Bash Plate Mod

[edteamslr]

Situation: The two lugs at the front which attach my bashplate to the frame have come off and I am looking for a different solution.

Help: Can anyone suggest how I might attach the bashplate to the frame other than lug welding or cable ties? And whom may be best placed to help?

[KTiM]

I haven't had a look at my bike to see if this would work but off the top of my head how about a big "U" clamp around the frame and then drill two holes through the bash plate?

[edteamslr]

That seems like a good suggestion. Anyone who's seen the weemoto crashbars will know about the U-clamps and how tough that solution is (enclosed, steel frame tube vs. puny, welded lugs!). I am bit concerned about having the bolt heads downstream of the front wheel, rusting mercilessly in the wake - maybe domed nuts - but they would be much easier to fit that way?
Anyone else? If I bought the rod, measured it up, bent it to shape where would I go to have the threads put on it?

[KTiM]

You could look for stainless steel perhaps. If you were to "bend your own" any local engineering shop or garage will probably have a die set to cut the threads for you or you could just use a length of stainless steel threaded rod and that would be that!

[edteamslr]

Good thinking. The rod with threaded ends would be the neatest/nicest solution but failing that, the threaded rod.
Thanks!

[Jenna]

personally i would be a bit cautious of putting any 'u bolt' round any structural part of the frame. To tighten the bolt you need to put a far old clamping force on the section which in turn could under impact (on the bash plate) transmit the force to the frame!!... the lugs are made like that so that any force on them is NOT transmitted further on.

If you must use a u clamp idea i suggest that making from a flat strip of steel that follows the section of the frame and spreads the force more evenly would be a better solution, you can also then drill and tap two bolt holes and fasten front to rear with 2 bolt that's well away from the wheel!

[edteamslr]

personally i would be a bit cautious of putting any 'u bolt' round any structural part of the frame. To tighten the bolt you need to put a far old clamping force on the section which in turn could under impact (on the bash plate) transmit the force to the frame!!... the lugs are made like that so that any force on them is NOT transmitted further on.

If you must use a u clamp idea i suggest that making from a flat strip of steel that follows the section of the frame and spreads the force more evenly would be a better solution, you can also then drill and tap two bolt holes and fasten front to rear with 2 bolt that's well away from the wheel!

I believe the bashplate does transmit the force to the frame spars (which are between the engine and the plate) Even if there is a small gap, one big bash and they'll move back so the plate touches. The point of the bolts and the lugs is to stop the bashplate falling off the rest of the time.
I wasn't suggest anyone uses a true 'u' clamp instead a squared 'u' but as I believe the clamp is only holding the plate in place rather than resisting a load pulling the clamp through the frame, I don't think it actually matters a great deal. If the they were, say, locknuts then you wouldn't need to tighten them hard as the bashplate doesn't weigh that much (mine is currently cable-tied on at the front).

[mick]

cant see your problem just make a new bracket and weld it on right if the weld is ok it will out last the lifetime of bike or use rivnuts and bolt the new bracket onto the frame

[wigs_1]

I made a bracket up for mine using a bit of mild steel. Just bent it around a bit and then got a bloke at work to weld it up for me. It took longer to disconnect the ecu, reg/rec, remove the bashplate etc than it took to weld it. Its way stronger than the original.

[edteamslr]

The welding option should obviously be my first choice, and the use of the stip welded in front of where the lugs used to be is now at the top of my list. I was hoping to find a solution that could be done quickly and with the tools I have available - I asked a mate at work but the best he could do was a spreadsheet and a highlighter pen