How to make axle covers

[Bdog]

I know not everyone has a milling machine or lathe but have you ever wondered when shopping for bling for the Nomad how it is made? This afternoon (raining) I made up a new set of axle covers and thought...hmmm..why not take some pics and post them for the curious to see how its done.
6061 aluminum being bored out
http://i171.photobucket.com/albums/u319/blackiedog/Bdog%20design%20works/axle/100_0827.jpg
brass plug and tap
http://i171.photobucket.com/albums/u319/blackiedog/Bdog%20design%20works/axle/100_0828.jpg
mill holes to even depth
http://i171.photobucket.com/albums/u319/blackiedog/Bdog%20design%20works/axle/100_0829.jpg
insert brass
http://i171.photobucket.com/albums/u319/blackiedog/Bdog%20design%20works/axle/100_0835.jpg
tighten with loctite
http://i171.photobucket.com/albums/u319/blackiedog/Bdog%20design%20works/axle/100_0836.jpg
cut at 30 degree angle
http://i171.photobucket.com/albums/u319/blackiedog/Bdog%20design%20works/axle/100_0844.jpg
cut grooves for o rings inside the axle
http://i171.photobucket.com/albums/u319/blackiedog/Bdog%20design%20works/axle/100_0845.jpg
polished up and mounted
http://i171.photobucket.com/albums/u319/blackiedog/Bdog%20design%20works/axle/100_0850.jpg
http://i171.photobucket.com/albums/u319/blackiedog/Bdog%20design%20works/axle/100_0848.jpg

[Nubbs]

Those look AWESOME!!

[Mad Kaw]

Nicely done but, you're right, not everyone has a lathe or milling machine. :( Or, the talent, for that matter. :)

So, now that you've given us the tease and, seem to have mastered these covers, when can we expect them to be offered to the righteous members of this illustrious site???? ??? http://s2.images.proboards.com/shocked.gif ;) (At a really good price, of course! http://s2.images.proboards.com/shocked.gif http://s2.images.proboards.com/cheesy.gif http://s2.images.proboards.com/grin.gif )

[medicaldawg]

Nicely done but, you're right, not everyone has a lathe or milling machine. :( Or, the talent, for that matter. :)

So, now that you've given us the tease and, seem to have mastered these covers, when can we expect them to be offered to the righteous members of this illustrious site???? ??? http://s2.images.proboards.com/shocked.gif ;) (At a really good price, of course! http://s2.images.proboards.com/shocked.gif http://s2.images.proboards.com/cheesy.gif http://s2.images.proboards.com/grin.gif )
+1

[cactusjack]

Nice. That brings back memories of Mr. Pendleton's vocational metal class back in 11th grade. We used to fabricate grill guards and roll bars for 4x4's and install them in our auto mechanics class. Those were the days! http://s2.images.proboards.com/cool.gif

[ringadingh]

Thats real nice, I wish I had that kind of equipment at home, Id be making all kinds of stuff.

[cajun2wheels]

Very nice.You would have no trouble selling those.

[nomad561]

Very nice.
When are they going into production? hehe

[josh]

I will sign up for 2 sets

[1ton]

Bdog
What diameter bar did you start with? I assume which I know is dangerous, that you are using only the friction fit of o-rings to hold cover in place.



Ron

[Bdog]

Ron..I started with 1 1/2" stock. Got the o rings at local auto shop..not sure what they are, except they are the same ones I used for my last set of covers. No problems with them working loose. Tolerances are tight..John. I met a nomader on my last trip that really wanted my last covers I had, so I took them off my bike and gave them to him..it paid for a nice motel while being on the road and he was a happy biker. I mentioned kawanow but he had never heard of it and said he would check it out..John

[medicaldawg]

Dear bdog please sell me those. haha jking. but seriously dude those look awsome. If you were willing to manufacture and ship I would be willing to pau http://s2.images.proboards.com/cool.gif . I wonder if we started up an order now how many orders you would get. Order number 1

[1ton]

Thanks Bdog,

I picked up some 1 1/4" and 2" at scrap yard today to make a set. I think I'll counter bore the holes and insert fired pistol cases in them.
Make them look like a revolver cylinder. They will match my grip ends .

Ron

[jestephens]

Bdog, that's a good looking set of covers. My design is similar, but I wanted to share my idea for you or others looking for ideas :)

I used a piece of all-thread to hold the covers on. Each side has a small hole for tightening the assembly. I've only had to remove them for new tire installation, otherwise they stay tight and maintenance free.

High- polish stainless steel.
http://i174.photobucket.com/albums/w117/jestephens/DSCN3164.jpg

My design did, however, require each side to be different because of the axle's asymmetrical design.
http://i174.photobucket.com/albums/w117/jestephens/DSCN3166.jpg
http://i174.photobucket.com/albums/w117/jestephens/DSCN3165.jpg

http://i174.photobucket.com/albums/w117/jestephens/DSCN3169-1.jpg

[wheelie]

Very nice both designs are great. I'll have to talk to my general manager tomorrow and tell him the two things a trash truck shop really needs is a lathe and a mill.

[josh]

Let me know what strategy you use for that wheelie, so I can try the same thing with the trash truck shop i work at

[Cajunrider]

Very nice. Talented folks here.

[jandreu]

bdog is such a tease http://s2.images.proboards.com/grin.gif shows us all his excellent bling but does not want to share ::) Thanks for the how to though.

jestephans...the all thread idea is the tits.. http://s2.images.proboards.com/cool.gif. I've been wanting to put a set of spinners on the axles. Only ones I can find are made for HD's and attach with a set screw on the end of the axle. Have been tiring to figure out how to attach them. Heck, I did not even notice the Nomad axle is hollow.

Now I know and think I can work out a solution with the all thread idea by cutting a blank the ID of the spinner and using all thread to hold the two together thru the axle.
Thanks for sharing. http://s2.images.proboards.com/grin.gif

[Jared]

Nice job, both of you!! Now I'm going to have to go tinker and see what I can come up with.

[Jared]

Bdog, that's a good looking set of covers. My design is similar, but I wanted to share my idea for you or others looking for ideas :)

I used a piece of all-thread to hold the covers on. Each side has a small hole for tightening the assembly. I've only had to remove them for new tire installation, otherwise they stay tight and maintenance free.

High- polish stainless steel.
http://i174.photobucket.com/albums/w117/jestephens/DSCN3164.jpg

My design did, however, require each side to be different because of the axle's asymmetrical design.
http://i174.photobucket.com/albums/w117/jestephens/DSCN3166.jpg
http://i174.photobucket.com/albums/w117/jestephens/DSCN3165.jpg

http://i174.photobucket.com/albums/w117/jestephens/DSCN3169-1.jpg

Where did you get your tips? Or did you make them??

[caper]

Very nice :) So are you guys going to sell em :):):)

[cnc]

Nice I have thought about making axle covers, and you both have given me some great ideas. Thanks for sharing.

[jestephens]

Utah,

Unfortunately, I did make those tips. I did leave out some of the details in the design though.

Those "bullets" are removable from the parts that thread on and hold everything in place. The bullets are held with a set screw like traditional axle nut covers.
Mine only holds these custom bullets, but if a guy were to produce something in mass, it should be able to accept all those existing aftermarket covers. . . . .

I don't work in a machine shop any more, or I would LOVE to start making these things. My wife doesn't (yet) see the value of machine-tools in our garage, especially CNC's. http://s2.images.proboards.com/tongue.gif

[dogdoc]

Bdog already told us he dont mass produce guys. LOL

[garyo4]

Awesome! As a former machinest, I can only imagine how great it must feel to make something so unique and nice for your own bike. Great job, keep thinking outside of the box!
Gary

[voyager]

Scott, that grade 11 class was in the sixties eh? http://s2.images.proboards.com/grin.gif

[Bdog]

Bdog, that's a good looking set of covers. My design is similar, but I wanted to share my idea for you or others looking for ideas :)

I used a piece of all-thread to hold the covers on. Each side has a small hole for tightening the assembly. I've only had to remove them for new tire installation, otherwise they stay tight and maintenance free.

High- polish stainless steel.
http://i174.photobucket.com/albums/w117/jestephens/DSCN3164.jpg

My design did, however, require each side to be different because of the axle's asymmetrical design.
http://i174.photobucket.com/albums/w117/jestephens/DSCN3166.jpg
http://i174.photobucket.com/albums/w117/jestephens/DSCN3165.jpg

http://i174.photobucket.com/albums/w117/jestephens/DSCN3169-1.jpg
Jestephens..good idea with the all thread insert. That opens up options for pre existing covers already made for bikes out there. Thanks for sharing and it seems this thread has now sparked others to come up with their ideas. Hopefully we will see some new axle covers soon from all you homebrewers..Bdog