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Step 3Make the fork dropouts
Right now, our forks are just two tubes. There's no way of attaching them to a wheel, so we need to make some drop-outs.
Pic 1 shows what we want to achieve.
The drop-outs need to be strong. I used some scrap steel plate, about 3mm thick. This is ideal.
Pic 2. Overlay one of the existing fork's drop-outs onto the steel to be cut. This will give an indication of the size and shape of the piece to cut out.
Use an angle grinder to cut out two pieces from the steel to form the drop-outs.
Pic 3. Angle grinding is never exact, so the drop-outs were not exactly the same. I aligned the drop-outs in a clamp and used the grinder to get their edges identical.
Pic 4 Use the grinder to make the edges neat. Remember, the straighter the surface, the better the join will be.
Pic 5. Clamp the two pieces together and cut out the slots for the wheel axle.This way, you can be sure that when you use an angle grinder to cut the slots, both slots will be identical. Take your time here - don't cut too much of you'll risk the wheel popping out. Your aim here is to cut a slot just big enough for the wheel's axle to fit snugly. Keep trying to fit the wheel axle into the slots until they just fit. A tight fit is needed - not a lose fit. (Pic 6)
Next, we need to weld the drop-outs to the forks. I used a magnetic mount to hold the drop-out to the fork. IMPORTANT: I made a mistake when I welded my dropouts - I placed them right in the centre of the tube - I should have moved them closer to one edge. I only discovered this later during a test ride when a wheel's spokes were rubbing against the inner side of the fork tubes. Luckily, I was able to use another wheel which fitted better, but take heed of this mistake!
Pic 7. Tack weld the drop out to the forks. Check your alignment. When your happy that all is well, weld it securely. Here's where the time taken to make a straight edge pays off!
Pic 1 shows what we want to achieve.
The drop-outs need to be strong. I used some scrap steel plate, about 3mm thick. This is ideal.
Pic 2. Overlay one of the existing fork's drop-outs onto the steel to be cut. This will give an indication of the size and shape of the piece to cut out.
Use an angle grinder to cut out two pieces from the steel to form the drop-outs.
Pic 3. Angle grinding is never exact, so the drop-outs were not exactly the same. I aligned the drop-outs in a clamp and used the grinder to get their edges identical.
Pic 4 Use the grinder to make the edges neat. Remember, the straighter the surface, the better the join will be.
Pic 5. Clamp the two pieces together and cut out the slots for the wheel axle.This way, you can be sure that when you use an angle grinder to cut the slots, both slots will be identical. Take your time here - don't cut too much of you'll risk the wheel popping out. Your aim here is to cut a slot just big enough for the wheel's axle to fit snugly. Keep trying to fit the wheel axle into the slots until they just fit. A tight fit is needed - not a lose fit. (Pic 6)
Next, we need to weld the drop-outs to the forks. I used a magnetic mount to hold the drop-out to the fork. IMPORTANT: I made a mistake when I welded my dropouts - I placed them right in the centre of the tube - I should have moved them closer to one edge. I only discovered this later during a test ride when a wheel's spokes were rubbing against the inner side of the fork tubes. Luckily, I was able to use another wheel which fitted better, but take heed of this mistake!
Pic 7. Tack weld the drop out to the forks. Check your alignment. When your happy that all is well, weld it securely. Here's where the time taken to make a straight edge pays off!
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