The design as simple enough get full travel with 2.5 shocks and keep it all under the DualSports Body.
Got to spend a bit of time playing with the bender.
Front shock hoops are 158 degrees if anyone wants to make a set
The primary upper and lowers are sleeved onto the beam and front section. I do this but chamfering the 1 1/2" tube and then making a sleeve from 1 3/4" cut on the same angle / notched. When they are installed I run a root pass on the 1 1/2" tube and then slide the 1 3/4" over the outside and tig it in place as well.
Doing this reduces the stress point and gives you two separate welded about 1/4" apart.
The end that is not going onto the other tube etc is notched at 90 degrees so that the weld sleeve is not a straight shear,
Everything is then cleaned, cleaned and cleaned again. Fit and checked and checked
Once I am happy with the fit it is time to get welding. My original plan to get my mate to weld it out didn't work out as he is crook as a dog and this build time line waits for no man. With that sorted I spent a few hours running some beads and getting my heat issues sorted and set to welding it out.
Once the roots were done I could push the sleeves down and burn them in as well. I had to get the sequence correct.
Anyway far from perfect but I am sure by the time I finish welding it out they will get better.
Hope to have her on wheels by the end of the weekend so I can do steering geometry and start buttoning up.
