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buzzer1955 |
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buzzer1955 Nitrous Nuisance
Joined: 12 Jan 2019 Karma :
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Easy-X |
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Easy-X Super Spammer
Joined: 08 Mar 2019 Karma :
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Posted: 21:34 - 08 Jun 2021 Post subject: |
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Wow! From bloated pig to Grom level svelteness ____________________ Husqvarna Vitpilen 401, Yamaha XSR700, Honda Rebel, Yamaha DT175, Suzuki SV650 (loan) Fazer 600, Keeway Superlight 125, 50cc turd scooter |
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struan80 |
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struan80 World Chat Champion
Joined: 04 Nov 2014 Karma :
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Posted: 22:09 - 08 Jun 2021 Post subject: |
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Very nice. One day I'll get a Ducati |
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jeffyjeff |
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jeffyjeff World Chat Champion
Joined: 02 May 2020 Karma :
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Posted: 10:50 - 12 Jun 2021 Post subject: |
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I like the blocks holding the seat up. Gives literal meaning to the term "wooden brakes". ____________________ History shows again and again how nature points out the folly of men - BOC |
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MarJay |
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MarJay But it's British!
Joined: 15 Sep 2003 Karma :
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buzzer1955 |
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buzzer1955 Nitrous Nuisance
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MarJay |
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MarJay But it's British!
Joined: 15 Sep 2003 Karma :
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Robby |
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Robby Dirty Old Man
Joined: 16 May 2002 Karma :
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carbon90 |
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carbon90 Two Stroke Sniffer
Joined: 10 Mar 2014 Karma :
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buzzer1955 |
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buzzer1955 Nitrous Nuisance
Joined: 12 Jan 2019 Karma :
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Posted: 11:15 - 08 Jul 2021 Post subject: |
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Sometimes I just sit for a while and look at the silhouette of a build in the garage with the lights out… I did this the other night (my wife thinks I am mad!) and I kept coming to the conclusion that the tank is not what I want… So off to the bike breaker who lets me wonder around his BIG unit. I took a cardboard cut out of the shape I wanted with me, and some measurements… of the hundreds of tanks I looked at (surprising how many are now plastic!) , none were suitable, mainly due to the angle of the frame.
On the last build I used a 999 tank which worked well, so I decided to try a shortened version on this build. I didn’t feel bad cutting this up as its so badly corroded, and it just goes to show what leaving a bike for a long period with ethanol based fuel in it does inside the tank. you can see from the light I am holding behind it that its actually perforated on the top! So its off to the blasters with it to see what state its in when it comes back…. I have a fall back, but its a perfect 999 tank, be a shame to cut it up... If the one comes back from the blasters and its too bad, I will probably use it to mock up, and see if I can find a dented one.
https://jtccc.files.wordpress.com/2021/07/tank-2-copy.jpg
My FCR 41's came this morning
https://jtccc.files.wordpress.com/2021/07/fcr-carbs.jpg |
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buzzer1955 |
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buzzer1955 Nitrous Nuisance
Joined: 12 Jan 2019 Karma :
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Posted: 11:16 - 10 Jul 2021 Post subject: |
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well the tank came back from the blasters… as you can see its full of pin holes, and for the first time in over 40 years of repairing tanks I feel I have been beaten! there is no point in trying to repair this! I put a light inside to shop the extent of the corrosion. look after your tanks guys!
https://jtccc.files.wordpress.com/2021/07/tank-22.jpg |
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GSTEEL32 |
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GSTEEL32 Traffic Copper
Joined: 24 Feb 2010 Karma :
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buzzer1955 |
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buzzer1955 Nitrous Nuisance
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G.Mantis |
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G.Mantis L Plate Warrior
Joined: 12 Jul 2021 Karma :
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buzzer1955 |
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buzzer1955 Nitrous Nuisance
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buzzer1955 |
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buzzer1955 Nitrous Nuisance
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Posted: 10:04 - 23 Jul 2021 Post subject: |
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To mount the carbs I needed to make some alloy custom manifolds. I made these using the pie /lobster cut method. I set the chop saw to 7 degrees and cut off a selection of pieces and tape them together until I have the right shape… I then mark the position of each and weld them together, ensuring I have good penetration, which I then grind off inside to make them smooth. the long bur in the picture is a beast to use!
https://jtccc.files.wordpress.com/2021/07/manifold-1-copy.jpg
https://jtccc.files.wordpress.com/2021/07/manifolds-2-copy.jpg
Onto the tank. I managed to source a very clean 999 tank, but of course this is too long for the build… so out came the angle grinder and off came the back! measure twice cut once!. I then fabricated a new back end and welded it into place. When welding stuff like this, everything needs to be clean for a good half inch either side of the weld, so I clean both sides with emery paper, and use to carb cleaner to ensure there is no grease… also wipe the welding rod with some as well…
Once the back/side piece was in place I planished the sides so the new piece had the same radius as the tank. then I welded the bottom in. to test for leaks I use two methods… some dye penetrant and developer, and if it passes this test, I do a final check with air at just 3 PSI and squirt it with soapy water.
https://jtccc.files.wordpress.com/2021/07/tank-modifications-copy.jpg
https://jtccc.files.wordpress.com/2021/07/tank-modifications-2-copy.jpg |
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A100man |
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A100man World Chat Champion
Joined: 19 Aug 2013 Karma :
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buzzer1955 |
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buzzer1955 Nitrous Nuisance
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buzzer1955 |
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buzzer1955 Nitrous Nuisance
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Posted: 20:17 - 24 Jul 2021 Post subject: |
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one of the most difficult things I find to make on a bike is the seat… this one i have used a different approach as (a) its a dual seat and (b) I am making the base out of aluminium. I mocked up what I wanted in cardboard first, and then transferred the patterns onto some 3mm aluminium. Then I seam welded it… It came out ok, be interesting to see what its like once its to the final shape and the foam and cover is on!
https://jtccc.files.wordpress.com/2021/07/seat-1-copy.jpg
https://jtccc.files.wordpress.com/2021/07/seat-2-copy.jpg |
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struan80 |
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struan80 World Chat Champion
Joined: 04 Nov 2014 Karma :
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buzzer1955 |
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buzzer1955 Nitrous Nuisance
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Posted: 10:52 - 01 Aug 2021 Post subject: |
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struan80 wrote: | Very nice sir. But a waste of a good bike. Well in my eyes. |
They are not a good bike these days... the tanks swell with the ethanol in the fuel, and leak, there is no long term fix for that... and its only going to get worse as we move to E10 fuel. Its so bad that many people end up cutting the frame x member to remove the tanks! Also the LCD screens go dim so you cant see the display... and the circuit boards in the clocks corrode, and you lose the indicators... Many are suffering ECU issues.
Next job will be the exhaust system but to do this I needed a silencer to get the mock up right… I wanted a small slim silencer, that was re-packable, and that I could fit a baffle come MOT time… and a bit retro/old school. I searched but couldn’t find any suitable, they were all too wide as I want an under seat, side mounted setup. so I modified a cheap (£16!) stainless steel one off eBay. I would have loved to have made one from scratch but don’t have a cone roller, and to buy a ready made stainless cone is expensive. the hardest part of making this was actually drilling three holes for the bolts to hold the end cone in. the stainless is incredibly hard! after blunting 3 new drills, and buying a cobalt drill and that not touching it, I ended up making a punch and die and punching the holes!
https://jtccc.files.wordpress.com/2021/08/silencer-1-copy.jpg
https://jtccc.files.wordpress.com/2021/08/silencer-2-copy.jpg |
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buzzer1955 |
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buzzer1955 Nitrous Nuisance
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Easy-X |
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Easy-X Super Spammer
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buzzer1955 |
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buzzer1955 Nitrous Nuisance
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Easy-X |
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Easy-X Super Spammer
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Old Thread Alert!
The last post was made 2 years, 311 days ago. Instead of replying here, would creating a new thread be more useful? |
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