The front subframe - designed to support the headlight and sidelights whilst holding the instrument panel in position, carrying the headlight ballast pack, mounting the lock-stops & mirrors along with supporting the front fairing. That's a lot of functions for such a small lightweight piece, so lets hope we have got the design right.
The subframe has been extensively re-worked in CAD, due to a number of modifications from the very original piece we mocked up. It's mounted lower on the headtube, to clear the ignition barrel and support the lock-stops better, shorter in length and made from 3mm, rather than 2mm sheet aluminium. It also has provision for the sidelight mounting brackets and a simplified design for the uprights to support the top of the front faring. We also decided to go with a two part main structure which will be welded along the centre, just to make it easier to bend during manufacture.
Lasercut parts returned, so time to bend up each half of the main structure.
Both sides have an interlocking face so they can't possibly be misaligned. This joint will then be TIG welded.
A comparison against the original (modified) subframe.
On the front of the bike with the cross brace fitted to locate the lower mount on the front fairing. We also have the headlight unit fitted. These two elements are key to the structure becoming rigid.
The riders view, with the instrument panel in place. The instrument panel sits on its own mount that is riveted in place and then welded to the two uprights that will come up along either side, where those holes are.
Fairing test fit around the initial parts of the subframe. A little awkard to get everything aligned and where we wanted it. Lock-stops also fitted and limited turning circle achieved!
Next time, we'll get the uprights in place and have this all welded and on the bike with photos.
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