There’s numerous jobs to do on an outdated bike mission – some dramatic, some messy, some tedious, some hardly noticeable. Certainly one of these is the magneto cutout, which is a small Lucas 76207 horn button mounted in a folded metal bracket to one of many handlebar clamp studs. It is right here:
You will recall I made some nuts final week – considered one of these was the locking nut for the cutout button:
The bracket can be a bit of two mm chilly rolled sheet, however its a little bit of an odd form because it has to look from beneath the highest yoke, go ahead beneath the handlebar after which come out between the handlebar and the casquette. It took me three goes to get it proper in cardboard:
I made the following prototype in 0.8 mm sheet which I may minimize with snips and fold simply:
This seemed OK however the swap wasn’t fairly in the fitting place:
It took me two extra goes on this sheet earlier than I felt assured that I would not be losing time if I went to the complete thickness. In fact, at 2 mm thick it was going to wish a bend allowance and it is simple to construct that in in the course of the marking out stage.
Here is a detailed up after drilling – you may see the double traces displaying the place of the bends. I exploit a bend allowance equal to the thickness of the fabric – on this case including 2.0 mm to every bend.
Right here it’s once more, having been minimize out with the hacksaw, filed and linished to the ultimate form:
I did not take any photos of the folding within the vice. I used to be cautious to make use of the graceful jaws, have the bend line precisely aligned with the highest of the jaws and to look at the bend forming as I pushed it over, such that the bend was fashioned between the 2 bend traces.
That is it. I’ve added it to the checklist of small bits to be zinc plated later.