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Old 02-24-2010, 10:14 AM   #31
justplainray OP
ucancallmeray
 
Joined: Apr 2009
Location: jolly old New England
Oddometer: 255
thanks...

for subscribing.
there's lots more to come.

justplainray

Quote:
Originally Posted by Byrdman
Fun stuff. I just love these rebuild threads.

Subscribed.
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Old 02-24-2010, 10:16 AM   #32
justplainray OP
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Location: jolly old New England
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Oh...yeah...

but I have a wonderful wife, our policy is simple...

Don't Ask...Don't Tell.

justplainray

Quote:
Originally Posted by wide
Nice.... but its sure looking expensive!!
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Old 02-24-2010, 10:20 AM   #33
justplainray OP
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the base gaskets

are obsolete, but the originals are a metal stamping, so we cleaned them up and re-used them with "SukuziBond". Art the mechanic swears by this stuff.

The head gaskets are still available thru Honda, I order them from either HondaDirectOnline or RonsDiscountParts. They're about $10.00 each.

stay tuned,
justplainray

Quote:
Originally Posted by mas335
Ray,
Looks like you are going about this project in the right way, no shortcuts, very nice. Where did you find the head and base gaskets?
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Old 02-24-2010, 10:26 AM   #34
justplainray OP
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Thanks,

the garage is a real pleasure to have, after years of working in the driveway, I finally could afford to build a shop/garage. Measures 20 feet x 24 feet with a 12 foot overhead door and a 10 foot ceiling and it's heated. My wife (god bless her) thinks garages are for parking cars, she just can't understand that there are more important uses for a garage.

stay tuned,
justplainray

Quote:
Originally Posted by 100mpg
You must ride on hollywood movie sets to find those rare cardboard rocks! It is looking good, even though I am jealous of your work space/garage.
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Old 02-24-2010, 10:46 AM   #35
100mpg
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Quote:
Originally Posted by justplainray
the garage is a real pleasure to have, after years of working in the driveway, I finally could afford to build a shop/garage. Measures 20 feet x 24 feet with a 12 foot overhead door and a 10 foot ceiling and it's heated. My wife (god bless her) thinks garages are for parking cars, she just can't understand that there are more important uses for a garage.

stay tuned,
justplainray

20x24...

Your lucky your wife thinks it is for parking cars, most wives think a garage is for storing JUNK for 20 years, then turning it into an apartment!
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Old 02-24-2010, 11:40 AM   #36
Lear60man
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Nice thread. FYI a standard RD4 skid plate bolts up with minimum modding. I started out with a really clean low mile TA for my TAAT. Keep up the pics!
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Old 02-24-2010, 12:26 PM   #37
Hans Petter
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18 " rear wheel

What kind of spokes did you use to build the 18 " wheel ?

stock hub ?

Great build, btw !
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Old 02-24-2010, 01:42 PM   #38
justplainray OP
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stock hubs..

rims, spokes and nipples came from Buchanans Spokes & Rim
http://www.buchananspokes.net/
It took a few phone calls to explain what we had in mind.
....Yes the bike is stock with 17 inch wheel, 36 spokes.
.....And I want to change to 18 inch wheel, 36 spokes.
.....Yes the rear hub is the original drum brake.
But in the end, they understood what we wanted.
Buchanans drilled the rim, supplied the spokes and nipples.
My local shop did the lacing and truing.
I really like the looks of the heavier gauge spokes too.
thanks for checking it out.

More to follow.
justplainray

Quote:
Originally Posted by Hans Petter
What kind of spokes did you use to build the 18 " wheel ?

stock hub ?

Great build, btw !
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Old 02-24-2010, 01:44 PM   #39
justplainray OP
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Location: jolly old New England
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yeah...but

Quote:
Originally Posted by Lear60man
Nice thread. FYI a standard RD4 skid plate bolts up with minimum modding. I started out with a really clean low mile TA for my TAAT. Keep up the pics!
I wouldn't have got to play "arts and crafts" with hot glue and cardboard. That was the best part.

justplainray
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Old 02-25-2010, 01:24 PM   #40
Hans Petter
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Thanks !

I'll contact Buchanans about the spokes and rims.



Keep up the good work !
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Old 02-25-2010, 08:44 PM   #41
showkey
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Oh...yeah...

but I have a wonderful wife, our policy is simple...

Don't Ask...Don't Tell.

justplainray

Quote:
Originally Posted by wide
Nice.... but its sure looking expensive!!



Glad someone is keeping the economy going

Nice work
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Old 02-25-2010, 09:03 PM   #42
Archangel007
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Spokes

Subsribed

Obviously heavy-duty stainless steel spokes and nipples Ray???

Looking very good there!

Cheers,
Tricky

Archangel007 screwed with this post 02-25-2010 at 09:19 PM
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Old 02-26-2010, 10:54 AM   #43
justplainray OP
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Spokes

Quote:
Originally Posted by Archangel007
Subsribed

Obviously heavy-duty stainless steel spokes and nipples Ray???

Looking very good there!

Cheers,
Tricky
Yes, the spokes are heavier duty than the originals, I think these are 9 gauge, the originals were thinner.

Note the brake rotor is bigger too. This an aftermarket rotor for a 650 Hawk GT (NT 650 '88 -'91) The caliper is original TA mounted on an adapter piece from MAP Engineering (thank you Jim Rowley, Colorado Springs, CO). Braided steel brake hose (e-bay). Tires Shinko SR244 (I like cheat tires).
Here's the original set-up for comparion.


Here's a shot of the frame and swingarm back from the sandblaster, with paint. It was too big for my blasting cabinet, so I had to send it out to Gary at American Dry Stripping, Milford, CT.






All the paint was applied with a 3/8" wide camel hair artist brush using POR-15 paint products, Caliper Paint to be exact (http://www.por15.com/8oz-CALIPER-PAINT/productinfo/CPB/). The exhaust pipe paint is a POR-15 product also, Black Velvet (http://www.por15.com/High-Temperatur...ts/products/8/)

More to come.
justplainray

justplainray screwed with this post 03-02-2010 at 06:32 PM
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Old 03-02-2010, 04:09 PM   #44
justplainray OP
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Joined: Apr 2009
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Today class....

...we will learn how to design an auxiliary fuel tank.
You no doudt have noticed the cardboard box between the rear frame rails, in this earlier photo.

So here are the dirty details. That is a mock-up of this...



This is a 3.25 gallon fuel tank, designed it in SolidWorks '09, it will be made of .100" Aluminum (5052 H32), the fill neck is a purchased component (RCI #7036B) from Summit Racing that required modifications, it hangs in between the rear frame rails on two steel straps. One the left side there will be a bracket to mount the Hondal CDI pack. The tank will completely eliminate the stock air box, battery tray and inner fender liner. (the tank is the fender liner) Heres a few more photos of the mock-up in position.








Here I'm checking the tire-tank clearance at full suspension travel. The shock is .800" longer than stock, I make a new clevis with the addition length built-in. Note the shock spring is removed and the tire is moved all the way forward for this check. Everything looks good.


With the African Twin tank and this tank, fuel capacity is approximately 9 gallons (US). Air filter duties are being taken care of by the UNI air filter clamped onto the stock air plenum (red, visible is several photos).

But...what about the battery?
That is for another time.

Stay tuned.
justplainray
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Old 03-02-2010, 06:01 PM   #45
BeeDub
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Ray, I'm lovin' your hard work and creativity. I don't know what kind of riding you're really planning on doing with this thing, but I want to caution you abut those UNI pod filters. I had one on my Husky for a few months, and really only did one dirty ride in that time. After that, I wanted to do some jetting and what not, and when I pulled the carburetor apart, there was a healthy amount of dirt in it. I had read posts about them before, but didn't believe that just because the foam wasn't encapsulated by something, it would allow dirt to pass. I doubt the "air box" itself is the reason, but these things do not keep desert dust out of the carb. Just warning you.

Keep up the good work!
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