Well, I picked up this basket case suzuki intruder last week for around 1K. My plan is to turn it into a bobber in the next 3 weeks, and ride it until I can sell it (and do it again).
Being that I'm a complete noob to machining, the going is slow. I'm sure I could just go buy these parts, but this project is untra-low buck so I've got to use what I can find.
First up, making a strut:
Trim the huge post for the shock off, using the wrong blade on the sawzall = lots of fun
Once I saw'd the post off, it was time to drill/tap it. Well, I bought some used surplus (new?) boeing taps last week. Too bad I had apparently tried to use the wrong drill bit (one size too small) and pop, broke the tap off. Great. That took about 2 hours to finally get out....pregnant dog.
Here is the sleeve, a bit too long now as I had to trim the post down. No worries, it'll still work
Just need to trim it down.
Ouch. Forgot to wear glove when grinding the bevel on the strut. Strut slipped, grinder went into thumb. Blood.
Welded on the bike
I've got to finish the upper sleeve (need a end mill or small boring bar) and weld it. Other side strut is done, and I still need to drill tap the post.
Not sure what to do about finishing the struts. Frame is going to be flat black. I figured I'd paint them, then chuck them back up in the lathe and touch the dimples I made to brighten them up. Might rust then, I dunno.
All in all, took me about 4 hours to make the bits, still have one strut left to finish. Should have another 2-3 hours in it to finish the rigid part of the tail. Next up, lowering the front, shaving the front forks (rear drum only) and getting a seat/mounting it.
Thinking about one of those chopper pans, with some small shocks under it instead of the typical springs. We'll see, thats $$$ (about 3 bills for the seat/shocks). I'm trying to get in/out of this thing for $1500 total.
