Today with some my time on my hands, I made a start at re shaping the stainless steel bearing housing to fork connector. As you are most likely aware this part is vital to the stability of the front wheel and therefore is made from stainless steel. The engineer copied my design exactly and now I have the hard part of re shaping the connector to fit inside the fork blades. Luckily I have my trusty Makita power file and with a 40 grit belt it slowly files it to the preferred shape. Which in this case is the inside diameter of the fork blade. Later on once it's a perfect fit I will drill a couple of holes in the bottom of the fork blades so it can be welded together. I have almost finished one today and now I'm finishing it off with a course bastard file to get a nice smooth fit. I have a slight headache today from prolonged use of the power file but the power file is really the only way to get the perfect fit as there is no way you could hand file such hard steel into the shape required.
Pictured above are a few photos showing the part I'm working on and the other connector with still needs to be re shaped
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