This was a fun and easy bracket to make. No clearance problems and an open mount area with existing bolt holes to screw into. |
The first order of business is to saw metal. I used a piece of 3"x1/4" bar as the base for the bracket.
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Behind the left headlight is an empty battery tray. This is a great location to mount the regulator. Here I removed the tray for easy bracket fit up. |
After laying out the tray contour, I chucked up the base in the Bridgeport and began cutting metal.
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This is another view of the slot nearly finished.
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Here the machined base is fitted in the pan. The mount holes are then scribed from the bottom. |
The holes are drilled and chamfered.
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This is a sanity check to make sure the base bolts up in the battery tray location. |
With the base complete, it is time to extend up to the regulator. Here I am making a tape template of the regulators bolt pattern. |
I took a piece of 2"x1/4" bar and milled out a slot to clear a boss on the regulator. then transferred the tape template to the bar. |
The holes are center punched and then drilled.
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When I bolted the bar to the regulator, I noticed the slot was just touching the boss. So back to the Bridgeport for some warranty work. |
Now there is appropriate clearance around the boss. With a little fit up, the bar is cut to length. |
This is a transitional piece from the base to the regulator. I am using magnetic angels to hold the pieces of bar together while I tack weld them. |
After tack welding the front, I flipped the assembly over and TIG welded the back. |
I then flipped it back over and TIG welded the front. |
Here is the final clamp up and weld of the regulator face plate to the base.
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The assembly is flipped over and the back side TIG welded. |
With a quick trip to the sand blasting booth, it is ready for painting.
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Well the bracket is finished and ready for installation. |
After installing the battery pan, the regulator bracket bolts in perfect.
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Next the regulator is mounted and clearance is checked. Well it off to the next task. |