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-   -   what do you get if you combine and RS 125 and a 640 LC4??? (http://www.advrider.com/forums/showthread.php?t=874714)

muttley92 03-30-2013 07:40 AM

what do you get if you combine and RS 125 and a 640 LC4???
 
This a a build thread for a supermono road bike, it's been done before but I've never seen a proper build thread. Several people have asked me for this so here it is.

muttley92 03-30-2013 07:48 AM

First things first
 
I should start by saying that I am 20, I live in the UK, I'm studying a masters degree in Mechanical Engineering at Loughborough university and this is something I'm doing for fun in my spare time.

muttley92 03-30-2013 07:52 AM

This is what I started with
 
http://i1222.photobucket.com/albums/.../WP_000008.jpg
http://i1222.photobucket.com/albums/.../WP_000005.jpg
http://i1222.photobucket.com/albums/.../WP_000007.jpg
http://i1222.photobucket.com/albums/.../WP_000009.jpg
http://i1222.photobucket.com/albums/.../WP_000010.jpg
The engine came from ebay 2004 640 LC4 from a duke II, the bike is a 2009 Apilia RS 125 that was a cat B write off and it arrived in bits.

muttley92 03-30-2013 08:12 AM

getting the engine in there
 
http://i1222.photobucket.com/albums/.../WP_000011.jpg
http://i1222.photobucket.com/albums/.../WP_000012.jpg
http://i1222.photobucket.com/albums/.../WP_000013.jpg
http://i1222.photobucket.com/albums/.../WP_000015.jpg
http://i1222.photobucket.com/albums/.../WP_000016.jpg
http://i1222.photobucket.com/albums/.../WP_000027.jpg
This engine looks like it was made to fit in the Aprilia frame! The mounts needed filing down by about 2mm to fit in the swing arm, and I had to take a little off the front of the swinger for clearance. The earlier engine is easier to get in the frame (you don't need to do anything to the swing arm) just the bushes. It's tight, but it fits :D

Kawidad 03-30-2013 08:12 AM

From the LC4 thread and I'm in. :clap

muttley92 03-30-2013 08:18 AM

Engine mounts
 
I cut down the standard RS engine mounting plates and modified them slightly
http://i1222.photobucket.com/albums/.../WP_000028.jpg
http://i1222.photobucket.com/albums/.../WP_000031.jpg
http://i1222.photobucket.com/albums/.../WP_000029.jpg
http://i1222.photobucket.com/albums/.../WP_000047.jpg
http://i1222.photobucket.com/albums/.../WP_000049.jpg
http://i1222.photobucket.com/albums/.../WP_000050.jpg
http://i1222.photobucket.com/albums/.../WP_000030.jpg
http://i1222.photobucket.com/albums/.../WP_000053.jpg
http://i1222.photobucket.com/albums/.../WP_000052.jpg

pennswoodsed 03-30-2013 08:20 AM

what do you get 640+rs125
 
Quote:

Originally Posted by muttley92 (Post 21068425)
This a a build thread for a supermono road bike, it's been done before but I've never seen a proper build thread. Several people have asked me for this so here it is.

A frame twisting mind bending wet dream ,and that's before it starts ! Subbed on the title value alone..
Go for it ,Ed !

muttley92 03-30-2013 08:24 AM

Then I made an exhaust
 
http://i1222.photobucket.com/albums/.../WP_000055.jpg
http://i1222.photobucket.com/albums/.../WP_000056.jpg
http://i1222.photobucket.com/albums/.../WP_000058.jpg
http://i1222.photobucket.com/albums/.../WP_000059.jpg
http://i1222.photobucket.com/albums/.../WP_000061.jpg
http://i1222.photobucket.com/albums/.../WP_000069.jpg
http://i1222.photobucket.com/albums/.../WP_000070.jpg
http://i1222.photobucket.com/albums/.../WP_000071.jpg
http://i1222.photobucket.com/albums/.../WP_000072.jpg
http://i1222.photobucket.com/albums/.../WP_000073.jpg
http://i1222.photobucket.com/albums/.../WP_000075.jpg
http://i1222.photobucket.com/albums/.../WP_000078.jpg
It's not the best but I made it, it's mine and it will work :D

pennswoodsed 03-30-2013 08:38 AM

Remembering your field
 
Hi,
Your 2nd post ,engineering student so maybe this is dumb ,the front mounts are single shear on a butt weld ,I would want to spread moment above and below weld. Maybe.
regards,Ed

Salsa 03-30-2013 09:32 AM

Quote:

Originally Posted by pennswoodsed (Post 21068770)
Hi,
Your 2nd post ,engineering student so maybe this is dumb ,the front mounts are single shear on a butt weld ,I would want to spread moment above and below weld. Maybe.
regards,Ed


Or overkill !!!!!!!!!!!!

Don

Droptarotter 03-30-2013 09:55 AM

Quote:

Originally Posted by pennswoodsed (Post 21068770)
Hi,
Your 2nd post ,engineering student so maybe this is dumb ,the front mounts are single shear on a butt weld ,I would want to spread moment above and below weld. Maybe.
regards,Ed


I'm no engineer, but have been around these thumpers for quite some time and the front mount looks like a crack waiting to happen.
Did you make the mounts just for a temporary hanger? Redo them later?

Good luck with this...........it looks like it will be a nice combination once completed!

Cheers

muttley92 03-30-2013 09:59 AM

That was considered. It's 3mm stainless 304 on both sides, since the engine deadweight is only around 40kg max and majority of the weight is on the rear mount I think it will be just fine. But I'll keep an eye on it and if it should crack I'll find a solution.

muttley92 03-30-2013 10:02 AM

Got hold of an FCR
 
http://i1222.photobucket.com/albums/.../WP_000081.jpg
http://i1222.photobucket.com/albums/.../WP_000084.jpg
http://i1222.photobucket.com/albums/.../WP_000085.jpg
http://i1222.photobucket.com/albums/.../WP_000086.jpg
And many thanks to the Loughborough University Formula Student team for letting me use the lab and the weld set!

muttley92 03-30-2013 10:12 AM

just to make things easier
 
Once finished the exhaust was difficult to fit so i modified it simular to the stock pipe
http://i1222.photobucket.com/albums/.../WP_000087.jpg
http://i1222.photobucket.com/albums/.../WP_000090.jpg
and i knocked up some rad mounts from the remnants of the standard mounts.
http://i1222.photobucket.com/albums/.../WP_000094.jpg
http://i1222.photobucket.com/albums/.../WP_000092.jpg
http://i1222.photobucket.com/albums/.../WP_000091.jpg

muttley92 03-30-2013 10:15 AM

first look
 
All the standard fairings fit fine over the new engine, would make a hell of a street sleeper if the left hand side fairings were still in one piece!
http://i1222.photobucket.com/albums/.../WP_000117.jpg
http://i1222.photobucket.com/albums/.../WP_000118.jpg


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