My Fork Design

[Chris Picone]

Redesigned to use less material / machine time, see page 2 for pics

So I can't find a threadless fork under $50 anywhere. So I designed one to make for myself!

Theoretically, $20 of material and 2 hours of machining at $15 an hour makes this $50 if I were selling forks, but I don't have the kind of time to start a business, so this would be just for myself if I make it.

This whole thing should take just three ops - boring out rectangle stock on a lathe, turning down the forktube on a lathe (I can get time on a CNC lathe), and milling out the fork pattern by MNC. All made from a single piece of aluminium rectangle bar stock.

Lemme know what you think, or if I fucked anything major up.

 

[michaelchavez]

looks sick i really like that style of fork, but it'd had to be steel or super thick alu for it not to bend

 

[Chris Picone]

looks sick i really like that style of fork, but it'd had to be steel or super thick alu for it not to bend

6061 AL, 1/8 wall tube, legs are all 1/4 thick. should i step that up to 3/8ths? (50% thicker)

 

[Joe Collins]

To be safe I would. You sould make some re-enforcements

 

[Bear Grylls]

i would make the legs thicker. But thats really nice!

 

[james blott]

Round of the top like smooth and round
For homemade im amazed
Should deff's sell them

 

[mason buckley]

i dont really like how pro modle forks look and this reminds me of it, but it sounds like it will be strong and plus looks dont matter its how good they are

 

[Chris Picone]

Round of the top like smooth and round
For homemade im amazed
Should deff's sell them

it's just a 3d render, haven't made it yet lol

it definitely would have rounded corners when machined, wouldn't want any sharp edges

 

[Connzi machell]

Love it. Good work Chris, I say just thicken it up a little for aluminium, just to be safe.
Good luck making it!

 

[Chris Picone]

Quick picture of leg detail. I added some fillets to make it take hard hits better without bending. still looking into thicker legs.

 

[Joe Collins]

Round off the outer corner aswel. Just play with it alot untill it's something unique

 

[Joe Rush]

i would buy one if you ever did decide to make more than one

 

[devinthedew2]

You need to make the fork legs thicker or add reinforcements becuase trust me it will bend.

 

[Derek Seay]

And, IDK if it's possible, buti'd add Spacers for the dropout's.

 

[R-Dubya]

This is like a pro mod fork and a Lucky LS had wild, STD-infected sex and produced a baby with the worst qualities of both forks.

 

[Derek Seay]

I would ride this, I love the way this looks

 

[Dusty]

Looks really good man. Although I would use steel because, well, steel > aluminum.

 

[JayJayScootsAllDay]

This is like a pro mod fork and a Lucky LS had wild, STD-infected sex and produced a baby with the worst qualities of both forks.

No, ffs.
Why are you such a cunt to everyone about everything?

 

[Derek Seay]

Looks really good man. Although I would use steel because, well, steel > aluminum.

Steel, you would need to weld, making weak points where it'll bend. And ALU looks better anyway.

 

[Chris Picone]

Looks really good man. Although I would use steel because, well, steel > aluminum.

It's all about strength to weight ratio, man.

Anyway, because I'm apparently on crack tonight, I redid the whole design. Instead of starting from a rectangular piece, I made the whole thing out of 1 7/8" round aluminium. Legs are thicker to make up for it. I also made some revisions that should make it MUCH easier to machine (those diagonal legs would have been a pain to do manually).