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Front Mudguard Stays
AS-J
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Background:
The front mudguard stays as described in the book are quite difficult to
make, due to the need to bend tubing cleanly and also to get the nyloc nuts
on the top balljoints to fit over an extra piece of 3mm steel and still
lock safely. The stays in this article are of a different pattern, and were
made by Martin Keenan - but they are easy to make.
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The stays consist of a triangular
mounting plate with an 8mm hole at each apex, to which two pieces of 19mm
tube are welded at 90 degrees to each other. These tubes have a length of
25mm by 3mm steel strip welded to their far ends - you will get the idea
by looking at the photos. The clever bit is the mounting system: the Cortina
upright has 3 M8 bolt holes in it to secure the brake dustcovers, and these
are used to mount the whole stay. |
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Step 1: with
the brake disk and hub off the stub axle, clean out the 3 bolt holes with
an M8 tap: the original bolts don't go right through the kingpin, and the
exposed part of the thread gets rusty. |
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Step 2: take 3 M8 bolts,
9cm / 3.5" long and screw them in to the holes in the kingpin, securing
the brake dust cover. Tighten the bolts firmly, then replace the hub, the caliper (the clearance between the caliper and the stay is tight, and you must have the caliper in place to get things right) and
the roadwheel. |
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Step 3: take some 8mm
internal diameter pipe (the pipe I used is "black pipe", a cheap
and rough thick-walled pipe which is nominally 8mm internal and about 13mm
external). |
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| Locate the mudguard bracket on the three bolts
and allowing clearance between the stays and the tyres measure the length
of pipe needed to space the bracket from the kingpin. Cut the pieces, assemble
and check the clearance. |
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Step 4: with the bracket
bolted in place you can bend the mudguard supports over the roadwheel using
a piece of 19mm pipe as a spacer - remember to allow clearance between bracket
and tyre for the nuts you will use to attach the mudguards. |
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Step 5: line up the mudguard, drill
the holes and bolt it in place........ |
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Footnote: I used the top rear mounting
bolt to attach a 3mm thick plate for the front brake pipe - this is just
about on the line of the kingpin rotation and so avoids a big change in
the distance from the body to the suspension as the steering turns. |
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