Hi boys and girls! Today I thought I would demonstrate how to build a simple custom bracket. In this example, I am constructing a bracket for an after market sissybar, however, the simple techniques shown in the following demonstration could be applied to many other types of brackets as well.
The sissybar will be mounted to the rear frame rails of a 78 GL1000. The standard outside dimension of the 78 GL1000 frame is 8 3/4" +/- 1/8". It just so happens that sissybars made for Harleys by Kuryakyn (part number 1587) have an outside mounting dimension of 8 3/4".
The specs on the sissybar are: 8-3/4 in. outside mounting dimension, .55 in. square stock mounting and 1-1/4 in. mounting hole spacing.
To mount the sissybar, you can buy a bracket system or fabricate one. I chose the latter. I went over to my favorite scrap metal yard and scored a 2 foot square piece of 7/32" for 6 bucks.
After designing the part and transferring it to the aluminum stock, I cut the rough brackets using a saber saw with a blade designed for thick metal. It cut like butter.
The next step was to take the parts and run them through the grinder to get everything smooth. Then, putting a small abrasive stone on a Dremel, I lightly rounded the edges.
At this point, I drilled the holes for both the sissybar mount and the frame mount.
Finishing consisted of 400 grit sand paper, followed by a 600 wet sand. The part was then taken over to the buffer and buffed to a mirror finish.
Finally, I drilled an extra hole in the frame rail and mounted the brackets and bar.
Using these simple steps, a person could make a bracket that extends all the way to the shock and adds a little design flair if they wished.
That's it for today, and remember, if your day doesn't shine, use a better polish!
Cutting the parts out of thick aluminum stock
Buffing the part
Drilling extra hole in frame. (be sure to seal the hole to insure it doesnt rust in the future)
Bracket mounted to frame
Bracket closeup prior to finishing