Head In The Shed

Nothing beats the satisfaction of a DIY farkle well done. Here’s what ABR reader Tam Forrester has been up to in his shed…

Nothing beats the satisfaction of a DIY farkle well done. Here’s what ABR reader Tam Forrester has been up to in his shed…

I have just ­finished making a sidestand foot-extender thingy for my trusted TDM 900 – and yes, that is a technical term! All that’s left to do now is paint it. It took me about ­ five hours to make and cost around £20, as I already had the aluminium kicking around my workshop. Here’s how I did it:

Materials

  • ­ 3mm-thick aluminium plate
  • ­ 4x M5x20 countersunk machine screws
  • ­ 4x M5 Nyloc nuts
  • ­ 4x M5 washers
  • ­ 4x 5/8″ tap washers

Tools

  • ­ 5.5mm drill bit
  • ­ Countersink drill bit
  • ­ Stepped hole-cutter
  • ­ 8mm combination spanner
  • ­ 4mm Allen key
  • ­ Ruler
  • ­ Scribe and centre punch
  • ­ Hacksaw
  • ­ Files

Stage 1

Mark out a template of the side-stand’s ‘foot’ on piece of card. Draw the outline again 3mm inside of the original template outline.

Stage 2

Cut out a second template to the shape you want for your side-stand extender plate. (At this point, it’s probably a good idea to check for any clearance issues by putting the side-stand up and using the cardboard template as a guide.)

Stage 3

Place the side-stand plate template on the aluminium and trace the outline using the scribe. I found the best way to do this is to clamp two pieces of aluminium plate together, then cut out the shape.

Stage 4

While the two bits of aluminium are still clamped together, now’s a good time to drill the four 5.5mm holes through the plates where you want the screws to go, making sure their position won’t interfere with the side-stand. Countersink the four holes on the plate that will be on the ground, so the ­ finished foot will sit flush.

Stage 5

Choose one of the plates you’ve now cut to shape and transfer the template of the side-stand footprint from step 1 on to it, then cut this shape out. I used a stepped hole-cutter and hacksaw for this. Check the ­ fit with the side-stand.

Stage 6

At this point, I test ­ fitted the ‘foot’ to the side-stand and realised as I tightened it that the whole thing was sliding backwards off the plate that was on the ground, so I had a cuppa and a rethink. To overcome this problem, I reduced the measurement of the top plate’s back edge by 4mm and put a slight fold on the bottom plate to stop it moving.

Stage 7

I reassembled it using four 5/8″ tap washers on each of the machine screws and four M5 washers as spacers, before tightening down the top plate. ­ Do you have your head in the shed? If you’ve got a DIY bike project to share, email details to [email protected] with a few pics of your handiwork, and if it’s featured in the mag, we’ll send you some ABR stickers for your pimped-up steed!