Making fork brace- engineering delrin?

[stinkwheel]

Right, I want to make a fork brace. Not so much to brace the forks as to hold a mudguard.

Traditionally you would make two alloy clamps to go round the fork legs with a bit of alloy plate joining them.

Now I don't have many power tools, certainly nothing that will allow me to machine billet to the tolerance required. I would like to have a go myself though.

I was thinking. What about using a plastic for the clamps and bolting an alloy plate between them? It would certainly be strong enough providing I make them chunky enough and I can form it using standard hole saws, hand tools and a dremmel.

So, I was thinking nylon, I can buy big blocks of it off ebay. I have also seen blocks of stuff called 'Delrin'. Not really come across this before but it looks to be a much more dense material. Apparently they make gears out of it amongst other things.

Anyone use the stuff, what is it like to work? Would it be up to the job? Would it take a tap rather than having to bolt through it?

Rough sketch of what I am thinking of below:
https://www.bikechatforums.com/download.php?id=24219
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I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.

[tatters]

l machine varoius types of plastic at my work for machine change parts, inculding PVC/Nylon/Nylotron (very strong stuff)/ and special anti-static plastic to name a few.


As far as l know you can tap Nylon but not soft plastics like PVC (have to use brass incerts).


Something like that would be differcult to make a good job of by hand, l would knock one up for you at work on the Rouater but we rarely use nylon theses days, only PVC or ployethlane
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[Bezzer]

Delrin will take a fair thread but really with being used as a clamp it would be better to countersink the back and use a nut to give more clamping strength. As Tatters says it will be hard to make a decent looking item by hand........Not that that would bother you much after seeing the photos of some of your other bikes
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I used to be indecisive but now I'm not quite so sure.