Aluminium Hugger

[legendlives]

As mentioned elsewhere here, when I bought my VTR it had a hideous carbon hugger which was so much the wrong shape that it had been worn through by the tyre. The design was terrible also, directing all of the road sh1t and grime straight onto the chain.
The obvious thing to do was therefore make my own out of aluminium.
Just after starting to beat out the mudguard section it occurred to me that it would be virtually impossible to do it nicely without an English wheel. I didn't have an English wheel so I delayed the project while I knocked up this:

Made from tube left over from a previous car project, two old clutch release bearings pressed into a bit of stainless tube, and an old iron caster wheel.
It works well enough:

The chainguard was the first thing I made. This needs a bit of fettling as it was copied from the dimensions of the hugger which bears no relation to the run of the chain!

You can see the 'mod' line in marker pen.
These are the two sides which will join everything together. They also need some shaping:

Hopefully will have it largely finished this week. Will keep you posted!

[lloydie]

Nice project just make sure you have at least 10mm of clearance around the tyre

[sirch345]

A man after my own heart, in making a tool/machine to do the job rather than taking the easy option and buying another hugger, although you'd probably struggle in finding one made in aluminium.
Good job keep up the good work

Chris.

[legendlives]

Nice project just make sure you have at least 10mm of clearance around the tyre

Kinda why I'm doing it. The aftermarket hugger was rubbed through in the centre by the tyre, and was obviously rubbing on the right side.
This one will be trial fitted 100 times before it's finally finished.

[lloydie]

Good man ,

[Kev L]

Nice project, good luck with it

[legendlives]

All tacked up and trial fitted:


It's a bit of a PIA as the bike is at home, and the TIG is at work, but the good news is that it fits!

I'll finish weld it this week and re-check the fit before I polish it.

Happy

[AMCQ46]

Nice work

[legendlives]

Finish welded, and the back end shaped up:

[lloydie]

Have you checked clearance to the front sprocket cover ?

[legendlives]

Have you checked clearance to the front sprocket cover ?

Yes.

[lloydie]

[THUMBS UP SIGN]

[AMCQ46]

nice skills mate ............ you going to try a belly pan next?

[sirch345]

That's looking great, well done

Chris.

[legendlives]

nice skills mate ............ you going to try a belly pan next?

TBH when I was looking for a bike my initial plan was to buy a wrecked one and then make all of the panels in aluminium. Good thought on the bellypan though as I don't like the original one.....