Steering

 

The first job required for manufacture was to cut the relevant tubes to their appropriate length, and to mark out the locations for mounting the spring bolt and insertion tube. All the welds necessary for this section were directly onto a flat surface and the insertion tube could be welded to the underside of the handlebars at an early stage. The excess material indicated on the technical drawing was then successfully removed from the underside of the handlebars. This task was not only effective in reducing the weight of the handlebars, but it also enabled greater access to the inside of the ovular tube. This was particularly beneficial when attaching and tightening the spring-loaded bolt with mechanical fasteners.

 

Once this was positioned, both the spring and the bolt were removed to align the holes through the insertion tube, and prepare the surface for drilling. After the holes were drilled, the bolt was reattached and the upper handlebar assembly was completed. The upper steering column was then cut to size, and the four holes at the top of this section were aligned and cut using the pillar drill. This fit closely over the insertion column and only some minor filing was required to enable full penetration of the spring bolt. At this stage the upper steering column was welded to the upper face of the hinge. On the underside of the hinge a second insertion tube, similar to the one on the handlebars was also welded, completing the upper steering sections.

 

Finally another hole was drilled through the top of the fork steering column, and this allowed the insertion tube on the underside of the hinge to be bolted to the fork. In this way, both the upper and lower steering sections were connected.