The process of making the sides to come out the same even though the original frame tubes are different make this the hardest frame rebuild I have ever tackled. Every tube is different so I can't make one tube then make another one to match it.
I cut down the uprights by installing the fender where it is to go, then put a level across the fender and making a mark on the tubes.
I then took hose clamps and installed them at the marks. when the clamps are tightened down they give me a line all the way around the tubes so I can cut them squarely across the tube.
This is a good way to cut a pipe at a 90 degree angle with a small grinder, just make a mark then put a hose clamp at the mark it gives you a perfect line to cut on.
I next made a couple of plugs to fit into the tops of the uprights, drilled and tapped to fit a 8mm X 125 bolt thread.
I welded them inside the uprights. I may make some kind of fancy top to go on them later.
The fender was installed on the temporary bracket on the swing arm and I blocked it up on the tire. The job now is to get the fender straight and centered just where I want it to be.
I cut a piece of flat stock and drilled holes for the uprights
Then bolted them down to the uprights.
I now need to get a center line to the fender brace I made.
I will use this to make the actual brace I want to use.
I am still thinking about the mounting of the fender and seat.
I an also debating if some small saddle bags might be good on this tank of mine.
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