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 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.
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)
Angle supports between the base frame and junction box can now be tack welded in place. (Photo 5)
The arrow in Photo 6 identifies the junction box which is used as the upper welding point for the angle supports. (22a)
The front uprights (red arrows in Photo 7) are cut and welded to the base frame and the front fork “junction box”.
Two more views of the front fork welded to the base frame. (Photos 8 and 9)
