Project started October 2023,

 

For the forks we started with a reproduction Indian girder, as we planned to modify it anyway. Would be a shame to cut up an original. Upon closer inspection the quality was pretty bad so we will either fix it or make a new one. At least I was able to get all the basic dimensions from it. As we needed longer legs we started with them.

 
 

I made some CAD drawings of the dimensions we would need, and we started by cutting some thick wall tubes in half, 25 mm outer diameter with 4 mm walls. Using my drawings we made a fullsize cardboard template for the sides. These were then cut out from 4 mm steel strip using the Doall bandsaw.

 
 
 
 

Using the sideplates as a template the halftubes were bent to match them. After tacking all together Aad ground out the gaps to get nice deep weld penetration and after cleaning the welds we had some sexy looking legs!