It's really cold today
I received a package today
from a subscriber and a friend who follows the channel
He wants to make something for him
Let's see what is in the package
A front steering system
from small motorbike
This system
will be modified
to be installed to a Honda cub
Some modifications are required
The threads are damaged
And these are the instructions he sent
Let's see what we can do
Well, it is a relatively easy job
it has been done before, but now
we will see with more details
The axle has damaged threads
as a result the locking nuts thread
as usual
but there is too much tolerance
And when you going to tighten them up
they will destroy the threads even more. The black nut is aluminum
the genuine Honda one is cast iron
but the axle is damaged
We have to turn it on the lathe
and press the old axle out
and make a new one.
Because we have to put a piece of steel here to install the steering lock
This one in order to lock the steering wheel
We have
to change the axle dimensions a little bit. For example if the piece is 5mm
We have to raise the axle
5mm more than current dimensions
so we can install the steering lock
just like that
and can be locked
The piece will be installed here
so it can be locked
This is the whole job
Easy cheesy
We have it on the lathe
on the 3-jaw chuck no need for
centering it to zero
We have to be careful
because it is large
and as it turns
we must check if
it touches on something while tool post is coming near it
So we must use extreme caution
In case it touches something
while turning it will be catastrophic
Moving the tool post near it
we check if it turns freely around
We should do this job slowly and steady
because this over here
when it is free it will turn indepentently
This is the most difficult part but overall it's easy job
(now cutting the old weld to free the axle)
So we have removed the old weld
and we have made a concave
so we can weld it later
It will be more difficult to hold it steady
and make this concave
When the weld is removed
we can see how roughly it was welded
It is not properly pressed and welded
It has to be really tight
so it cannot turn
and the weld
has the task of securing it even more
In this case it is probably chinese made
Overall it is roughly made
Not the best quality manufacturing
we will take care of this now
so we will heat it up and press the new axle
to be really tight fit
Then we will weld it for more secure fit
We now will measure
the dimensions of the old axle
Like this one
The thread is M22 with 1mm pitch
This old dimension (22,42mm) is for the first steering bearing
it is probably 22,50mm brand new
the axle overall is pretty damaged on bearing surfaces
Same on the second bearing on 23,98mm
it is probably 24mm brand new
we will check it having the bearings on hand
All dimensions are measured
And we added 5mm more for the steel plate
required for the steering lock
We can start turning it
using the micrometer
and the typical ruler. Not much precision needed here
and using metric pitch gauge for thread measurement
The threads are M22x1mm
we can match the threads using the genuine lock nut
so we can be sure that the threads are perfect
These lock nuts
can be
roughly made sometimes
So we match the threads for these nuts to fit perfectly
and secure the steering stem tight
We will turn this to the dimensions needed
and cool down slowly to room temperature
so we can begin making the new threads
and the correct bearing surfaces
and the correct dimension down here for tight fit
(Now turning the new axle to correct dimensions)
So we turned it down to correct measurement
which is 23mm wide
so the second bearing can pass through for fitment
We left this part to cool down
to turn it down precisely
So this part to make
the new threads correctly
Now we will wait to cool down
We have turned it down, axle is cooled down
so we can make the new threads correctly
and have a tight fit
The old threads were damaged and the nuts were loose
and roughly made
Now it will be as tight as it can be and nuts will fit nice and tight
We are now ready to
turn the first bearing surface
To be continued.....
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