Thanks, Mike. I will contact him when I get the fairing done enough to remove from the bike and I show it to him.
It is time to make some fairing brackets. There are two choices for the aluminum, 2024, an alloy with copper as a main ingredient, and 6061, an alloy with magnesium and silicon as primary alloying ingredients. The 2024 is very strong with poor corrosion resistance and fair machinability. The 6061 is strong enough and it has good corrosion resistance and very good machinability. I order a 13-inch long stick of 6061 from Fastenal. My machine tools are a Sawzall, an air grinder, some files, and an old drill press. Hole saws are used for the fancy work. Here are some tricks to make this hole saw magic happen.
First, select a hole saw with a set to the teeth. The groove it makes is wider than the saw barrel and it will not bind as easily. Ace Hardware hole saws are made in the US and the teeth have a lot of set.
Second, use the pilot drill to get the saw started, then take it out. The drill creates a lot of drag and makes cutting harder.
Third, use a slow speed and lubricant. This will keep the saw from packing up with aluminum and binding. Kerosene is a good lube but it smells bad. I use the odorless kerosene made for kerosene lamps.
The bar will make two brackets. I do not detach them until the very last step. It is a lot easier to clamp the part down if it is longer.
Happy New Year.