So I had a discussion with the old man about the electrical tray. He gave me some suggestions on how I could improve the section with a radius on it.
So here is Electrical tray version 4.0. The majority of V 3.0 was ok all except the radius and how it mounted to the frame
First I measured her all up again. Except this time I was doing the radius in 3 parts, so on the initial cut out all that is there is the base.
The next thing was at the back of the tray where it angled up and reduced in width I needed to cut the sides shorter to allow it to slip up and under the bike frame.
Next I used a combination of the bench vice and metal bender to start bending it into shape.
This time instead of using rivers which stick out and then need to be siliconed after I decided to use solder.
You have to prep both surfaces, unfortunately there was over spray from the previous tray on the metal so I had to hit that with turps, then wax and grease remover then the flux before soldering.
Next I soldered the sides where the tray angled up. Because in this section the width decreases from 185mm to 170 mm the continues up for another 100 mm at 170 mm wife to the base of the radius. I had to cut the sides then solder in a piece of metal on the inside.
The next thing I did was cut the sides for the radius, it was about 355mm long and 40mm wide plus 20mm for the tabs which I cut out to allow me to bend the radius.(credit to old man Murphy)
Then I used the metal bender to bend the tabs at a 90 degree before bending it then clamping it down. As I bent it I made the tabs go over, under, over, under so it would remain even. Once it was bent I clamped it down then soldered it in place.
I put it in to see how I was going for fit and she was all good, so the next part was the flange that would sit along the top side of the tail hoop ( credit to old man Murphy for this idea).
So for this one I outlined the radius of the tray onto the sheet metal then went an additional 20 mm further to serve as the flange lip and in 20 mm for the tabs. Cutting the tabs on the inside of the radius was a little more challenging to try and keep them all even.
Once all the tabs had been cut I bent them all up at 90 using a pair or pliers, once this was done I put it into place and secured it with clamps before soldering it in place.
I had to trim the flange back a little at the base of the radius on both sides so it followed the bike frame as it tapered down
So that’s version 4.0 still needs to be sprayed but it was too late and I was happy with today’s progress, plus I want to work out how I’m going to run the electrical wires out I’ve bought rubber grommets and flexible conduit. I’ll have to work out everything that’s going in the tray and check what wiring is going to come out.
Still not 100% on battery location but we will see.
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DO THE TON