle-box." Originally, I was thinking of just hanging the two baffles from the cut out top of the tank, but it dawned on me that just building a box would be simple, and the most solid design. Here you can see the box sitting on where the cut out will be made (also, enabling me to install a couple of brass gas gauge fittings inside) The box will drop straight down in this position and be pop riveted to the top "door" into those two bent flanges you see here.
You can see the many 1/2" lightening holes allowing a good oil/gas mixture. (THIS IS A NO FOAM ZONE)
Just visions of the future. Mounting details are a bit hazy, with just a general design in mind.... but it will come together. The worst is behind me.
