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Old 08-24-2013, 09:28 AM   #91
ben2go
Moto Flunky
 
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Location: Upstate SC USA
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Looks like a complete factory bike.Sweet ride.
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Old 08-24-2013, 01:56 PM   #92
sanjoh
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Having had a Dorso, how do plan to address the tiny/small tank?

I remember looking for a gas station at 100miles if I didn't keep out of the power.
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Old 08-24-2013, 03:02 PM   #93
jerdog53
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It does look good!

Does it run? Does it Drive?


Almost looks like this one......


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Old 08-25-2013, 03:35 AM   #94
Bobmiller90 OP
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Quote:
Originally Posted by sanjoh View Post
Having had a Dorso, how do plan to address the tiny/small tank?

I remember looking for a gas station at 100miles if I didn't keep out of the power.

Build a new one, that's about the only option. I can't decide whether to use the standard silencer as a slave tank, and run a low exhaust, or just build a bigger main tank.
Decisions...
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Old 08-26-2013, 01:24 PM   #95
snowhawk jockey
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I recognize that recipe for fun! I have the same "cook book" on my shelf at home.

Nuthin like an overpowered SM setup for dirt sliding!
Get those knobs spinning sideways and see how long they last...

My formula called for a couple extra CC's and some orange plastic, just add spokes.
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Old 08-27-2013, 12:35 AM   #96
Bobmiller90 OP
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Quote:
Originally Posted by snowhawk jockey View Post
i recognize that recipe for fun! I have the same "cook book" on my shelf at home.

nuthin like an overpowered sm setup for dirt sliding!
Get those knobs spinning sideways and see how long they last...

my formula called for a couple extra cc's and some orange plastic, just add spokes.

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DT125LC, RZ50LC, CR125R, Z1000R-ELR, RZ350YPVS, XL600R, XR600R
XR650R, FE650, KTM300, 900SS, FZR600R, GS500E, CB600F, KLX250
TE610, TRX850, WR250, XT500, YZF-R1, DR650, WR200, KTM640, ApriliaSMV750.
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Old 09-04-2013, 04:08 PM   #97
High Country Herb
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Well someone beat me to the knobbies on the DD. Maybe if I hurry I can still be the first in the US.

Speaking of that, keep an eye on that oil filter. I found some pretty large dents in mine after a few hours off road, and I was on smoother tires. Those tires are going to throw some rocks. I have a homemade skid plate now, but for a while was using a rubber cap over the filter. If you can't find the right size, you could probably use rubber tool handle dip. A few coats should keep it from getting pierced.

On the subject of the radiator guard, the most free flowing one I have seen is sold by Mike's Grilles in the UK. There are others, but they are generally restrictive to air flow, or have company logos on them. Second choice would be Palmer Products, also in the UK.

Looking good, man!
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Old 09-04-2013, 06:03 PM   #98
sailah
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Did the ZX12R rotors bolt right up to the Harley hub? Inquiring minds want to know

I was planning on using Hayabusa rotors clocked and drilling a new 5 hole bolt pattern.
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Old 09-05-2013, 12:13 AM   #99
Bobmiller90 OP
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Quote:
Originally Posted by High Country Herb View Post
Well someone beat me to the knobbies on the DD. Maybe if I hurry I can still be the first in the US.

Speaking of that, keep an eye on that oil filter. I found some pretty large dents in mine after a few hours off road, and I was on smoother tires. Those tires are going to throw some rocks. I have a homemade skid plate now, but for a while was using a rubber cap over the filter. If you can't find the right size, you could probably use rubber tool handle dip. A few coats should keep it from getting pierced.

On the subject of the radiator guard, the most free flowing one I have seen is sold by Mike's Grilles in the UK. There are others, but they are generally restrictive to air flow, or have company logos on them. Second choice would be Palmer Products, also in the UK.

Looking good, man!
Yes that oil filter and the oil pressure sensor are very vulnerable to damage. And the front cylinder header too, for that matter. I am thinking of having the lower engine protection bars as the mount point for the skid plate. Watch this space.
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Old 09-05-2013, 12:18 AM   #100
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Quote:
Originally Posted by sailah View Post
Did the ZX12R rotors bolt right up to the Harley hub? Inquiring minds want to know

I was planning on using Hayabusa rotors clocked and drilling a new 5 hole bolt pattern.
No, but they were very close. I had Derek Chittenden from Hijera Racing Developents fit them, he had to bore out the disc carriers standard holes and in the process move their PCD about 2mm larger. He then made inserts that fitted inside the carrier holes for the stock Harley bolts. The centre hole is almost right too, about 1mm larger than it needs to be.
The discs would have fitted to the hub, but the PCD was just that little bit off.
The discs also needed a 2mm spacer underneath each of them, to space them out to the required 134mm (outside edge of one disc to outside edge of the other).
I will see if I can get some photos for you.
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XR650R, FE650, KTM300, 900SS, FZR600R, GS500E, CB600F, KLX250
TE610, TRX850, WR250, XT500, YZF-R1, DR650, WR200, KTM640, ApriliaSMV750.
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Old 09-21-2013, 07:00 AM   #101
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Seat work

Time to do something about that abysmal seat.
I bought a used one with a gel insert of eBay but it was rubbish - no more comfortable that the standard one. It had the standard seat pan of course so that was the starting point. Remove the stock cover and discard, keep the gel:


The gel has to be the weirdest feeling stuff ever...

Take all of the sprayed in factory foam and fill in the hole at the back:
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DT125LC, RZ50LC, CR125R, Z1000R-ELR, RZ350YPVS, XL600R, XR600R
XR650R, FE650, KTM300, 900SS, FZR600R, GS500E, CB600F, KLX250
TE610, TRX850, WR250, XT500, YZF-R1, DR650, WR200, KTM640, ApriliaSMV750.
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Old 09-21-2013, 07:22 AM   #102
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Seat (2)

Then I got some really hard, closed cell foam and started with the layering:


The bend was too tight for the foam, so I inserted some corners to fill in the gaps where I had to cut it.
After the first layer was adhered to the seat pan, I put the second on, here it is next to the stocker:


After that got a good grip I made a "spatula sander and started on the first bit of shaping:


Just on the front part.



In the above pic I also added another layer of foam across the part I want to fill in and duct-taped it down hard to make sure it sticks. I also put more adhesive on the parts that had peeled a little from the seat pan and wrapped the whole lot in tape:

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DT125LC, RZ50LC, CR125R, Z1000R-ELR, RZ350YPVS, XL600R, XR600R
XR650R, FE650, KTM300, 900SS, FZR600R, GS500E, CB600F, KLX250
TE610, TRX850, WR250, XT500, YZF-R1, DR650, WR200, KTM640, ApriliaSMV750.
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Old 09-21-2013, 07:27 AM   #103
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Brake pedal bolt.

...will go straight through the clutch cover if you topple on the right side:


Its a button head capscrew, so it has a high point. I have had a Husky TE610 brake lever go through the cover before, so I would like to avoid that!
I took a s/steel CSK cap and countersunk the steel part above. Then put the bolt through and loctite'd it:





No high point. Should help a little, might get a brake snake too.
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DT125LC, RZ50LC, CR125R, Z1000R-ELR, RZ350YPVS, XL600R, XR600R
XR650R, FE650, KTM300, 900SS, FZR600R, GS500E, CB600F, KLX250
TE610, TRX850, WR250, XT500, YZF-R1, DR650, WR200, KTM640, ApriliaSMV750.
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Old 09-21-2013, 07:35 AM   #104
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Engine protection bars.

...will be bolted onto the engine mounts. These holes in the frame are about 30mm in diameter:


So I am making some 1" tube extensions, similar to the crash mushroom setup, where I will weld the bars onto. The front will go around the water pump cover (a good idea) and them under the pipe and over the starter. it will be a 2-piece part (otherwise I couldn't get it on). The rear will run down past the oil filler cap, in front of the foot brake arm and under the motor, coming out to the same bolts on the other side and protecting the exhaust too. it will also need to be a 2 part for the same reason. Onto this I will mount ally plates to cover the engine. I think I may also need to have a central tube that runs from the front bar to the rear bar.
A little difficult to explain - pictures will be better and forthcoming shortly.


The above is the start of the right-front engine protection bars.
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DT125LC, RZ50LC, CR125R, Z1000R-ELR, RZ350YPVS, XL600R, XR600R
XR650R, FE650, KTM300, 900SS, FZR600R, GS500E, CB600F, KLX250
TE610, TRX850, WR250, XT500, YZF-R1, DR650, WR200, KTM640, ApriliaSMV750.
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Old 11-15-2013, 04:16 PM   #105
Pokeyjoe
Aprilia Dorsoduro
 
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Joined: Nov 2008
Location: Long Beach, CA
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Quote:
Originally Posted by Bobmiller90 View Post
That is the most bad-ass looking bike ever. Bring on the apocalypse!
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