MODIFICATION: FORK SWAP STEP 5: STEERING STOPS

The part of the fork swap that is the least "plug & play" is making it so that the triple tree bolts do not piece the gas tank in the event of a "tank slapper." Usedtobefast solved this problem in a pretty sleek way by tapping to the original triple tree stops and installing bolts that would contact a welded on tab to the ATK frame before the triples contacted the tank.

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I bought some bolts and went to my local art welder with pics of usedtobefast's swap hoping to recreate the same thing. After looking at the stock 490 frame steering stop steel bar welded under the downtube, we mocked up a couple of stainless ball bearings, thereby extending the stock stops ~1 cm.

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Since they were round, they wouldn't ding the cast aluminum triple tress either. You can see there is plenty of room left between the triples and the tank. Left side:

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Right side:

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COST: $25 to the welder for at least 1.5 hours of his time