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Old 08-03-2013, 12:36 PM   #76
Roadracer_Al
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Originally Posted by Mercury264 View Post
Is his name Richard by chance ? If so, small world.....he's my BIL.
Handy guy to know!

In for the rest. Nice work. I am a fan of motor swaps - I put a KX500 motor in a TZ250 chassis, and a XT600 motor into a GS500 chassis for racing friends about 15 years ago. I must be a curse, however: the KXTZ owner had a spinal infection that sidelined him from racing permanently, and the XTGS owner was killed in a car accident. Neither ever ran in anger.
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Old 08-08-2013, 02:39 PM   #77
muttley92 OP
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So the cooling problem has been narrowed down to the water level in the rad being below the water pump. I scored these off of ebay for 2.20


BARGAIN!!!


I rigged them up from the bars so that they were of sufficient height and plumbed it as close to stock as I could.


At 105C on the clocks the rad was hot! Result. So I need to make a header tank and possibly get a booster pump if it runs hot at idle.

On a high note the bike now starts first time from hot
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Old 09-03-2013, 08:29 AM   #78
mbrick
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If I understand the problem with the first radiator... can you lift the front end up to 45 or so to get the air out of the pump and prime it, and put the rad cap on?

Shocked at how cheap those dirt bike radiators were.

Agree with the others, you should forego the oil tank due to bleeding and drain hassles, don't want some air going through to the big end of the rod.
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Old 09-05-2013, 02:37 PM   #79
Krasniewski
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Just read the whole thread - great work so far! This is going to be a really sweet ride - can't wait to hear some riding impressions.

Maybe my opinion doesn't count for much, but the build quality looks really quite good, and that includes the motor mounts.

Best of luck in the completion.
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Old 09-20-2013, 02:21 PM   #80
muttley92 OP
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Been busy recently with work but just bought an electric booster pump to try and sort out the cooling. Will hopefully get it fitted this weekend and get back with an update. The tank has started leaking again, not best pleased with that but it's a reason to make an alloy one. I'm going to get a tig set in a couple of months and I'm planning to make a fuel tank, a header tank, reinforce the engine mounts (not because anything has cracked, but since I'm getting a weld set I might as well do it) Make a bracket for the oil tank. And eventually start work on a frame jig for my next project, but going to finish this one first. I'll soon be after another set of rads too. Another update soon.
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Old 09-22-2013, 02:56 PM   #81
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Well the water pump has sorted the cooling issue. I've removed the thermostat and made a big washer so that it doesn't leak. I had to turn the rd around to get the stock outlets where I needed. By the time the clocks read 50 deg the rad is hot. Winning! The pump is of the Davies Craig flavour and I highly recommend it to anyone looking to boost cooling potential at low rpm. I'll make a proper bracket for it shortly. here are some photos.

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Old 01-05-2014, 05:42 AM   #82
Lornce
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Brilliant effort. Good on you, lad.

Just saw this bike the other day. Perhaps it'll give you some inspiration.

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Old 01-05-2014, 07:10 AM   #83
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That looks awesome. Nicely finished and more complete than mine will ever be. I like the breather solution into the subframe. Might try that on mine. I know it all seems to have gone quiet but Im slowly sorting things out. Been really busy with work of late. Made a header tank yesterday, will get some brackets on it and hopefully route the cooling hoses by the end of the month. I'll try abs put some photos up when I make significant progress with it.
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Old 01-12-2014, 09:09 AM   #84
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I've made a header tank and a bracket to hold it in up the front that also replaces the original radiator mount, (No penis jokes please ) will get some grommets and weld some bosses on the header tank to isolate it a bit, need to make another bracket to go on top too. I've got a filler neck and some stainless hose joiners to weld on to finish it.






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Old 01-15-2014, 05:57 AM   #85
MikeJansen
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That is looking brilliant mate!

Small world, I did Automotive Engineering at Loughborough Uni and was a member of both LSUMC and LSUMCC while I was there. I'll be following this as this looks mad as a box of frogs.

Mike
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Old 01-16-2014, 06:24 AM   #86
muttley92 OP
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Pretty sure I saw you asked to join the LSUMC the other day? Think Matt added you, he's running the facebook page on his own whilst I'm on placement. Hopefully I'll be more involved next year.
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Old 01-17-2014, 07:51 AM   #87
MikeJansen
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Originally Posted by muttley92 View Post
Pretty sure I saw you asked to join the LSUMC the other day? Think Matt added you, he's running the facebook page on his own whilst I'm on placement. Hopefully I'll be more involved next year.
Yeah I just found the FB page through Tom and Tish. I was Garage Sec in 2004-2006 of both clubs but gradumacated in 2010. Been down in Essex since 2011.
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Old 02-06-2014, 02:18 PM   #88
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I've also given up with the fuel cell idea and cut up an Old RGV tank I was given by my good friend Ian at BikeMotorWorks in Grendon.



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Old 06-15-2014, 01:14 PM   #89
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The new fuel tank

It's taken a while but I've been busy. Finished welding up the tank and had it painted at work. Unfortunately the fuel tap fouled the subframe so I had to change that too. I've also incorporated the subframe as an oil catch tank as seen in the posted link. Then I adapted the side panel around the new tank and re fitted the seat lock. Also I welded on a stronger exhaust mount and reinforced the engine mounts. I've now sorted the cooling system routing s well but have no photos yet. Loom to go in again next week.
 photo WP_000284.jpg
 photo WP_000355.jpg
 photo WP_000287.jpg
 photo WP_000365.jpg
 photo WP_000370.jpg
 photo WP_000341-1.jpg

muttley92 screwed with this post 06-15-2014 at 01:22 PM
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Old 09-29-2014, 10:10 AM   #90
muttley92 OP
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Thankyou Mr MOT tester...

Long story short, the bike is now technically road legal! Passed its MOT last week but I can't use it until the DVLA pull their finger out and tax it! Utterly useless they are. It's changed somewhat from how I intended. A person who shall remain anonymous dropped part of a paddock stand on the tank so I had to repaint it and decided to apply some decals at the same time. It was a bit bland as was. Work kindly laquered all the panels for me and it looks ace!



I've clocked only 14 miles from new so far. To the MOT station and to the post office (where I was denied tax) then home again. It pulls strongly to around 5k then tails off somewhat to a peak at 7k revs. The fueling needs work at the top end but I'll play with some options when I've done a few more miles. On the plus side it will wheelie at any rpm in first and if you snap it in second. It will clutch up in every gear! I weighed the bike without the fairing and 2 gallons of fuel at 70kg R 71kg F so I reckon it's under 150kg wet as it stands now and it will only get lighter. With some time and effort I think I could cut upto 20kg off the bike with aluminium parts and a track fairing.


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