Fabricating a custom swingarm for an Aermacchi road racer with Paul Brodie

[@ronhuffman7973]

The best things in life, machining, welding, fabrication, bicycles, and motorcycles. In no particular order, at least today....

[@paulbrodie]

Good comment. I think we could get along!

[@mikey7278]

I love how Paul can eyeball something and it fits perfect first time

[@paulbrodie]

Some times I have good luck to help.

[@joehovanec1985]

You are a talented in so many ways. It takes a combination of many skills to do what you do. You do precise and knowledgeable work. Enjoy your videos, especially the motorcycle work.

[@paulbrodie]

Thank you Joe. We will keep doing the motorcycle videos a little longer...

[@Dnrjhn7]

Im so happy to see Mr. Ian McShane happily fabricating swing arm now. That's a pure talent and skill work tho! I might try this in my Dad's shop. Thank you, Sir!

[@JTSMotorsports]

This is some of THE BEST CONTENT I’ve seen on KZbin! Love it! 🤙🏻🤘🏼

[@paulbrodie]

Thank you Jacob. The Aermacchi content has been some of our most watched videos. Bike sounds great too, once we got the jetting figured out....

[@jepershaolin9673]

I'm smiling while watching how you done the work,very impressive,excellent.

[@paulbrodie]

Yamasuki, thank you very much.

[@Kevin_747]

I loved my 1970 Aermacchi/HD 125cc. It was brand new and was my 15th birthday present. It was wicked fast for a 125 and a maintenance nightmare. Thanks for the video.

[@paulbrodie]

Yes, the dealers only wanted to sell and work on the big Harley's. They resented having to sell and fix the Aermacchis sold as little Harleys.

[@joell439]

Paul, it is such a joy to watch you work. Thanks for taking the time to show us...... 👍👍😎👍👍

[@aghaazhar9048]

Nice and perfect Fabrication with cool instruments........... Cool Mind

[@paulbrodie]

Thank you Agha.

[@MadeOfSteel_eBikes]

When I watch a Brodie video, I take coffee and celebrate life

[@paulbrodie]

It sounds like you have got your priorities in order. Thanks for watching!

[@mattyceks380]

I love how all older machinists welders ect can do a job and when they're done the clothes their wearing are still clean im filthy after i finish a job hahahaha always amazed me as an apprentice and still dose love your work Paul your an inspiration and absolute legend.

[@paulbrodie]

Matty, thank you very much :)

[@thedr309]

I have been fabricating over 40 years and I got to admit your work is superb! I do lots of race car work an it's great to see you using some of the same things we do as far as lay out. if you were closer I'd love to sit down with you over coffee and swap idea's... oh your camera man has a super cool name!

[@paulbrodie]

Thanks Mitch! That would be cool to sit down with coffee and swap stories.. Do you know Dwain Kreymr? He lives close by and does a lot of cars, like GT40's.

[@MAFZ1200]

I´m not going to comment "engagement" every time, I´m just whatching your videos in order, jajajaja! I´m a bike mechanic and in the future I want to build my own bikes. Thank you for this!!!!!!!

[@paulbrodie]

Glad you like them! I hope you do learn to build your own bikes.

[@MetaphorCanada]

I'm loving your maker videos Paul. Each one better than the last. Cheers xx

[@paulbrodie]

Thank you :)

[@paulbrodie]

thank you :)

[@steveyoung5520]

Paul, I'm sure I'm an audience of one, but I would LOVE to see more videos on your Aermacchi project. I'm a Sprint guy since I was 15 (51 years ago; sheesh); my first motorcycle was a Sprint. I have a bone stock 1966 that I restored, and my retirement project is a 350 flat-tracker / street tracker. I have a 1963 frame with a title, but I've decided to build a new frame for it, just because. I'm using a 1972 bottom end and a 73 / 74 top end. I've scoured eBay several years for parts, and have scored a NOS ERS piston and F-grind cam. I've known about your Flashback Fab site for a long time and gleaned every bit of information I can from it, and I'm excited as hell that you have a KZbin channel and are re-creating your road racer. In between bicycle videos (which I learn a ton from just on general frame building), please throw me a bone occasionally on the road racer! Thanks!!!!

[@paulbrodie]

Steve, good to meet you! That's great you have an Aermacchi project. You'll be happy to know the next few episodes will all be Aermacchi :)

[@dulanfu3452]

Too sweet. There were no Chinese subtitles in the past. Now I can understand the content of the film more clearly. Thank you!~

[@paulbrodie]

That was Mitch's idea :)

[@cbpuzzle]

It's impressive how fast and efficient he is.

[@paulbrodie]

No sense hanging around and wasting time!

[@Minskification]

Искал совсем другую информацию,но случайно попал на это видео. Очень качественно и мастерски выполнена работа! Теперь я смогу получить дополнительные знания из ваших видео и подсмотреть интересный инструмент и оснастку для станков) Спасибо!

[@zmotorsports62]

Excellent workmanship. Thanks for the video. Mike

[@otaviofl]

I am amazed how calm and steady you get it all Done. Didnt ignore editing, of course. Welding, fabrication and motorcycle... If you add a beer after all that, its my description of heaven. Are you accepting apprenticeships?

[@paulbrodie]

Sorry, no. But thanks for watching!

[@5tr41ghtGuy]

This is the first high precision fabrication video I've seen. Very interesting, and very appropriate for a road racer. Thanks for posting!

[@paulbrodie]

And thanks for watching!

[@mikec6659]

One of the best video I ever seen on KZbin. Most of them are blacksmith but Paul you are very professional, methlogical , accurate, wise man and super talented in all aspects. The welding was done so neat as if it was welded by the robot. I seen robot welding in our shop . Thanks you so much for sharing this video I learned so much and maybe come to use one day.lol

[@paulbrodie]

Glad you enjoyed it. Thanks Mike.

[@timcurzie9429]

You are now officially my mentor. Good luck to us both 👊🤓 🦶

[@marklohnes6313]

Fabulous series! You’ve got another new subscriber! I’m learning from every video I watch. Cool bike too!!

[@serdaraytemiz9978]

Love watching your videos Paul. Awesome build again.

[@paulbrodie]

Thanks Serdar.

[@davidforeman2734]

I wish I had that knowledge when I built my sidecars

[@paulbrodie]

We do the best we can with what we've got. Thanks for watching!

[@marcelsteinhauer4377]

Thx for sharing all your knowledge. Such a great video as always! Greetings from switzerland

[@davidbarnes7064]

Wishing you were my neighbor so I could hangout looking over your shoulder! You have a very interesting life. Thanks for your videos.

[@paulbrodie]

Thank you David. We can be KZbin Neighbours!

[@davidbarnes7064]

@@paulbrodie I used to ride a 250cc HD Sprint and had a neighbor with a 350cc ERS flat tracker. That was an amazing bike!

[@moderatefkr6666]

4:05 Paul, when I was 12 years old in Mr Ware's metalwork class, I dislocated my left thumb doing that. The emery cloth gripped just for a millisecond and dragged my thumb under and round the workpiece. Instinct and a huge amount of luck caused me to let go of the emery cloth very quickly. It was hellishly painful, and one of the best lessons I ever had in the machine shop, and in life. Consequently, I treat all dangerous things with a huge amount of respect. I still do dangerous things, but I mitigate risks by following sensible procedures. You should of course only ever use a pad of emery cloth held under the workpiece with one hand, and NEVER EVER wrap it around the workpiece like that. I know, you've been doing it for years and never had an issue. I also know I was incredibly lucky to escape with just a dislocated thumb. Mr Ware told us about a guy who lost his arm doing that. The memory has stayed with me. Yes, it could easily have been an apocryphal story to scare the kids (what else is school really about?), but it wasn't. Mr Ware had seen combat in WW2, so he had demons. He also had a small collection of gruesome photos of industrial accidents. They weren't in colour, but a blood splattered lathe looks scary even in insurance company monochrome! I offer this advice as a fair trade by way of thanks for sharing your work. You're a very talented and nice guy, so I'd really like you to be able to keep making these great vids. Peace

[@paulbrodie]

Yes, it's good to be very careful. I lost the skin off the top of my thumb trying to polish aluminum with steel wool in the lathe. Yes, I do wrap the emery cloth, but never too close to the piece. Thanks for writing in, and thanks for watching!

[@garyyorke1080]

Very interesting to see how it's done. Nice use of the tooling and a good clear instruction on what's what and why . Thanks

[@paulbrodie]

Thank you Gary.

[@ScrubsIsee]

... I‘m very happy with that! Word!

[@paulbrodie]

Happy is a good place to be:) Thanks for watching!

[@huddleberryfin]

Perhaps you should toss some tools on the floor before I come and visit your shop so I can ask the “is it for sale” question. Would love a “Paul Brodie” belt sander. Haha. Great job Paul. Very nice work.

[@paulbrodie]

I'm not sure why I would toss some tools on the floor?

[@huddleberryfin]

@@paulbrodie probably why I’m not watching Tom’s channel.

[@colinbatchford8007]

Some really nice welding you have going on there looks a proper job.

[@jasonjohnstone686]

Nice work, can tell you are a true craftsman's.

[@StraightLineCycles]

Those are really good tig welds!

[@paulbrodie]

Thank you. I have had a little practice :)

[@OwlShadow]

this dude is just to calm for its skill level but that what it makes this channel unique

[@dennisyoung4631]

Using a drill-press vise/vice to hold stuff for welding. I bought one for that exact reason, but have yet to use it. Good to know I’m not crazy for thinking about using one…

[@robwal3665]

Very well done

[@quartfeira]

Nice! 🤙🏼 Just the white balance in post production was a little fckd up, quite blue-ish! I love your videos Paolo! ♥️

[@paulbrodie]

This was one of our earliest episodes, and Mitch has learned a lot about video production since then. Thanks for watching.

[@quartfeira]

@@paulbrodie yes, I see. I didn't mean to criticize Paul! For shure he improved a lot! 👍🏼 Cheers

[@dominikdo8160]

Wow, großartige Arbeit. Ich bin beeindruckt! Das ist echte Handwerkskunst 👍

[@paulbrodie]

Thanks for watching!

[@minigpracing3068]

Wow, that was useful to me. If I can ever get back to racing, I want to build a new swingarm for my KAYO MR125 to maybe extend it a little, and fit a shock that is longer. It uses a short Honda NSF100 shock that is nearly impossible to find or far too expensive for the hobby racing that I do. And the stock swingarm is pretty flexible too.

[@paulbrodie]

Making a swingarm is a great project! I'm back to working on this little Aermacchi in a couple episodes.

[@whydahell3816]

You should make some tig welding videos. Great filter!!!

[@paulbrodie]

Thanks. We did make a Tig welding video. Have you seen it?

[@EndlessDelusion]

You can tell you're talented because you made it look too easy!

[@paulbrodie]

Thank you EndlessDelusion!

[@marte5366]

Magnifico lavoro Paul

[@smithtracing]

Always wanted an Aermacchi race bike. Now, when I win the lottery, I'll know who to look up to do some work!

[@paulbrodie]

I really like building race bikes, especially Aermacchi. I do believe there are some of my racing stories on my website: www.flashbackfab.com

[@rc166honda]

Beautiful work, great to see skill and precision in fabrication. 👍 subscribed 😉

[@Tonyous]

There is nothing more pleasing than watching master at work! P.S. is it just me or does Paul look like the secret love child of Bill Clinton and Robert Redford!?!

[@paulbrodie]

Hmmmmmm.

[@didhyphitol9784]

Very best worker ... best of the best..maantab... from me indonesian people (South Jakarta )....Getting better..

[@paulbrodie]

Thanks for watching!

[@steveguest8028]

Awesome work 👍

[@paulbrodie]

Thank you Steve.

[@gb4408]

Ron Huffman you are so on to it!

[@darkojovanovic007]

I fully enjoyed watching it. Love it. Excellent , informational stuff.

[@paulbrodie]

Thank you Darko.

[@hondanickx]

Great work , i love the attention to detail ! What i don't like is welding without those sleeves pulled down or any gloves.Your skin will last longer with them on! And the lube used to press on the tube works better ,but it is really bad for the weld .You'll never get all the oil out . I would have pressed it on dry ,if both surfaces have a really smooth finish this works too.

[@paulbrodie]

You are correct. I will be wearing gloves in future to set a good example for our viewers. Safety Third. Regarding the Press Lube: I am quite conscious of the potential to contaminate the weld. I used it very sparingly, and only started 1/4" from the end of the larger tube. As the smaller tube is tapped in, it will actually help to move the lube even farther away from the end of the tube. There is a method to my madness. Thanks for watching!

[@uguyssss]

Will you be doing a video on swingarm bushings? Thanks

[@paulbrodie]

I just ordered swingarm bushings for the Cub, so I will be installing them and possibly reaming them too...

[@johnod1955]

Very good, thanks.

[@truth.speaker]

Some guys spend tens of thousands to learn this stuff at university Others just Google it! Thank you kind sir for sharing your knowledge

[@paulbrodie]

Thanks for watching!

[@luissouza5501]

Parabéns , trabalho altamente técnico e muito bem executado !!!!!!!!

[@paulbrodie]

Luis, thanks for watching...

[@Metal-Possum]

I love the Tom Ritchey stories. :)

[@Benji...]

Paul do you know a good way to do swing arm conversions and make sure everything is aligned?

[@paulbrodie]

Not sure I understand your question. Is a conversion making it longer, or converting it into something else? If you're just making it longer then a surface table and a couple of axles is the way to go.

[@Benji...]

@@paulbrodie I'm actually converting an older gs750 to have a ducati single sided swing arm. I will be setting up a table to act as a jig to keep everything in line and then machining any bushings needed, wondering if you have any tips on lining the swing arm to the frame. BTW great to see your shop at UFV, I'm also in the Fraser Valley and involved with UFV and local education

[@paulbrodie]

@@Benji... I see, you are local. I'm not sure why you need a jig unless you are changing the location of the swingarm pivot. Or modifying the swingarm. You are probably not doing either. The Ducati swingarm will probably mount in the stock location, with a little help. You need to be concerned about sprocket alignment, and shock linkage related issues. Make sense?

[@Benji...]

@@paulbrodie Ok great, thank Paul. Sounds pretty much what I have been expecting, just making sure there wasn't something else I was missing

[@kjsetv7253]

ขอบคุณที่แปลภาษาไทยให้นะครับ ขอบคุณมากๆ คลิปละเอียดมากครับผม

[@paulbrodie]

Thanks for watching!

[@gustavoarielalassia]

Excellent job 👏👏 My positive forever 👍💯👈

[@tomanycooks]

pretty cool mate

[@whiskybon1]

Maestro, perfecto trabajó

[@OpenEmoto]

Nice Nice! I usually pour a lot of oil on my hole saw when doing miters. I believe it protects the tool. Is this a myth?

[@paulbrodie]

Oil can protect the holesaw, especially if the metal is very hard. 4130 is tough, but not particularly hard. I don't use oil because it makes a mess, and takes more time to cleanup.

[@dennisyoung4631]

There is a paste-type lubricant that doesn’t travel as much as oil - *supposedly* - and I recently bought some. (Walks over to get it) “Relton Rapid-tap Cutting Paste” is the label. It *might* help while not making too big of a mess.

[@miamatti]

cool project

[@artworkbyjohn3254]

You should have put a plug weld also, But still very good work very good vid

[@rustusandroid]

All that measuring and then you just eyeball the cross tube.... ok. Fun to watch though :) The tubes will always pull in the direction you weld :)

[@chrislee7817]

I had a 350 "sprint" it had a one into two exhaust system 🙄. Trying to be a Harley I suppose. I used to import old Italian bikes from Italy into the UK back in the day. Love your work by the way. I building three Supermono's at the moment. Keeps me off the street.

[@paulbrodie]

Yes, those were terrible exhaust systems. Trying to make a single look like a twin. I'm back working on my Aermacchi Racebike. Thanks for watching!

[@dzozepe]

Ur work is great I consider building my swingarm myself after watching u but If I may ask, why dont u make the rear mounting for the wheel at last? I mean maybe weld it at last or machine it at last so you wont have to bend or deal with weld distortion?

[@paulbrodie]

I view the swingarm as 3 pieces: The cross tube and the two side tubes. What you are suggesting is 5 pieces, so you are making it more complicated. I have found that simple is usually the best. Thanks for watching.

[@1ManShowCy]

Grate work sir. 👌

[@johnyoung7794]

Would like to see more motorcycle build videos

[@paulbrodie]

Coming up. Your timing is pretty good!

[@joechancio5177]

Really cool. This is a dieing art. Everyone wants a touchscreen to push and have a computer cut out or 3d print now. Lol

[@apousidisvasileios9571]

Perfect job Bravo !!!!!!!!

[@bill3641]

Thanks for sharing your passion with us . Question : Why don't you use an auto darkening helmet for welding ?

[@paulbrodie]

Thanks Bill, I don't like those auto darkening helmets. I think there's a milli second before the shield darkens. Call me old school if you like.

[@bill3641]

@@paulbrodie Thanks for the response , I've been using an auto darkening helmet but at lower amps( tig) I've been flashed a couple times . I think I'll try your approach and eliminate the possibility .

[@paulbrodie]

@@bill3641 Unless you have a very expensive helmet, they don't work well at low amperage on thin metal.

[@brentonlee7071]

I'm considering this battle to put a disc-braked wheel on the rear of an RD350. Great video to let me know what I'm in for! Thanks.

[@paulbrodie]

Go for it! It won't be stock, and what will the purists say?

[@brentonlee7071]

@@paulbrodie Haha, I dragged it out of the mud in a junkyard. Quiet happy to put it back there and a 'purist' can dig it back out.

[@atheistmillwright9229]

What kind of hole saw are you using? Is it starrett or what type? What kind of filler rod and tungsten are you using?

[@paulbrodie]

I used whatever high quality hole saws my supplier sells, including Starrett. Filler rod is Mig wire and tungsten is 2% thoriated. You should watch our Tig welding video. That will answer more of your questions.

[@atheistmillwright9229]

@@paulbrodie I’ll try just stumbled across yours. I was honestly looking for something completely different.

[@dnc23x]

yes, my next project is the rear swingarm for the homemade full suspension ebike :)

[@paulbrodie]

I hope it goes well. Swingarms are not the easiest structures to make.

[@dnc23x]

@@paulbrodie basically just copy and extend the existing one, the neighbor is a welding pro, I'll be supervised. but thanks to your guidance, the confidence gained!

[@paulbrodie]

@@dnc23x Good Luck 😉

[@dennisyoung4631]

Interesting. Wondering about the mid-between region between this and a regular bicycle..?

[@paulbrodie]

Interesting. What does the "mid-between region" really mean?

[@dennisyoung4631]

@@paulbrodie this is when one uses, say, .049 straight gage tubing instead of bicycle-specific tubes, as one is planning on carrying heavy loads with the aid of a 1.0 (or so) kilowatt electric motor - at, say, 12-19 mph. One could endure a few added pounds then, as the motor puts a fair bit more strain on the frame. One needs to “build for downhill,” or similar, is my (possibly addled) thinking.

[@paulbrodie]

@@dennisyoung4631 Yes, .049" 4130 tubing is quite strong and entirely suitable for building an electric bicycle frame.

[@dennisyoung4631]

@@paulbrodie thanks much!

[@stevenpleasant5834]

Hello Paul very nice work you do wish I had some one to help me build some of my parts for my builds.

[@paulbrodie]

Thank you Steven. I hope you do find someone to help build parts.

[@TheLunarFX]

This guy looks like the father in the movie Hot Rod. "NEVER sneak up on a man who's been in a chemical fire."

[@paulbrodie]

I have no idea what you're talking about...

[@TheLunarFX]

@@paulbrodie Ian McShane :)

[@poreektik1320]

Curious if you are using any form of air extraction when tig welding? Or is it not needed when doing such small amount? also, for tig welding bicycle tubing, what filler would you use? Same when tig tacking?

[@paulbrodie]

No air extraction; I don't do enough welding. Filler rod is .035" Mig spool, copper coated.

[@dennisyoung4631]

Based on what I bought in that size (2 pound spool; Lincoln Super-Arc, I think) it’s probably ER70s-6.

[@realmanaesthetics]

Mr. Paul Brodie. Nobody has ever done a video on custom rear disc brake caliper for a swing arm. Would you consider doing a video on it?

[@paulbrodie]

Maybe one day, but I'm in hospital right now, so not from this little channel right now 😉

[@realmanaesthetics]

@@paulbrodie I wish yu recover soon first then ☺️

[@paulbrodie]

@@realmanaesthetics Thank you!

[@puridade1]

amazing work

[@paulbrodie]

The 18" front rim just arrived, so it's back to working on the Aermacchi. Thanks for watching!

[@1963corvette327]

so inspiring and informative,,if i may, what is your profession in?

[@paulbrodie]

Fabricator, artist, engine designer, mechanic, self taught engineer, author, University instructor, motorcycle racer, bicycle fabrication, spray painter, KZbin creator.

[@1963corvette327]

@@paulbrodie That's It.? lol very inspiring, I'm about #7 out of Your#12, but more on the southeast side things, keep up the fight ole friend...

[@heckenzwirn]

Great Work! Love it!

[@leedale4008]

You are a very talented man ,the world needs more skill and less social media.

[@paulbrodie]

Thank you Lee.

[@minigpracing3068]

I'd like to get an Aermacchi for a restoration project, mostly non-existant in my area.

[@paulbrodie]

20 years ago I was buying whole bikes for $300. They seem to have gone up a bit since then, but you can still find them.

[@shawngurney7659]

Surprised to learn the plate adds that much more strength. I thought they were just for show.

[@cozydram1]

awesome stuff ty

[@samoel2343]

Pretty good

[@aquiline-m1590]

Which is lightest and strongest metal I can use to build my dirt bikes subframe? I dont want to use aluminum.

[@paulbrodie]

I would use 4130 steel. Not cheap, but very good...

[@aquiline-m1590]

@@paulbrodie Thanks for your reply. I just subscribed to your channel. I hope I will learn many things from you. Love from India.

[@danceswithcarsdc]

TIG welding without gloves, but wood block for isolation, hope stool is isolated too. Or am I missing something?

[@paulbrodie]

I don't think so...

[@ronhuffman7973]

Lol!

[@karm4vitch918]

Thats a cool one sir ..new sub here luckily YT introduce ur channel to me thou 😁 ..i hope to see more fabrication ✌

[@paulbrodie]

You bet. Thanks for watching!

[@felmarnb5140]

i love it

[@paulbrodie]

More Aermacchi fabrication coming soon!

[@garyweaver4435]

Awesome work. I live in AL. What is the easiest way to simply hang around or work for someone like yourself?? Id love to learn this

[@paulbrodie]

Good question Gary. When I was 18 I got a job as an apprentice working in a machine shop. I learned a lot there. I don't believe that is happening so much these days. I'm retired now, so I'm not needing any helpers. I did take a couple of night school courses when I was in high school, but mostly I'm self taught. Years ago when I was driving cab, I had a work bench in the basement. Vise, hand drill, hacksaw and files. And oxygen-acetylene. That's it. And I made a lot of motorcycle parts. So, I encourage you to start #makingstuff. You will make mistakes but you will learn. Read books on machining and metallurgy, maybe watch videos! It will slowly come together. Good luck!

[@hunterneal7591]

Was the crossbar the same Diameter of the rest the tubing!?!?

[@paulbrodie]

Do you mean the pivot tube, or the curved reinforcing tube?

[@hunterneal7591]

@@paulbrodie the pivot tube

[@paulbrodie]

@@hunterneal7591 Same size. Both the pivot tube and side arms are 1.5" OD w/ .095" wall 4130.

[@raymaroney8355]

😊😊☮☮

[@Caz885]

no tig welding without gloves! otherwise very nice work and your workshop looks good and clean!

[@paulbrodie]

I have been scolded by others too.

[@daveanderson2316]

Just an FYI, that is an insert style shell mill, a fly cutter has one "arm" style blade. Love the videos, very well done, very to the point. Keep up the great work. Hi to Mitch, great job sir!

[@paulbrodie]

OK, I'm still learning. Thanks for watching!

[@daveanderson2316]

@@paulbrodie if that's your "just learning", you are way ahead of the curve my friend! Beautiful work.

[@brianbrown4965]

wow

[@paulbrodie]

Thanks for watching!

[@philmay7834]

I thought you might put a chamfer on both the tube you added and the original piece of the swing arm legs so you would end up with a small V to fill in when you braze them together. I’m not any sort of a welder, so maybe what I’m suggesting isn’t necessary, and it wasn’t meant as criticism. It was certainly interesting to watch nevertheless.

[@paulbrodie]

I Tig welded the tubes together. There was a small step between the tubes, so that was my "V". Thanks for watching!