A learning experience for sure. I made a hammer form out of some oak. Used a carving gouge to rough the shape then a few different burrs in a die grinder. Finally some sandpaper. Put another piece of oak on top of the aluminum to sandwich it in place for clamping. Just a square piece. I'll add some more pictures tomorrow. After I annealed the aluminum, it was still a little warm. I clamped it in place, and with a few good wraps with a teardrop shaped plastic mallet, was able to form the shape I needed without much distortion at all. It needs some metal finishing, but I think it will be okay for a first try. Lou

A few more pics. I'll drill a hole for the brake reservoir line. The rear brake line clears fine. Still need to get rid of a few nicks here and there, and a few uneven surfaces. Lou

Still needs a bit more work on the finish. I promise these are the last pics till I finish installing it. The hardware should be in by the end of the week. I have one blemish I will probably have to weld and metal finish. For now I will leave it to remind me to be better. Hopefully this weekend I will start on the oil catch reservoir. Lou

very nice.

Thanks Brad! Here are a few pics of how I'm attempting to make the catch bottle. Figured I'd make a hammer form buck from oak. Had to laminate 3 pieces together. Today I will try and refine the shape, and it is a strange shape indeed. Lou

Honestly Lou, this is fascinating. Combined with watching Lucifer’s Hammer, it is inspirational. Makes me want to venture out from my “kit bikes”.

MikeV

Thanks Mike and Paul, you are right. Everyone on this Forum is an inspiration! We've been lucky to assemble a great group of craftsmen and friends. Here are a few more photos from today. I took some license in making the catch bottle. The radius on the catch bottle were a little tight so I made them just slightly larger to help with the aluminum forming. I also made it slightly less thick. The originals were so tight to the shock spring. Still a work in progress. The edges need more chamfering.I am trying to use AN fittings for the hose from the crankcase to the bottle. Another exercise in frustration. Pics to follow. Lou

Great work Lou!
Paul

Thanks Paul! The learning continues. I've never done this before, but I've always wanted to, and have read a lot, and seen some video's. Much harder than it seems! Here is my first attempt. 3003 .063 thick aluminum. I annealed the piece I cut, even that process I'm learning. It does soften the aluminum quite a bit, so it's easier to bang around with a plastic mallet. So you use a plastic or rawhide mallet so as you are banging around the edges you are shrinking the ally. A steel hammer would stretch the aluminum and you are trying to 'shrink' it around the wood. I will make the backside piece then a strip around the perimeter to join the front and back. I think there is a baffle inside that catch bottle. Anyone have a picture? I hope it looks good on the bike, if not I'll try again. Lou

What a great start, impressive Lou!!