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Old 09-29-2012, 06:07 PM   #271
Kernel
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Hand built gas tank, rear fender and side panels?
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Old 09-29-2012, 06:29 PM   #272
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Originally Posted by Kernel View Post
Hand built gas tank, rear fender and side panels?
OTTMH, used the stock frame and cut off the cradle below the front engine mounts. Welded triangulated steel tubes to the shape of the tank and rear storage box, bracing and triangulating the the steering head and swing arm pivot and swing arm, with tapered rollers for the pivot, and braced top shock mounts. Then pop riveted and glued the al sheet to the steel frame and sealed it up with Kreem. Had to drop the engine to do the valves each time. So the tank is structural. Ahead of my time? No, it'd been done before I think. Most things have. Ceriani forks, Suzi 4ls brake, S&W shocks, Akront ally rims and hd spokes, Cibie Biode headlamp, 2 x 100 QI bulbs on high beam, 1 for low, in the one 7" unit. Engine had the starter removed because it wasn't powerful enough to crank it, Piranha electronic ignition, Yosh cr gearbox and custom one off idler gear to enable the kick start, lightened balanced crank, Yosh Duralamin rods, cut up 750 pistons for <> 600 cc, Yosh Daytona cam and head and valves, 750 carbs, cut and shut Dunstall exhaust, Lockhart oil cooler and more. Went good, when it went, and lots of quality shed time in the interim with lots of good learning.

When I sold it, study, land etc etc, and the need for a pillion seat for the now SWMBO, the guy who wanted it just wanted its engine for a speedway car. Brought his mate along who rode bikes and owned a Duke at the time to test it out. He came back from his test ride and said that he wouldn't allow it to be broken up, it was too good, and he brought it himself

I lost track of it after a couple of years, but it was still going well when I last I heard, about 1983/84 I guess.
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BergDonk screwed with this post 09-29-2012 at 06:46 PM
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Old 09-29-2012, 06:46 PM   #273
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So I'm out in the shed working on MKIII. Should be fine, but not as simple to make for many now.

Test process with some 3 mm scrap:








Now to make a real one with 2 mm. Same as before, but lower profile, and only one more stage for me, but not so easy for others out there I guess. See where its going?

More to come....
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Old 09-29-2012, 07:02 PM   #274
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Very nice bike build, how true......nothing is ever done.

Quote:
Originally Posted by BergDonk View Post
So I'm out in the shed working on MKIII. Should be fine, but not as simple to make for many now.

Now to make a real one with 2 mm. Same as before, but lower profile, and only one more stage for me, but not so easy for others out there I guess.
See where it's going?
Only $347. http://www.bing.com/shopping/truper-...ammers&FORM=EG
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"BTW, I don't do style. It's a dirt bike, not some girlie dress-up thing." -
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Old 09-29-2012, 09:35 PM   #275
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Thumb MKIII Evolution

Looks promising, maybe I've cracked it, but not so easy for anyone without access to a press, although if you can track a lathe down, then a press probably isn't far away.

Same template as before, so mark it out the same, and 2 or 3 mm sheet is OK, I now have one of each. Trim to suit.






Now using the template, centre punch the holes and check the measurements




Now attach, centred, the packer for the depression. I used 2 pieces of of left over hole saw 'washers' I had in my collection from some other project, one 60 mm dia and 3 mm thick and one 53 mm dia and 4 mm thick sticky taped together. Then sticky taped to the plate, with the 53 mm dia to the plate on the engine side, or back.




Then to the press and get it centred and using the old bearing outer I found in the shed at 90 mm OD, squeeze.




Dill some holes, same as before,



And it seems 7 mm is the number that results, 3 + 4 from above, amazing.




Test fit with 8 mm shorter spacers, which means that #2 is now 0 mm. Arithmetic doesn't quite add up from before, these numbers seem to snug up OK with the same tap washer.







So for me, its one less spacer to make, and shorter screws, and one extra step with the press, and good to go.

The only thing I can't now be fully confident of is a 525 chain with a 14 t or smaller css. I THINK it'll work, but I've already said something similar and proven myself wrong.

So exit the shed shortly, time for some exercise, then its the League grand final and then the GP, so telly and beers soon.

Later
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Old 10-03-2012, 12:09 AM   #276
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So after a little more testing, I have 3 MKIII prototypes. Went up to Canberra again today and caught up with the invalid again. Fitted it up to his bike with a 14t and his RK GXW 525 and no worries.

With 14t css







No matter how we twisted and shifted the chain and css about, plenty of clearance. A 13t might well be OK too, but we don't have one to test.

This one in the pics is no 3 and is made out of 3 mm sheet and is my preference because it comes out of the pressing neater and requires no 'panel beating' to straighten it out, whereas the 2mm ones need more work to finish, and they don't look as pretty as a result. Creates another 1 mm clearance though, but not needed for the 14 t and bigger sprockets. Simple enough though to make either with the same tooling.

So I guess these are now for sale, and the 3 prototypes have actually been allocated, with no 3 still on the invalid's bike and will stay there, he seems to like it. PM me if you are interested in acquiring one.
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Old 10-03-2012, 12:11 AM   #277
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Old 10-03-2012, 12:28 AM   #278
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Quote:
Originally Posted by BergDonk View Post
OTTMH, used the stock frame and cut off the cradle below the front engine mounts. Welded triangulated steel tubes to the shape of the tank and rear storage box, bracing and triangulating the the steering head and swing arm pivot and swing arm, with tapered rollers for the pivot, and braced top shock mounts. Then pop riveted and glued the al sheet to the steel frame and sealed it up with Kreem. Had to drop the engine to do the valves each time. So the tank is structural. Ahead of my time? No, it'd been done before I think. Most things have. Ceriani forks, Suzi 4ls brake, S&W shocks, Akront ally rims and hd spokes, Cibie Biode headlamp, 2 x 100 QI bulbs on high beam, 1 for low, in the one 7" unit. Engine had the starter removed because it wasn't powerful enough to crank it, Piranha electronic ignition, Yosh cr gearbox and custom one off idler gear to enable the kick start, lightened balanced crank, Yosh Duralamin rods, cut up 750 pistons for <> 600 cc, Yosh Daytona cam and head and valves, 750 carbs, cut and shut Dunstall exhaust, Lockhart oil cooler and more. Went good, when it went, and lots of quality shed time in the interim with lots of good learning.

When I sold it, study, land etc etc, and the need for a pillion seat for the now SWMBO, the guy who wanted it just wanted its engine for a speedway car. Brought his mate along who rode bikes and owned a Duke at the time to test it out. He came back from his test ride and said that he wouldn't allow it to be broken up, it was too good, and he brought it himself

I lost track of it after a couple of years, but it was still going well when I last I heard, about 1983/84 I guess.
Forgot to comment on this. Wow, that's mental! How long did that all take? I daren't ask the cost xD
I couldn't figure out what you meant by OTTMH?
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Old 10-03-2012, 02:39 AM   #279
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cool stuff Steve

tis a bit of a shame really that your berg hasn't really ever broken id like to see what you'd do to it
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frame build http://www.husaberg.org/forum/viewtopic.php?f=8&t=13268
engine http://www.husaberg.org/forum/viewtopic.php?f=5&t=12131
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Old 10-03-2012, 05:37 PM   #280
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Forgot to comment on this. Wow, that's mental! How long did that all take? I daren't ask the cost xD
I couldn't figure out what you meant by OTTMH?
Cost everything I had except food, weekend beer, and the occasional text book. No Google back then.

OTTMH is a typo, should be OTTOMH or Off The Top Of My Head
http://www.acronymfinder.com/Off-the...OTTOMH%29.html

It started after I got the bike Christmas 1972 and left home for the big smoke and uni. A few other bikes at college and I started learning stuff.

Slid down the road on some split diesel and that was an excuse for a 4 in 1. After a bit, I wanted more fuel range, so a 5 gall tank and a full fairing somehow got fitted. More power, more ground clearance, more light,, more, more, more.......... The Hannan Bros were getting going with their business nearby down the road from where I was living at the time, and they were the then, and I think world's first, Yoshimura importers. They also specialised in setting up drum brakes with Ferodo linings and stuff, and didn't mind me hanging about from time to time. It was always in bits waiting for new stuff, and/or fixing broken bits, and was my sole form of transport, and a treadly. I did a lot of cycling and riding OPs at the time. It got 'finished' about 1980 and other life priorities took over. Late 1970s I built up my first car, which I kept for 17 years. A Mazda R100. Ended up with a ported RX7 12A, 5 spd, big 4w disc brakes, reengineered suspension, with air suspension up back, extra links etc etc. Light, fun, fun, fast, economical car. And reliable once you knew the tricks. I got about 120,000 kms to a set of seals, and did over 500,000 kms in it. Still some regrets about selling it, but new priorities at the time.... Look up 'Q' ship. it was one.
http://en.wikipedia.org/wiki/Sleeper_%28car%29
http://en.wikipedia.org/wiki/Q-ship

Been some other projects too, bult a buggy from scratch, pipe frame, reversed VW mechanicals for mid engine configuration. Still got that, I can post some pics if someone is interested, but getting away from 2 wheels and DR650s in particular.
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Old 10-03-2012, 05:51 PM   #281
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cool stuff Steve

tis a bit of a shame really that your berg hasn't really ever broken id like to see what you'd do to it
Ahhh, how to improve on perfection? CF body, custom frame, 700 kit perhaps. Wait, someone has already done it , I wonder who?

How about this one for an upgrade option? Ben Ballard has been busy:
www.husaberg.org/forum/viewtopic.php?f=5&t=16625&p=137061



Should have it over your measly 700, although not sure about the height, and weight up there for solo use.

The only thing that I might eventually do is graft on a linkage rear end like my 501 has instead of the PDS. The PDS works fine once setup, but the 501 tail is better, and very similar to the DR650 one with the Ohlins in the way it hooks up. Of course they both have less to deal with, so it may not be that simple, but if I trip over an older frame one day for the right price, or my 501 dies. But in the meantime, I'm just happy riding them.

In many ways, getting the DR650 setup has brought me full circle, and back to my CB500, except I've stayed out of the engine, and the frame is mostly stock. I'll quote myself from early in this thread FWIW, "I've learnt over the years to mostly leave engine internals factory, and play with the outside for reliability, and cost effectiveness. The best money you can spend is actually on rider training followed by suspension" without forgetting ergonomics.

A real soon now job is a new water pump seal, again. Ah well, routine maintenance. The 501 seal is still original on the end of the cam shaft
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Old 10-03-2012, 07:07 PM   #282
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Back to DRs


I've posted this shot elsewhere, but might as well here too. Just been dodging wildlife and searching for a lost DR and rider, and now almost at Tibooburra and heading home back in April after the Flinder's Classic.

The lost one decided to lead from Merty Merty and took the old Strez instead of keeping going straight for Cameron Corner. We looked for him at the bus, but no. He must have been on a mission, so must be at CC, not. He did arrive after crashing however, and some discussion about our next move.




He'd realized after he stopped to take pics of us cresting dunes that something was wrong, and headed back to look for us. Then he was in a hurry, and riding outside his comfort zone, and guess what, the track jinked after the crest of a dune, and he didn't quite.

All good in the end, but might not have been...............

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Old 10-04-2012, 01:39 AM   #283
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it is a nice beast I have the full specs on the M1 engine, 40kgs, same as a raptor engine, can big bore those to 990 which would be cheaper but not as cool, in that weight class the folan twin is only 45kgs

FWIW the nice lil blue water seal out of an 07 ktm65 water pump is very good in the berg

back to DR s yes my mate has been all over the place on his, absolutely loves it to death sheepskin seatcover and all ...
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2008 Husaberg 700F 104kgs all fluids no fuel

frame build http://www.husaberg.org/forum/viewtopic.php?f=8&t=13268
engine http://www.husaberg.org/forum/viewtopic.php?f=5&t=12131
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Old 10-04-2012, 01:42 PM   #284
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Old 10-04-2012, 05:15 PM   #285
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Hey BergDonk, where are you at with the Cush drive bearings ? I changed mine out half way through the TAT along with wheel bearings. It wasn't really bad but had movement in the sprocket. The wheel bearings were really clunky !
That's after about 6000km mainly offroad. I has to get a new Cush drive hubb prior to the TAT as when I went to change bearings the new one just fell in one side of the rear wheel had already been pin punched by previous owner and I had to pin punch the othe side when I changed it on the TAT.
Just about ready to ditch the whole rear wheel.
Looks like Procycles Rad hub uses the stock Cush drive so no advantage there. Seen some pics of Talon Cush drive hubs. Haven't been able to find out much about them as far as durability.
My DRZ front wheel seems to chew through front wheel bearings as well, they are only small bearing so not surprised. I would like to find another wheel that uses larger bearings.
Cheers Phil
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