Flyer Production

hsvmick said:
g'day Pat,
i see your great springer has come to life,they look amazing.can i ask about the Rear reaction plate does this pivot inside the pistons itself ?
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Yes it does rotate. The front fork will move up and down in an arc because of the lower attachment to the swing arms. If the pistons don't rotate on the reaction plate pin the forks could bind. Without the pivot the pistons would have to be a very loose fit. I couldn't exactly find any directions on this particular fork design so I had to basically read between the lines on how they function.
 
AWESOME work Pat! Seems to me that Flying Merkel did a similar thing with internal spring way back when. But they didn't think of the friction "shock" to help control the rebound / dampening. Excelent reverse and sideways engeneeringdance1
 
butchl said:
Question: Why do you braze instead of tig weld??
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I do both in the build of a bike, brazing and tig welding. There are lots of reasons I braze, with lugs, on the frames and forks.

A brazed lug is stronger than a notched and tig welded fillet weld.

Vintage frames were built before welding was common. Any vintage frame is a series of formed tubes brazed together with lug sections. So I do it for that vintage accuracy.

I have access to frame lug pieces, so I use them. I also think it looks cooler.
 
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Here is a picture of the completed fork front section, friction shock installed, and the handlebars. Still need to complete the rear section. The bridge between the two fork tubes is tig welded construction to be similar to a vintage cast lug piece, then the lugs braze to the fork tubes. The fork tubes are now unwelded continuous tubes from top to bottom. The lower tabs were welded into notches machined into the bottom of the tubes. Reaction plate lugs will braze to the rear tubes.

Super Duty Springer by Sportsman Flyer, on Flickr

Super Duty Springer by Sportsman Flyer, on Flickr
 
Totally awesome stuff, universal just change the mounting brackets and it will work on all your forks,love it............Curt
 
Looks awesome! When can we expect to see these on the website? Mainly curious about the pedal frames, GC160 mounts, Indian style tanks, and truss rods. Keep up the solid work!

Keith
 
Finished fork still warm from brazing! Been dreaming about this for awhile.....

Super Duty Springer by Sportsman Flyer, on Flickr

Fork is absolutely rigid and very smooth with no free play. I can see why this basic design was so popular on vintage bikes. I really enjoy taking an idea to drawings, then manufacture and hold the part in my hands for the first time. Very rewarding. This fork is going right on my race bike for testing.

Super Duty Springer by Sportsman Flyer, on Flickr
 
Wow they are a piece of the best
Keystone frame
new tank design
and now this fork
AMAZING
you Pat sure show as the best
 
Do both of the bikes on the Worksman Cycles website, the "Worksman Flyer "BTR" Board-Track-Racer by Sportsman Flyer" for $949 and the "Worksman Flyer "Cruiser" by Sportsman Flyer" for $499 use the same frame as what your calling the pedal frame or is one upgraded like the Sportsman 200 like you speak of?

http://www.worksmancycles.com/shopsite_sc/store/html/flyer-by-sportsman.html

I guess the same question would apply to the Sportsman Flyer and the Sportsman Flyer Pedal Bicycle located on Sportsman Flyer Website.......

http://www.sportsmanflyer.com/bikes.html


sportscarpat said:
The Pedal bike frames use the Worksman INB rear triangle, have 110mm hub spacing, and use 1" o.d. .090" wall ERW tube in the front triangle, 5/8" and 3/4" tube in the rear. All engine mounts clamp into the frames. HF79, GC160, and China two stroke engines can be mounted. GC160 mount is still a couple weeks away as I finalize details.

The Sportsman 200 uses 1" o.d. .120" DOM tube in the front triangle, 5/8" and 3/4" rear tubes and 135mm hub spacing. All engine mounts either lugged and brazed or tig welded to the frame. The GX200 series engine is the only option.

The Bonneville is basically identical to a Sportsman 200 in the front triangle with 1" o.d. .120" wall DOM tube and weld in mounts. I cheat the head tube another degree for more rake. Rear triangle is 3/4" .120 all DOM and adds 2" of wheel base. Fatter forks, steering stops and stabilizer mount. Couple other details here and there.
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Say say one of the big problems with porn is that after viewing it, its hard to get excited by what you have at home. Thanks Pat....
 
Pat the new forks certainly look to be deserving of the name "Super duty" & I will refrain from ever again calling them "pea shooters" which is mildly defamitory in light of what you've created. Great work can't wait to see them mounted on a green & cream Harley-ish machine. Rick C.
 
indian22 said:
Pat the new forks certainly look to be deserving of the name "Super duty" & I will refrain from ever again calling them "pea shooters" which is mildly defamitory in light of what you've created. Great work can't wait to see them mounted on a green & cream Harley-ish machine. Rick C.
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Hi Rick,
I have thought about doing a Peashooter type build and probably will eventually. For now testing will have to take place on my Keystone Flyer. Yeah, I know, an Indian tank and Harley forks. What was I thinking? These forks are taller, raising the front end to add 1 1/2 degrees more steering rake, and the swingarms are 3/4" longer to lengthen wheelbase. This was planned as the 250cc engine could reach mid to high 80 mph range! Now the fun begins. I have to tune the crazy things...........

Keystone Flyer by Sportsman Flyer, on Flickr

Keystone Flyer by Sportsman Flyer, on Flickr

Everyone asks what the left side lever is for. That's an SCTA required remote fuel shut off to run the fuel class. The cable needs a very shallow bend to operate the fuel petcock correctly.

Keystone Flyer by Sportsman Flyer, on Flickr
 
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Couple more views. This engine is a stroked 212 so it's running about 238cc. It also has an electric starter that I still need to finish wiring. You can see the Keystone design frame here. I chopped off the loop in the down tube to lower the engine and move it forward in the frame. Just like Harley and Indian did. I have also been messing around with a different engine crade to carry the 30 hp jr. dragster flat head billet Briggs engine. SCTA said don't even bother, they would never let me run it. Long story.....

Keystone Flyer by Sportsman Flyer, on Flickr

Keystone Flyer by Sportsman Flyer, on Flickr
 
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