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Discussion Starter #1
Well since my bike is apart waiting for a magic tank fix from Norm and I cant keep my hands off my bike in the meantime I'm doing some little projects I had in mind. Today I took on the triple clamp. I have cycle cat clip-ons on my bike and I always hated the way the stock riser was cast into the clamp and looked like poo with the clip on's. So today I decided to hack that sucker off. I was all pumped to finish the metal work tonight and post some pics but I cant find my damn digi cam. So tommorow I promise. I think everyone will be pleased with the result. I will give the rundown on how to do this right now though.

Allow 3 hours to complete.

Tools needed: (what I used at least)
Saws All
40 grit sandpaper
4 1/2 inch angle grinder
Disc sander
Sanding disks (40grit)
Dremel
Step 1: remove triple clamp (duh)
Step 2: clamp peice into vise
Step 3: Use saws all to make first cut removing as much material as you can. (not real easy to cut)
Step 4: Use angle grinder to cut the rest of the metal away. This will take the most time. 30min. on each side minimum. Make sure to follow the form of the clamp and be careful not to cut to much material.
Step 5: Use orbital sander/disk sander to start smoothing out the grinder marks. If you were smooth with the grinder things will start to look pretty good soon.
Step 6: Get your 40grit sand paper and hand sand any areas that are still rough.
Step 7: I then went to 80 grit to get it a little smoother. It really starts to look nice when you get to this point.
Step 8: Decide if you want to have it powdercoated or poilished. If polish is your thing you some more work to do. If its smooth and no scratches in it you can get it powdercoated at this point. I havnt decided what I want to do yet.

Note: The risers are kind of hollow and you will remove so much material that you end up with a 2 regtangular holes in the clamp where the riser was. You will also have a hole in each side that one of the old riser bolts went into. I took the dremel and smoothed these out a little. If you never knew the risers were there you would just think that ws the design. I was thinking about enlarging the regtangular hole to remove the bolt hole but I think ill leave it for now. This will make more sense when I get the pics up tommorow. Well... this is a tough little job and youll be all dirty when your done... have fun!
 

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03monster800:

Oooohhhh... that thing looks SWEET. Nice nice work :) Maybe I'll get me some clip-ons after all.

M.
 
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Looks awesome. I wondered if anybody did this. Glad I don't have to deal with it! ;D
 

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I'm really looking forward to seeing it on your bike. I might have to do it to mine as well.
 

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Discussion Starter #12
Ok finally got a pic of it installed on the bike. Looks really nice I think. I should have taken before and after pics. If someone can take a stock pic w/ clip-ons for comparo that would be cool. Here it is!

 
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My triple clamp is getting some further mods. I am going to fill the bottom side with aluminum from a Tig welder before I do any grinding or cutting so I have a smooth finish across the top. I'll send picture when I get it finished.
 

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That looks terrific! I think I am going to have to give it a shot this winter as well. I really want clip-ons & have been looking for a good way to make it happen. I think this jut may be it. I will leave more coin for other mods versus going the Cycle Cat triple mod.
 

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Cycle Cat has a stock 620 triple from Gman86 that they are using to fab up a replacement just for the new 620 & 750 Mosters. It hopefully will be out this year if we're lucky. I haven't heard anything about it lately. Maybe if Gman sees this thread he might be able to get us an update. I'm eager to see what they will be coming up with.
 
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I went the extra step and will post pics in the near future.. I actually cut off the risers with a portable band saw then used an angle grinder to get them close.. then had my buddy fill the holes with aluminum. then finished grinding then buffing...now in the polishing stage...look really cool only difference is in the two different grades of aluminum and defects in the casting. but looks very trick. If anybody wants them done I'm sure we can work out a price!
 

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Sounds very cool. I'd like to see them. I was thinking of doing something like this myself then repainting the triple. Looking forward to seeing what you have done.
 

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Bike looks great. Now all you need to do is get those cans chopped down about 8 inches so you can get a nice shot of that tail and rear wheel

David
 
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