How to Make Homemade Springer Forks

A springer fork is a multispring suspension assembly that provides independent suspension for the front wheel of a motorcycle. Expensive bikes have built-in, adjustable springer forks. Until motorcyclists began to seriously experiment with modifications to their bikes it was fairly difficult to engineer a front suspension assembly. Motorcyclists have fashioned very high-quality suspension units for the front wheel of a cycle. With a creative and welded vertical spring assembly it is now possible to fashion a custom springer fork.

Things You'll Need

  • 1/2-inch by 2-inch steel bar stock
  • Steel vise
  • Tape measure
  • Power hacksaw
  • 1/2-inch power drill
  • 1/2-inch by 1-inch steel angle
  • 140-amp stick welder
  • 1/2-inch by 1-inch steel angle
  • 3/4-inch by 10-inch heavy steel bolt
  • 3/4-inch by 6-inch steel U-bolt
  • 3/4-inch steel rod
  • 1/4-inch by 1-inch steel bar stock
  • 1/2-inch by 1-inch steel bolts
  • 1-inch by 6-inch heavy steel spring
  • 3/4-inch by 4-inch heavy steel spring
  • Wrench set
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Instructions

    • 1

      Insert a piece of 1/2-inch by 2-inch steel bar stock in a steel vise. Measure and use a power hacksaw to cut a 10-inch piece of this steel. Drill a 5/8-inch hole through the middle/center of the 10-inch piece. This piece is the fork bridge that connects to both bike frame forks.

    • 2

      Measure and cut two pieces of 1/2-inch by 1-inch steel angle. Measure the distance from the front center of one of the bike’s vertical frame forks horizontally to the other. Mount the 10-inch piece of 1/2-inch steel in the vise and weld the two pieces of angle steel to it. They should be welded – angle flange end to plate edge -- at the points where the angles can then be welded to the frame forks. Weld the angle/bar assembly to the bike’s vertical frame forks. The resulting weld will produce an attached suspension bridge that extends flat and horizontally in front of the frame forks. The springer fork shaft will move up and down through the hole in its center.

    • 3

      Measure and mark two 2-inch lengths of the 1/2-inch by 2-inch bar stock. Keep the piece in the vise and mark and drill 1/2-inch holes in both measured pieces dead center in the piece. Cut the two drilled pieces of bar stock. Weld the two cut pieces to the bottom end of the bike’s frame forks. The welds should hold the drilled pieces parallel to the long axis of the fork, allowing an axle rod to be inserted laterally through them.

    • 4

      Build the springer fork by welding the nut end of the 1-inch by 10-inch steel bolt to the back (curved) end of the 6-inch steel U-bolt. The long axis of both pieces should be parallel. Hold the front wheel up against the welded 10-inch plate (the suspension bridge). Measure the vertical distance between the plate and the axle hole in the wheel. This is the total length of the forks that need to extend down from the U-bolt curve-weld. Measure, cut and weld two pieces of the 3/4-inch rod to the ends of the U-bolt ends, producing the final springer fork.
      Make two more 1/2-inch drilled extension pieces, identical to the pair welded to the ends of the frame fork. Weld these, with the same location and angles as those on the frame fork, to the ends of the springer fork.

    • 5

      Cut two pieces of 1/4-inch by 1-inch steel bar stock 6 inches in length. Drill three 1/2-inch holes in each piece – one on the end, centered, and 3/4-inch from the end; the third should be in its middle center. These are the stretcher pieces.

    • 6

      Bolt one end of the stretcher pieces to the fork extensions on the bike’s frame fork. Bolt the bottom of the springer fork to the middle holes on the stretcher pieces. Lift the springer fork, insert the big spring (the suspension spring) over the top, singular shaft (the welded 10-inch bolt) and insert it through the hole in the bridge plate. Insert the smaller spring (the reaction spring) on the singular shaft and place a washer and bolt on the end.

    • 7

      Mount the front wheel by running a 1/2-inch axle bolt (varies by bike) through both end holes on the stretcher pieces and the wheel. Adjust the tension on the springs by cranking the single bolt up and down.