Manufacturing fork ears?

[koolio]

I actually want to have fork shrouds/ears but lower the ears and headlamp 1-2 inches or so.

The Cb500t ears make the headlamp sit quite high. I bought Cb450 K6-k7 fork ears thinking that would do it but unfortunately they are too short by about 2cm when on the bike!

Anyone have any ideas how I can go about this? Perhaps fork ears from another bike, or manufacturing/modification?

Perhaps a skilled machinist/metal worker can weld plate on top of the CB450 fork ears to make up the 2cm distance?

 

[crazypj]

I wasn't happy with what's available so I made my own for 41mm fork tubes

If you want the full shroud, 'unpick' the welded on 'ear' and have it re-welded lower

 

[koolio]

Yes but those are cafe racer style fork ears.

I'm talking about the shrouded versions, like on the original bikes.

I mean taking the below and lowering the arms by an inch.

 

[crazypj]

I added a bit underneath picture, some of the Honda ones have 2~3 spot welds that wouldn't be too difficult to remove. Either braze or weld them
Suzuki and Kawasaki often use parallel tube so can be flipped over to change height

 

[crazypj]

With two sets, it would be real easy to use ears from one set and 'tubes' from second set, that way you don't have to be so careful taking them apart

 

[koolio]

Thanks, I only really have the one set, and if I could do it with one I'd prefer to do that.

Do you think from what you can see there is a way for me to seperate the arm from the tube?

 

[VonYinzer]

Drill the welds out and have them rewelded.

 

[koolio]

Drill the welds out and have them rewelded.

I will have a go and report back, may dremel instead.

 

[neevo]

I wasn't happy with what's available so I made my own for 41mm fork tubes

If you want the full shroud, 'unpick' the welded on 'ear' and have it re-welded lower

PJ? How did you make those fork clamps? Thinking of redoing mine as whilst it looks ok, I would prefer it to be a bit more finished and I think some more time on the CNC could fix that:

 

[crazypj]

I just sketched out something I liked the look of and made it ;D
The clamps are offset to give correct width for headlight (instead of being centered) somewhat 'd' shaped 8)
If I ever find a GSX1100 headlight at a reasonable price I can reverse the clamp direction to get more width