With the main tubes of the rigid fork in place, we get started on the trees that hold the spring assembly in place on the rigid forks. The picture below demonstrates the difference between theory and reality. The theory is that we need something that looks like the drawing. The reality is that we have a piece of plate.

We start by drilling holes for the tubes of the 1-1/4 rigid forks and the 1-1/4 bushings of the spring rods.

I like to do any machining while the billet is still square since the final shape is mainly for aesthetics. Measurements for quality checks are fourteen million times easier to take when measuring against a straight or square edge. Below is the drilled plate with lines drawn for plasma cutting for shape and to clear the steering neck.

Here is the plate with a very rough plasma cut done (heavy plate is tough to do free-hand).

And, ground and sanded (CNC plasma-cut version available on the site).



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Man alive - I'm ready for some cuttin', hackin', welding and general mayhem with Big Daddy. Oh yeah, and a little ink too...

Hey - you can visit Big Daddy and his crew online at:
http://www.bitterend
choppers.com

...tell 'em Warren sent ya.