We are now ready to weld the frame together and mount the corner gussets. I would recommend clamping the frame down and using a square to get it straight. After welding the frame, take the corner gussets and drill four holes for some ¼” or 5/16” bolts (your choice). Clamp the gussets to the frame and drill the holes for the bolts. After bolting the gussets to the frame, you can now weld them to the frame. This may not be necessary, but I believe in redundant redundancy. Grind off and smooth out those welds and any other areas that need it.
Also, it would be a good time to mount the axle plates to the frame. Notice that the axle plate is a little wider than the axle mount, but is the same length as the axle. Before you weld the plate, you should clamp the plate to the axle and determine the place of the mounting holes. In my case the axles each had six holes of 5/16”. After I determined the placement (I wanted at least two of the bolts to go through the frame, axle plate and axle mount), I drilled the six holes in the axle plate. It is easier to do this in a drill press than when it is on the frame. If you look closely, you will see that one of the bolt holes is 5/16” (the rear one) and five of them are 3/8” (although all the mounting bolts are 5/16”.) This is so that the rear bolt acts as a pivot and there is enough slop in there to allow some movement if necessary to align the wheels.
To determine the placement, I clamped one of the axles with a wheel installed to the frame when I was trial fitting it. I tried to line the wheel on the frame up with the rear wheel of the scooter. Just eyeball it - you don’t have to be absolutely accurate. Be sure that the frame and axle clear the muffler and CVT cover. Notice in the pictures that I welded in the bottom of the right and left frame a piece of the channel to add a little extra strength where the axle plates will mount. You will have to grind down each side a little bit to get it to sit level in the frame. You can then weld it in.
Using the placement determined above, place the axle plate on the frame and lightly clamp it down. Square up the plate to the frame. This is a somewhat critical step. If you get them crooked, the wheel alignment will be off and cause problems with handling. When you are certain of the alignment, tighten down the clamp and tack weld the axle plate to the frame in several places. Recheck the alignment and drill the two center holes through the frame. Remember, the rear one is 5/16” and the front one is 3/8”. You can now finish welding the axle plate to the frame and clean up the welds.
Read more: http://scootdawg.proboards.com/thread/23163#ixzz2oyFSbHI3
Also, it would be a good time to mount the axle plates to the frame. Notice that the axle plate is a little wider than the axle mount, but is the same length as the axle. Before you weld the plate, you should clamp the plate to the axle and determine the place of the mounting holes. In my case the axles each had six holes of 5/16”. After I determined the placement (I wanted at least two of the bolts to go through the frame, axle plate and axle mount), I drilled the six holes in the axle plate. It is easier to do this in a drill press than when it is on the frame. If you look closely, you will see that one of the bolt holes is 5/16” (the rear one) and five of them are 3/8” (although all the mounting bolts are 5/16”.) This is so that the rear bolt acts as a pivot and there is enough slop in there to allow some movement if necessary to align the wheels.
To determine the placement, I clamped one of the axles with a wheel installed to the frame when I was trial fitting it. I tried to line the wheel on the frame up with the rear wheel of the scooter. Just eyeball it - you don’t have to be absolutely accurate. Be sure that the frame and axle clear the muffler and CVT cover. Notice in the pictures that I welded in the bottom of the right and left frame a piece of the channel to add a little extra strength where the axle plates will mount. You will have to grind down each side a little bit to get it to sit level in the frame. You can then weld it in.
Using the placement determined above, place the axle plate on the frame and lightly clamp it down. Square up the plate to the frame. This is a somewhat critical step. If you get them crooked, the wheel alignment will be off and cause problems with handling. When you are certain of the alignment, tighten down the clamp and tack weld the axle plate to the frame in several places. Recheck the alignment and drill the two center holes through the frame. Remember, the rear one is 5/16” and the front one is 3/8”. You can now finish welding the axle plate to the frame and clean up the welds.
Read more: http://scootdawg.proboards.com/thread/23163#ixzz2oyFSbHI3
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