Front Fork

Photo 1 – Setting front fork angle

The front fork will be set at a 28 degree angle (matching the angle of the original voyager) and held in place using two upright supports and two angled supports.   While being set up for welding, the fork is held in position on an adjustable tripod (the orange legs in Photo 1) to keep it at the correct rake angle.  Note the lengths of 1×2 tubing (see arrows) which have been clamped to the side rails of the base frame, squared, and extended forward. These rail extensions act as guides for centering the front wheel and fork with the frame base. (Photo 1)

Photo 2 – Centering front wheel and fork

Photo 2 is a front shot of the fork being positioned. Note the extended side rails to the left and right of the front wheel used for determining the center position of the wheel.




Photo 3 – Close up of stops (red) and centering pin (white) which limit wheel turn radius
Photo 4 – Shims clamped in place to center front wheel, steering head and connection box

The steering tube and front fork have machined “stops”  (See red arrows in Photo 3)  and a centering pin (See white arrow in Photo 3) which prevent the front wheel and fork from being turned too far left or right thereby creating a dangerous or unstable condition.    By fitting identically sized wooden shims between the center pin and the stops on each side, the fork and the “junction box” can be clamped in place at dead center to insure the junction box, steering head and front wheel will be pointed straight forward when the fork is welded to the frame. (Photo 4)


Photo 5 – Angle supports tack welded in place

Angle supports between the  base frame and junction box can now be tack welded in place. (Photo 5)

Photo 6 – The angle supports are welded to the fork’s “junction box” (arrow)





The arrow in Photo 6 identifies the junction box which is used as the upper  welding point for the angle supports. (22a)






Photo 7 – Front uprights are welded in place

The front uprights (red arrows in Photo 7) are cut and welded to the base frame and the front fork “junction box”.





Photo 8 – Front fork welded to base frame
Photo 9 – Front fork welded to frame

Two more views of the front fork welded to the base frame. (Photos 8 and 9)













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