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Old 06-21-2013, 02:40 PM   #91
PhiSig1071
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Subscribed, this looks cool. Makes me wish I still had my old XR100.
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Old 07-10-2013, 12:30 PM   #92
MrPulldown
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What is going on with this build. Any news. Hope you did not get sucked back up into the working world.
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Old 07-20-2013, 01:10 PM   #93
Billedale
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I've been wondering the same, this is a really cool project and it was coming along quite well!

Edit: Oooh, this is my coming out of lurkerdom on this forum! See how important your project is :).
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Old 07-20-2013, 03:04 PM   #94
TangentRogers
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Originally Posted by Billedale View Post
Edit: Oooh, this is my coming out of lurkerdom on this forum! See how important your project is :).
Its enough to finally bring me out of the shadows too!

This is an awesome build XCgeek, definitely the best and most thorough I've seen here. I wish I had your CAD skills. I'm still stuck in 2D using AutoCAD, haven't got my head around solid modelling yet.

Any updates for us?
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Old 10-18-2013, 05:48 AM   #95
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Old 10-21-2013, 12:12 AM   #96
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I love what you are doing here. a couple thoughts:
switch to a marzocchi 888 or a fox 40. you will shed quite a bit of weight and not sacrifice a lot of stiffness. the 888 is very affordable, stiff, plush, and available in several levels of trick-ness depending on your budget. the fox 40 is the stiffer fork but much more maintenance intensive, more expensive, not quite as plush, and not as reliable in the long term. FWIW I have had 3 different 888's, various boxxers, and currently run a fox 40 on my DH bike. what you have got going on with the monster T is fine, but keep in mind that you may not gain much in stiffness with that fork and certainly that is the only thing the monster will have over any other DH fork. 888's are basically foolproof, plush, and very servicable. Im not sure how easily you will find replacement parts for monsters also.

building your shock mounts to a readily available DH size like 9.5x3 would allow you plenty of economical(and not so economical)options to try out new setups.

as for your welding, keep the gas flowing higher than normal, remember the post flow, keep your arc length short, and your tungsten sharp. a corroded, irregular tungsten makes proper technique way harder especially to the beginner. grind the tungsten properly and frequently. on these thin materials it's quite easy to heat soak the part so weld smaller portions before continuing and do a bunch of practicing. keep the amps at 1 amp per thousandth of an inch or below for thin materials. ie .065 run 60-63 amps until you feel that amps are holding you back.

sonic reducer screwed with this post 10-21-2013 at 12:18 AM
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Old 10-23-2013, 01:39 PM   #97
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Might as well be a dead post.

Op must have scored a real job again and has left us.

Or he is dead.
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Old 10-23-2013, 03:53 PM   #98
ben2go
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Originally Posted by MrPulldown View Post
Might as well be a dead post.

Op must have scored a real job again and has left us.

Or he is dead.
Let's hope not the later.
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Old 11-10-2013, 03:13 AM   #99
XCgeek OP
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Hi. Uuummmm sorry about the lack of progress reporting. Some I can blame on a month and a half holiday to Montreal, some to a month and a half motorcycle tour around New Zealand, some to getting engaged (will this mean an end to these projects?) but most to just being a slack arse that likes to do and not so much about talking.

But please rest assured I am still here, still alive and much progress has been made.

One item for the build that has been giving me nightmares and at the same time, I have been really looking forward to starting is the fuel tank.

I have always wanted to weld with Aluminium and an aluminium fuel tank makes a lot sence. Light, strong, fabricatable, corrosion resistant…..

The design is tricky. 6 litre capacity with the air box built into it. The initial design also structural tubes passing through it to allow for the throttle cable routing and airbox drain.

Here are some images of the first trail!


View from below, large tube is airbox manifold, the other two small tubes are for throttle cable and drain


Filler neck starts life as a piece of 2" round bar


Airbox cavity. The top tube interfaces with the seat, the lower tube would be the tank mount to the frame, the middle tube is that pesky throttle tube. The throttle tube will be dropped for the second try


You can see here where the airfilter attaches within the airbox


Ugly!

Damn this is difficult. The design is too complicated to start with but I also learnt a whole lot about welding aluminium. This stuff moves, pulls, melts, cracks, gets really really hot!

The fuel cap is from a Beta trials bike which has a thread that does not measure up to any thread, metric or non metric that I can determine other that it has a 2.5mm or 10tpi pitch. No worries, I have a lath so I made a spout to fit the cap.

This tank was great learning so now to make mark 2. Simpler and marginally more skill.
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Old 11-10-2013, 10:18 AM   #100
Te Hopo
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Welcome back XCgeek, I look forward to seeing what you come up with for tank no.2
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Old 11-10-2013, 06:35 PM   #101
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Old 11-10-2013, 09:54 PM   #102
Luke
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Yes, welcome back.

I've got a couple of airbox MK1s, one's hanging on pegboard and the other's buried in a box somewhere. Yours is nicer.
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Old 11-13-2013, 05:55 AM   #103
aposaric
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Welcome back dude, hope you had a nice rest
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