Custom Aluminum Kickstarter!

[KTM RACING 559]

Im sick of the ugly a$$, heavy steel blaster kickstarter LOL, so I'm fabbin up an aluminum one. Using the original lower steel splines and shaft pivot for now. Lower portion of the alum. Kick assembly is 1" thick billet. And the upper kick pedal is 3/8" 6061 T-6 plate cut out with a plasma torch. Here's what I got sofar.

Used an impact screwdriver to remove the retainer screw, but it ended up stripping out the phillips bit and the screw, so I jus welded the bit to the screw and it came right out with no other problemsI:I

With that issue out of the way, I started cutting out the 1" piece of billet aluminum.

Cuttin it out on the vertical band saw.

All done with cutting, now time to shape it and remove some material on the belt sander.

 

[KTM RACING 559]

Tracing out the shape of the upper portion of the kickstart assembly to be cut out with a plasma cutter.

Time to fire up the ol plasma lol

All cut out, and both pieces ready to smooth out on the belt sander.

 

[KTM RACING 559]

Quick comparison of the steel one to the "soon to be" aluminum one lol

After smoothing on the belt sander.

 

[KTM RACING 559]

Made a notch in the bottom of the kicker, so when the time comes to weld it up, it ill have a nice fit up.I:I

Time to drill out the hole for the steel pivot shaft.

 

[KTM RACING 559]

The hole is all drilled out, about 1 inch of depth.

That's all I have done for now, more pics and progress maybe tommorow, but definatly by next week!

Here's a "sneak preview" of the stainless stator cover I'm gonna make. Lol

Basically nothing done yet, but jus bearly had time left in the welding shop to start tracing it out on some 10 guage 308 stainless steel.

Here's a pic of the aluminum diamond plate oil pump cover I made a couple weeks ago, basically a replica of the one 79 Bronco made. A thanks goes to him for sharing pics in his thread.

 

[Blaaster]

I only have one word to describe what I would like to say, "WOW"

 

[Awk08]

damn nice work so far !
do you plan to cross drill the kicker pivot for the spring and ball used to keep it in place against the engine ?

 

[OConnor Racing]

Nice stuff ...................

 

[Blaaster]

I can just imagine the orders piling in, do you require a workshop manager?

Can I be the first to order one?

 

[KTM RACING 559]

damn nice work so far !
do you plan to cross drill the kicker pivot for the spring and ball used to keep it in place against the engine ?

Thanks! Yes, gonna use the same mechanical design as the steel one. countersink the retainer screw into it the same way as well as drill the small hole for the ball bearing to lock into.

 

[KTM RACING 559]

I can just imagine the orders piling in, do you require a workshop manager?

Can I be the first to order one?

Hahaha! Yeah, if I get some more free time in the shop this next week or so, ill try to make a couple more, but I first need to test this one when its done to be sure its strong enough before I make more lol.

 

[KTM RACING 559]

Nice stuff ...................

Thanks! Hey just wondering, are you selling the 6mm cranks yet?

 

[dirtysquared]

Looking good buddy!

You always out do yourself

 

[KTM RACING 559]

Looking good buddy!

You always out do yourself

Thanks dude!I:I

 

[YZX]

That is a real nice kick start. Let us know how it holds up

 

[KTM RACING 559]

That is a real nice kick start. Let us know how it holds up

Thank you! And When its finished, ill be sure to test it out and give you guys the results!

 

[harley1-5]

awesome fab work I could use your talent on my never ending projects

 

[79 bronco]

Looking good buddy! More pics please!!I:I

 

[KTM RACING 559]

awesome fab work I could use your talent on my never ending projects

Thank you! Yeah same here man, I have waaayyy too many projects too haha

 

[KTM RACING 559]

Looking good buddy! More pics please!!I:I

Thanks dude! I should have alot more pics hopefully by monday!I:I