hi i'm paul brodie i'm here with mitch he's behind the camera and this is my shop today we're making
a pair of clip-on handlebars for my little arimac eraser and i've got a bunch of steel here
this is is chromoly and it's going to get welded onto this tube this tube first has to be ovalized
so we're going to do that in the arbor press and then that gets bolted onto the clamp it
gets welded onto the clamp tube and this is going to be at an angle of 10 degrees
then there's the pinch lugs the pinch lugs get brazed onto that so we're going to use
a hacksaw a lathe a milling machine oxyacetylene and tig welder that's what we're doing
we got half inch steel here this is just cold rolled steel nothing fancy
i'm gonna make a pinch lug out of this and i can buy pinch lugs but it's more fun to make your
own and i'm pretty fussy too so i think i make a little nicer pinch like than what i can buy
so i need to face the end and i gotta drill some holes of different
sizes so now i've got a a six millimeter drill and i don't know if you can see can
you see there's a little felt pen mark right there that tells me how far in i'm gonna go i'm gonna
go halfway through the pinch lug and it'll let the six mil allen screw go in and then start to
thread now i've got a special drill which i've i've modified
can you if you want to zoom in on that and you can see how
this is six mil here and so this is the right size for the head of the allen screw
it's a countersink tool and i don't need to hold it in the
lathe or anything i can just hold it with my hand and i can just press and
you can see that i've made a nice little shaft from the inside there
so there we go we have four of the pinch lugs and they're all notched out all mitered to
so it fits on the clamp too
okay there comes the chip can you see the chip in the bottom as it comes through
that's what the tap's doing it's forcing the chip down the bottom
and that's tapped
i've got my tig torch i got a a 16 inch inch tungsten here i've got a
rod it's uh off a mig spool it's 0.35 rod so i want to just put a tiny little
little tic tac right there i'm just eyeballing how far down the pinch leg is
i'm not actually measuring just eyeballs it also helps if you take a pair of side cutters
and if you cut off the very end of the rod it just makes a nice it's a clean start on the rod
okay we are attacked
so they have to be have to be uh abrased now i'll say nickel silver because that's the rod
i'm going to use and it's it's tig tacked on the outside so what i'm gonna do is to
heat up the inside and i'll start on the inside because there's no sense starting here on the
outside if the inside isn't powered we're gonna put some flux on here it's a type b
paste flux from the it's from the gas flux company elriot ohio somehow i always remember that
and this protects the metal a little bit and it also helps the nickel silver to flow
so that's why we put it on there i'm going to wear some gloves safety third
add some oxygen want that neutral flame
a little bit of preheat i've got a 1 16 nickel silver rod in my left hand it's
uh i think it's also called a 773 rod it's very strong for what it is and it flows quite nicely
if you feel it brazing it's not a good thing to use because it doesn't have the kind of
of characteristics you need when you build up a lot of metal but it's very good for small
braisons especially ones that have to be strong like a pinch lugs brake boss things like that
uh
that's one done it gets pretty hot doesn't it you can see the red
okay round two
and that's it switch off acetylene first oxygen second
so on these extension tubes we want the whole thing to be ovalized we want to ovalize it equally
so what i'm going to do is i'll put the tube in the middle like that
and i'm going to put some plates on each end got one plate here and that's a three-quarter inch
plate so is this one this is an inch tube and i i want to take it down a little less than 7
8 which is the od of the handlebar so this is three quarters so what i'm going to do is
i want to have it a little bit higher i'll take a little bit of cardboard put it on each end
i'll use one of these so this is a little heavier tube so it's going to take a little bit more force
that's not going to work like that so we need a spacer
let me put some more leverage on this thing it's a chromoly tube
so it's definitely got some strength to it so i've got this in the right position now
i got a struggling bar that's what this is it adds leverage on to the
there we go so that's squished take all the plates off let me just do the second one now
having the spaces on each end what that means is that
is that both of these tubes now are ovalized exactly the same it's not like one's the size
and the other one's a little little bit different they're both exactly the same
like so
so looks like a couple fish mouths i'm gonna put a tig tack on this side and
then i'll put a tic tac on the other side i'll do the second one and then weld right around
i haven't tig welded for a while so we'll see how i do
here's the color that was stressful in the in the center of the tube is is zero
so i've offset it 3.135 so what i'm going to do is that's why i got so much writing on here
i just take a felt pin i write it on the vice or the table you can see all the scribbles here and
when i do the other side i put the extension tube out the other way and i go to the same
that means that each of these tubes is going to be the same
one left and one right
i've soaked these in hot water and and that takes off the flux and then what we're left
with is a little bit of of blackness from the heat so i think what i'd like to do now is to
have them in the bead blaster and just take that off a little bit and just clean them
up a little bit because that's the easiest stage to do that right now
off the bee blasting you can see what it looks like it's a lot cleaner you can see
if there's any little lumps i've got a little see a little spot there i need anything need
to file off that little bit of braze there sloppy but aside from that it looks okay
i'm just gonna hold this by hand and i'll put a little fusion tack there that's what
i'm going to do because i don't really have any way i can i can i can clamp this onto that
so all that is is just like a little fusion tack i didn't use a rod i just melted one piece
onto the other so i'll take it out carefully because it's not held by much and then i'll
use the rod and i'll put a tack on the other side
one last look to make sure everything is symmetrical and we got the pinch
lugs on the outside we don't have pinch log outside pinch like inside
that wouldn't be good so i think we're going to weld them up now
it's nice welding chromoly and and also seamless you see how it's got a shine to it
if your weld has a shine to it that's usually a good sign
i'm going to hold this really carefully on the pinch like that
not too tight at all and that's all it does it make can you see that in the light
it makes a pretty nice job just takes off the burrs
and there's my handlebars thank you for watching maybe next time