Well, I’m finally starting the build I first contemplated probably five years ago, the High Roller recumbent cycle. I just picked up a couple of 26” 21-speed bikes, and last night I cut the forks off of one of them. I made a practice weld on the square boom and prepared to weld the forks on. But, I encountered some questions that I’d like to get some clarification on before I make these critical welds.
First of all, I’d like some advice on how to clamp the forks in position on the boom prior to tack welding. Of course, the forks are bolted onto a wheel as described in the instructions. I’m looking for a good way to hold them fast to the boom so that I can check alignment prior to tacking in place. My largest C-clamp opens to 7”, but I need closer to 8”. I looked at a ratcheting squeeze clamp, but it did not hold tightly enough to keep the forks from rotating against the boom. So, I’d welcome any suggestions here.
Second, I have questions about the wheel alignment with the boom when using a front fork to hold a rear wheel with a hub of seven sprockets. There is a gap of 1/4-3/8” between the cut parts of the fork (which will be welded to the boom) and the boom when the forks extend at right angles to the axle. If I put the cut part of the fork against the boom in preparation for welding, there is an interference between the fork and the small sprocket. I can put a couple of washers on the axle to provide clearance between the fork and the sprocket, but the the wheel is slightly off-center relative to the boom. The most obvious solution seems to be attaching some plate to the boom as spacers and the welding the forks to the spacers, but maybe you have a better suggestion.
[I tried to add pictures, but I got an error message.]
First of all, I’d like some advice on how to clamp the forks in position on the boom prior to tack welding. Of course, the forks are bolted onto a wheel as described in the instructions. I’m looking for a good way to hold them fast to the boom so that I can check alignment prior to tacking in place. My largest C-clamp opens to 7”, but I need closer to 8”. I looked at a ratcheting squeeze clamp, but it did not hold tightly enough to keep the forks from rotating against the boom. So, I’d welcome any suggestions here.
Second, I have questions about the wheel alignment with the boom when using a front fork to hold a rear wheel with a hub of seven sprockets. There is a gap of 1/4-3/8” between the cut parts of the fork (which will be welded to the boom) and the boom when the forks extend at right angles to the axle. If I put the cut part of the fork against the boom in preparation for welding, there is an interference between the fork and the small sprocket. I can put a couple of washers on the axle to provide clearance between the fork and the sprocket, but the the wheel is slightly off-center relative to the boom. The most obvious solution seems to be attaching some plate to the boom as spacers and the welding the forks to the spacers, but maybe you have a better suggestion.
[I tried to add pictures, but I got an error message.]