Grab Bar for 1975-1977 GL1000

[cfairweather]

I have been making some more bars but I have to say it is an expensive, difficult and time consuming process. I probably won't make anymore after this batch. I do have plans to try and make some that do not require any silver braising and if this works out, it would be much easier and take less time. If I am successful, I will post some pictures. For now, here is a picture of a 1975-1977 bar that I just finished. It is made from a 4' piece of unpolished stainless steel tubing. It takes a lot of work to make it look like chrome, but stainless is so much better than chrome plating a piece of steel. You can buff scratches out and it is more durable. I enjoy making things, but this is the hardest item I have ever made.

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[Rat]

Wow …

Gord

[Whiskerfish]

Wow …

Gord

Yea what he said!!

[digger]

What they both said, Wow! You are an artist. I’m sure it does take a lot of time, but really looks nice, and stainless too boot.

[Fred Camper]

That is some terrific craftmanship. Outstanding fabrication for sure. You are now our hero.

[cfairweather]

Thanks for your kind words.

[kerryb]

Wow! Very nice. Curious what method you used to bend the tubing?

[cfairweather]

Over time, I have made and modified two primary tools to make the bends. I also made other tools to precisely drill the holes and accomplish other challenges that come with making the bar. I use a pully like wheel attached to a GL1000 final drive to turn the wheel. The the big loop is formed by bending the stainless tubing around the "pulley." I used a router and made the pulley out of oak. The other tool is also made out of wood. After I form the big bend, the bar is clamped into this tool using a hydraulic press. Then I manually make the other two bends. I will take some pictures when I have time so people can see how I did it. I might be willing to sell the tools at some point.

[kerryb]

Over time, I have made and modified two primary tools to make the bends. I also made other tools to precisely drill the holes and accomplish other challenges that come with making the bar. I use a pully like wheel attached to a GL1000 final drive to turn the wheel. The the big loop is formed by bending the stainless tubing around the "pulley." I used a router and made the pulley out of oak. The other tool is also made out of wood. After I form the big bend, the bar is clamped into this tool using a hydraulic press. Then I manually make the other two bends. I will take some pictures when I have time so people can see how I did it. I might be willing to sell the tools at some point.

Thanks, Very nice, your results look better than factory stuff

[cfairweather]

Here are the main tools that I use to make the bars. I also use a hydraulic press. I used a GL1000 final drive and disk brake to turn the wooden pulley wheel. I made the pulley wheel out of oak and used a router to make the groove. Can you figure out what each tool is used for? I know, the tools are not pretty but I don't care, they work.

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[Fred Camper]

Great craftmanship and great tool building. Shows you are very talented.

[gltriker]

WOW !

[cfairweather]

The clamping tool, bottom picture with the vice, is used to precisely drill the holes. The 304 stainless steel is hard and only high quality cobalt bits will go through it. I start with a small hole and then graduate to a larger bit until I get the hole to the right size. The step bits work well for part of this process. The 56% silver braising rods are perfect for making strong, beautiful joints; however, silver is expensive these days. Also, the torch heat discolors the stainless, so you have to work hard to polish it to a chrome finish. For this reason, my goal is to make a bar that requires no braising. I have the ideas in my head but just haven't had time to do it yet. I am getting a used Grizzly G9729 Combo Lathe/Mill in a couple of weeks which I think will help me with my projects. That is, IF I can figure out how to use it . Thanks for your comments.

[5speed]

you're going to turn this in to a business if you aren't careful.

[cfairweather]

Now that made me laugh . I look at this as a service to the GL1000 community, but I am going to make a profit. It takes so much time to make one of these things... But since I am retired, time is not a problem. I understand why there isn't a business making and selling them, because it doesn't make a lot of sense . I would be willing to donate one of my "seconds" to the NGWClub web site if they want to raffle one off or have a contest to promote the web site. The winner would have to pay the shipping which is about $20.00 in the USA.