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Discussion Starter · #1 ·
Just an easy DIY clamp for many applications.
When I first wanted to build a fighter was very displeased with the selection of clamps for fork mounting a headlight. The nice billet were lets just say not worth the price to me, or back ordered and still pretty high dollar wise for what you get.

I found the stock at Lowes. Thin easy to work with no heat needed.
It comes in Various width, so you can pick and choose what you need.







It doesnt have to be thick to clamp on and hold. The trick is in the Bend.
I first used a PVC pip as my mold to bend. took my micrometer and measured my forks and then went and found a pvc pipe slighlty smaller in diameter. Remember its a clamp and you want a tight fit. This stuff will rebend as you tighten it to fit better.

Cut your length you want. (this was scrap I had laying around) Make the cut slightly longer than you intend, you can trim it after but too short and your laser guided fingers will always make it off.



I ended up buying a set off cut off fork legs for some caps and adjusters so lucky me have exactly what I need to bend now.


Measure and clamp in the center for a guide.


Bend as evenly as possible



Clamp ends together to bring everything in straight.



Clamp with vice or c-clamp
You can sand and buff any marks out later. Or use a smooth face vice jaw. You can make those with the same stock just a little wider.



Clamp is made , so before you take it out of the PVC and unclamp everything, now would be a good time to drill a hole for bolt and nut.


Here is a set I made for my headlight. Im thinking of redoing it with a smaller width now.

I put the trimmed and bolted end in the inside and it is rock stable with the forks. Also used the same method fot an overflow bottle.

A lot easier to make the stuff as needed versus finding the correct diameter everytime.

Hope this helps someone.
 

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Discussion Starter · #4 ·
And very easy to do for anyone, with an unlimited amount of applications.

No heat needed with the thinner aluminum, I started with a thicker piece that I had to heat. Its a clamp the strength is in the width of the metal not the thickness for this application. I went through a ton of flat stock learning this , heating and bending and then bought the thin stock lowes/home depot had.

Clamp it onto the pipe on a middle mark, bend with your hands around the pipe.

Once the 2 ends meet,clip the ends together to keep the metal from going sideways,

use a c-clamp or turn it in the vice, . Then just tighten the vice/cclamp up to finish the bend.

Instant clamp.
 

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Good show!

I've used the same stuff all over. On the cbr fighter I made brackets and mounts for the belly pan and CDI. On the gsxr I made some straps for mounting the coolant overflow reservoir

But this is new to me. I'll probably do something like that for the bobber i'm trying to get started
 

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Discussion Starter · #13 ·
One didnt uploaded for whatever reason, but never went back and fixed it.
 

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Discussion Starter · #17 ·
Ive been running them over a year no issues. The only maint required every so often while cleaning I hit them with a little #0000 steel wool just like you would an exhaust can after its seen alot of rain and weather.
 
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