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Offline alanB

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Back Mudguard Bracket
« on: May 11, 2012, 02:45:57 pm »
The little aluminium bracket under my back mudguard keeps cracking.  Which is strange because I dont carry any loads on the subframe (I'm too short to kick my leg over anything mounted there  :biggrin:)

After repairing and reinforcing the original once, which I see has cracked again, I sat last night and drew up a far beefier unit on CAD and took that through to the local Laser cutting/bending shop.

They have quoted me R150 odd with at least a weeks delay (they're quite busy).

If anyone else would like one, say so fast and I'll ask them to make extra's.

My design is 4.5mm thick with far more material around the bolt holes where it normally cracks.

If you want me to post it to you, allow some extra cash for postage.

Alternatively I can send you the CAD file.
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Offline sidetrack

Re: Back Mudguard Bracket
« Reply #1 on: May 11, 2012, 08:36:11 pm »
Mine has not cracked yet but I'm interested  :thumleft:
Little by little, one travels far

J.R.R Tolkien
Ride reports :
http://www.wilddog.za.net/forum/index.php?topic=134175.0 Penge's pass and the Old Forest http://www.wilddog.za.net/forum/index.php?topic=9421.0 - Orange Atlantic adventure http://www.wilddog.za.net/forum/index.php?topic=7514.0 - 805 km day trip http://www.wilddog.za.net/forum/index.php?topic=20260.0 - East Cape Bash http://www.wilddog.za.net/forum/index.php?topic=70199.0 - Two KTM thumpers head north
 

Offline alanB

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Re: Back Mudguard Bracket
« Reply #2 on: May 11, 2012, 09:14:42 pm »
I've attached a pdf print of the design.

Let me know if you whether you want me to get a part made for you on Monday latest please.

Alternatively as I said I can just send you the CAD file.

Husqvarna '09 610TE - Great Bike!

I just finished a SciFi novel Extinction: Task Team, download the preview.
 

Offline sidetrack

Re: Back Mudguard Bracket
« Reply #3 on: May 11, 2012, 09:56:52 pm »
Silly question but will this be welded to the rest of the subframe or bolted ? Have not seen my subframe without the fender.
Little by little, one travels far

J.R.R Tolkien
Ride reports :
http://www.wilddog.za.net/forum/index.php?topic=134175.0 Penge's pass and the Old Forest http://www.wilddog.za.net/forum/index.php?topic=9421.0 - Orange Atlantic adventure http://www.wilddog.za.net/forum/index.php?topic=7514.0 - 805 km day trip http://www.wilddog.za.net/forum/index.php?topic=20260.0 - East Cape Bash http://www.wilddog.za.net/forum/index.php?topic=70199.0 - Two KTM thumpers head north
 

Offline alanB

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Re: Back Mudguard Bracket
« Reply #4 on: May 11, 2012, 10:05:37 pm »
No its just a plug and play replacement for the existing little bracket. 

Remove bolts

Remove old bracket

Insert new one, re-bolt
 
 8)

You just need some extra washers at the back.
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Offline blazes

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Re: Back Mudguard Bracket
« Reply #5 on: May 16, 2012, 11:26:51 am »
What Aluminium are they using A---- if its the right grade i would be interested --- as a spare --R600 plus for a new one ---
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Offline alanB

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Re: Back Mudguard Bracket
« Reply #6 on: May 16, 2012, 02:33:57 pm »
I asked them and they couldnt tell me what grade  :biggrin:  Its aluminium and its 4.5mm thick, thats all we know.

Should be ok, its not a critical part.  Just badly designed with the bolt holes right near the edges. 
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Offline blazes

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Re: Back Mudguard Bracket
« Reply #7 on: May 16, 2012, 03:04:40 pm »
I asked them and they couldnt tell me what grade  :biggrin:  Its aluminium and its 4.5mm thick, thats all we know.

Should be ok, its not a critical part.  Just badly designed with the bolt holes right near the edges. 

Actually it is critical imho --made many products withy aluminium in the past --some are to hard and bend badly thus cracking in no time --some are to soft and will wear out at the bolts or holes .

Thank's Alan
People DON'T Change --we just get to know them better
Current Scooters --

Husqvarna TE 610 --Best Small DS Bike ever --Had two -- Dakota Just bought the one --
Aprilla 750 Dorsodura another DD Another Project Bike in the making 2012 model - Conceived To Thrill  Husqvarna 634 SMR Factory Works Replica --One of 100 in the World -ORGASMIC -  SOLD -To the USA
 

Offline BiG DoM

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Re: Back Mudguard Bracket
« Reply #8 on: May 17, 2012, 07:40:19 am »
Presumably they are /have done the bending too? Do you have a pic of the finished product? Was looking at reinforcing mine.
"Love is the feeling you get when you like something as much as your motorcycle" - Hunter S. Thompson

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Offline alanB

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Re: Back Mudguard Bracket
« Reply #9 on: May 17, 2012, 08:53:47 am »
Ja it will be bent to spec.

Should get it tomorrow.  Sure it will be fine.

As I said its not a critical part so the grade aluminium isn't as important as say the wheel hubs or the fork clamps  or something important etc

Its definitely going to be a lot stronger than the original.
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Offline BiG DoM

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Re: Back Mudguard Bracket
« Reply #10 on: May 17, 2012, 10:19:54 am »
Becomes critical if you have a rear rack that often bolts to it (much said on Cafe Husky re the 630 in this regard). I presently have a small TT rack and 5litre  Krigge bag and all good so far.
"Love is the feeling you get when you like something as much as your motorcycle" - Hunter S. Thompson

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Offline sidetrack

Re: Back Mudguard Bracket
« Reply #11 on: May 17, 2012, 11:46:12 am »
Becomes critical if you have a rear rack that often bolts to it (much said on Cafe Husky re the 630 in this regard). I presently have a small TT rack and 5litre  Krigge bag and all good so far.
Hijack : how did you find the 610 on the bash trip ?
Little by little, one travels far

J.R.R Tolkien
Ride reports :
http://www.wilddog.za.net/forum/index.php?topic=134175.0 Penge's pass and the Old Forest http://www.wilddog.za.net/forum/index.php?topic=9421.0 - Orange Atlantic adventure http://www.wilddog.za.net/forum/index.php?topic=7514.0 - 805 km day trip http://www.wilddog.za.net/forum/index.php?topic=20260.0 - East Cape Bash http://www.wilddog.za.net/forum/index.php?topic=70199.0 - Two KTM thumpers head north
 

Offline alanB

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Re: Back Mudguard Bracket
« Reply #12 on: May 17, 2012, 01:52:17 pm »
Ok whatever.

If you want the CAD file you can get it made out of titanium if necessary  :biggrin:

If anyone's interested I'll send them the file.


Husqvarna '09 610TE - Great Bike!

I just finished a SciFi novel Extinction: Task Team, download the preview.
 

Offline sidetrack

Re: Back Mudguard Bracket
« Reply #13 on: May 17, 2012, 02:03:15 pm »
Ok whatever.

If you want the CAD file you can get it made out of titanium if necessary  :biggrin:

If anyone's interested I'll send them the file.



Hi Alan, can you send me a copy please. Sent you a pm
Little by little, one travels far

J.R.R Tolkien
Ride reports :
http://www.wilddog.za.net/forum/index.php?topic=134175.0 Penge's pass and the Old Forest http://www.wilddog.za.net/forum/index.php?topic=9421.0 - Orange Atlantic adventure http://www.wilddog.za.net/forum/index.php?topic=7514.0 - 805 km day trip http://www.wilddog.za.net/forum/index.php?topic=20260.0 - East Cape Bash http://www.wilddog.za.net/forum/index.php?topic=70199.0 - Two KTM thumpers head north
 

Offline alanB

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Re: Back Mudguard Bracket
« Reply #14 on: May 17, 2012, 02:24:12 pm »
I've attached the Autocad file to make it easier, anyone who wants it just help yourself.

Should have done that right up front I suppose  :P

Edit:

I have removed the file because the final dimensions changed slightly.
« Last Edit: May 24, 2012, 12:51:03 pm by alanB »
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Offline BiG DoM

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Re: Back Mudguard Bracket
« Reply #15 on: May 17, 2012, 06:15:42 pm »
Becomes critical if you have a rear rack that often bolts to it (much said on Cafe Husky re the 630 in this regard). I presently have a small TT rack and 5litre  Krigge bag and all good so far.
Hijack : how did you find the 610 on the bash trip ?

Fooking awesome  :ricky: - the right weapon for the gunfight  :biggrin:
"Love is the feeling you get when you like something as much as your motorcycle" - Hunter S. Thompson

Scoots: BMW HP2  Husky 701R  Husky  TE610E  BMW G450X  KTM 250XCW  Yamaha YZ250X BMW R100S YAMAHA BWS 

 :ricky:
 

Offline alanB

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Re: Back Mudguard Bracket
« Reply #16 on: May 24, 2012, 01:06:50 pm »
Finally got the final part back from the fabricators.



There are some "stretch marks" on the bends - but it doesnt look serious to me - given that its not carrying a lot of load.

We finally went with 3mm aluminium because I was worried that if the bracket was too strong then the subframe would crack instead from the vibration load or whatever is making the bracket crack.  This little bracket is much cheaper and easier to fix. 

They apparently changed the dimensions of the cut-out part so that ot would conform to my specs once bent.  I'm getting their file back from them - hopefully.

I'm thinking about adding gussets to the obvious weak point on the subframe but am in two minds.



I dont really need it because I never carry anything on the back and I'm hesitant because a bad welding job will damage an otherwise undamaged subframe - so its a risk that doesnt seem that necessary other than one can see that without gussets the subframe will probably break at a specific point if any load is placed on it over time.




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Offline BiG DoM

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Re: Back Mudguard Bracket
« Reply #17 on: May 24, 2012, 04:16:07 pm »
Looks good - I would not worry about the gusseting unless you are loading the rack.
"Love is the feeling you get when you like something as much as your motorcycle" - Hunter S. Thompson

Scoots: BMW HP2  Husky 701R  Husky  TE610E  BMW G450X  KTM 250XCW  Yamaha YZ250X BMW R100S YAMAHA BWS 

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Offline alanB

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Re: Back Mudguard Bracket
« Reply #18 on: May 25, 2012, 07:22:57 am »
Mounted the bracket last night.  It fits perfectly

I checked that all the holes etc line up and worked out what was the best way to orientate the little insert washer things that fit through the plastic parts.


The original part had a dog leg bend in it which I didn't bother with.  So I inserted two thick washers as a spacer at the back.


I decided to stick the middle bolt's washer insert in from the outside because that hole in the plastic mudguard was being chewed by the steel thread insert in the subframe.  So I had to use an additional washer there as well.


All in all its much stronger without being much heavier as well as being fairly neat  :thumleft:



« Last Edit: May 25, 2012, 07:24:50 am by alanB »
Husqvarna '09 610TE - Great Bike!

I just finished a SciFi novel Extinction: Task Team, download the preview.