http://www.onlinemetals.com/merchant.cfm?pid=7333&step=4&showunits=inches&id=250&top_cat=0
.875" Outer Diameter, 0.065" wall - Crossbar
http://www.onlinemetals.com/merchant.cfm?pid=7341&step=4&showunits=inches&id=250&top_cat=0
1.12" Inner Diameter, 0.065" wall - Steer Tube
For any bars smaller than or exactly 24" high x 24"� wide, buying a two foot precut piece is your cheapest option.
1) Height/Width
Use a miter saw/hacksaw/pipe cutter to cut the bars to the sizes you want.
Having trouble deciding what size? Look here: http://www.scooterresource.com/e107_plugins/forum/forum_viewtopic.php?830515
2) Notch
To make the notch for the crossbar, use a bench grinder.
Or a tube notcher.
Or a dremel.
Or a drill press w/ hole saw.
It's hard to not find something to make the notch.
I CAN NOT STRESS THIS ENOUGH: Grind in far enough so that there are two tabs sticking up.
Then hammer the little tabs down onto the crossbar to hold it in place it in.
(When the tabs are shorter, the weld breaks MUCH easier.)
3) Gussets
A) Wee Style
You want this piece to be about 6" long.
B) Slayer Style
Just cut or grind the tubes so the ends are at a 45�º angle.
4) Tabs
After you make the notch, put the crossbar in and hammer down the two tabs that are sticking up.
5) Welding
Take the bars to get TIG welded professionally, or do it yourself.
6) Slit
Take a hacksaw and cut 2 slits, less than 2mm apart, wherever you want a slit to be.
You can also do a single cut with a miter saw.
A good way to determine where to cut the slits and how many to make, is by the kind of clamp you use.
7) Finishing Touches
Be creative, do what you want! I like to use a hand file and grind down the top of the tabs where the crossbar is held by the steer tube, because sometimes they are very sharp.
Be sure to paint your bars, 4130 chromoly rusts very easily, even when it doesn't get wet.
8) Enjoy!
.875" Outer Diameter, 0.065" wall - Crossbar
http://www.onlinemetals.com/merchant.cfm?pid=7341&step=4&showunits=inches&id=250&top_cat=0
1.12" Inner Diameter, 0.065" wall - Steer Tube
For any bars smaller than or exactly 24" high x 24"� wide, buying a two foot precut piece is your cheapest option.
1) Height/Width
Use a miter saw/hacksaw/pipe cutter to cut the bars to the sizes you want.
Having trouble deciding what size? Look here: http://www.scooterresource.com/e107_plugins/forum/forum_viewtopic.php?830515
2) Notch
To make the notch for the crossbar, use a bench grinder.
Or a tube notcher.
Or a dremel.
Or a drill press w/ hole saw.
It's hard to not find something to make the notch.
I CAN NOT STRESS THIS ENOUGH: Grind in far enough so that there are two tabs sticking up.
Then hammer the little tabs down onto the crossbar to hold it in place it in.
(When the tabs are shorter, the weld breaks MUCH easier.)
3) Gussets
A) Wee Style
You want this piece to be about 6" long.
B) Slayer Style
Just cut or grind the tubes so the ends are at a 45�º angle.
4) Tabs
After you make the notch, put the crossbar in and hammer down the two tabs that are sticking up.
5) Welding
Take the bars to get TIG welded professionally, or do it yourself.
6) Slit
Take a hacksaw and cut 2 slits, less than 2mm apart, wherever you want a slit to be.
You can also do a single cut with a miter saw.
A good way to determine where to cut the slits and how many to make, is by the kind of clamp you use.
7) Finishing Touches
Be creative, do what you want! I like to use a hand file and grind down the top of the tabs where the crossbar is held by the steer tube, because sometimes they are very sharp.
Be sure to paint your bars, 4130 chromoly rusts very easily, even when it doesn't get wet.
8) Enjoy!
