Hi there!
In this video I will give more details about the springer fork building process
This is how I did it for my bike, it doesn't mean that it is right or not, it has just
served my needs
I am sure it can be done in many ways
The goal of this video is to show deeper the suspension building process, as well, all
used parts on it, than, you may design your own springer forks
I wanted a very stylish, functional and lightweight forks spending around $150
To match the bicycle's style, I inspired myself in the classics Harleys Davidsons springers
forks
It had to be simple and with all parts visible
I also needed to use the fork to raise about 10cm the bicycle's front
To keep the budget, as I had installed a brand new double crowns forks, I've decided that
the suspension would be added and adapted to the original forks
I started the project, drawing all necessary parts in Adobe Illustrator and then I transferred
the parts to a 3D software to see all parts working together
The project was very similar to the designed concept and its features
Next step, print all moving parts and use a PVC pipe as a prototype
(unfortunately I have no pictures for that)
Since I knew that all parts would be made of aluminum and cut with water jet (CNC),
I had to make sure that all parts were well designed and working as they should
Any error at this stage, would increase the final production value
After few attempts, I finally found all necessary measures
I finalized all parts that would be cut using a 3D software and sent them to the CNC cutting
company
The front arch and the springs guide are made of stainless steel
The distance between each leg is calculated according to the rim size and it is parallel
to the original forks
For the chrome appearance, all parts are made of stainless steel and very well polished
In the initial design I used two old springs of an conventional bicycle front suspension
I'll talk more about the springs functions soon
This is the 3D model used in development stage, I'll use it to illustrate all parts in detail.
Here we can see all elements created for the suspension that will be added to the original
fork
These are the parts designed and made especially for this project
These are the parts I bought ready or recycled from old bicycles
I'll start with the top base
This part must fit perfectly on the existing fork and offer full support for the springs
As it receives all impacts in both directions (up and down) it's made of a thick hard aluminum
sheet
To enhance the stability and eliminate any slack, I added a 4mm bolt in the backside
Springs supports
They are turned in the lathe to offer the perfect support for all springs and keep
the guide rail stability
Springs: I originally used two old springs
The lower springs are left in the original size and the upper rebound springs are cut
shorter
With the project ready and after testing around six months I had to make all springs again
with higher tension
To help the rebounding springs and reduce the noise, I added two pieces of very stiff
rubber
The rockers
These two parts have the very important function of moving and connecting all parts together,
plus raise the bicycles front up to 10cm higher
They must have the exact size to keep the suspension and the fork aligned with the very
same angle, otherwise the suspension wouldn't work well
Any inclination will impair the spring rails movement
The left side is break disks ready
The parts were lowered using a milling machine
Finally, the binder bolts
I bought four sit binder bolts, they are essential for the joints because the
threads are hidden reducing the friction between the connected parts
I had to add some washers to give the correct grip
The connection of all parts should be stable, but not too tight to guarantee the movements
Grease is required in all joints and moving parts
In the springers guides I placed two nuts to close the system
All parts are assembled under pressure, the springs are constantly pushing the base
All aluminum parts were very well sanded and polished to give the perfect chrome appearance
So, the total investment with man work, material and CNCs: is about $160
I hope this video will inspire and help you to create your own springers fork
Please let me know your opinion about this project!
Sharing ideas is always good
Thanks for watching and see you soon!
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