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Old 06-06-2013, 06:05 PM   #61
XCgeek OP
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We have a roller! Well almost.

I finished painting the rear suspension linkages so I could assemble the frame fully (then I promptly damaged the paint!). Action is good but there feels to be too much rebound damping even when fully backed off. I have not set full air pressure yet though as the mounts to the frame are only tacked on.





I tacked on those mounts while fully assembled to ensure they ended up in just the right place regardless of weldment movement, heat distortion and shoddy workmanship. Worked out well.

I have also started working with some aluminium. Made up a rear disk caliper mount that is press fit on one of the hub spacers and will have a spot of weld on it later once disassembled. It engages with a nut on the other side of the chain tension bolt to stop rotation



I also turned up the hub spacers (love using aluminium in the lathe) and made the snail cam adjusters.

I then made up some new front engine mounts cause I was not happy with the stock Honda ones weight. Honda = +500grams. Mine = 108grams. I know that isn’t much mass savings but if I want to hit 55kg total, every little bit counts.

Now I have the engine fitted so I can check chain alignment, chain slider position, will need a couple of chain rollers etc.







While I have it at this stage, I will also modify my exhaust and re-route it through the frame. Hopefully that will make the next post.

Oh, and why only nearly a full roller? Just the rear axle. Currently there is just a length od threaded bar in there so I need to make up a rear axle.
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Old 06-06-2013, 07:58 PM   #62
Marco Moto
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Want! Nice work!
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Old 06-06-2013, 09:27 PM   #63
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Omg, jealouse and ill take one.
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Old 06-06-2013, 11:01 PM   #64
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Looks great.
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Old 06-07-2013, 01:58 AM   #65
Te Hopo
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Super super cool work man, it looks good and your objectives sound like a fun bike to me.
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Old 06-07-2013, 08:03 PM   #66
MitchG
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Love the build, but can't wait for the scale when finished!
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Old 06-08-2013, 09:30 PM   #67
anonny
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Impressive! Whats the steering head angle? Mine will need to have room and mounts for a Sherco 2.9 motor
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Old 06-11-2013, 05:16 PM   #68
smacka
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You made those snail cam chain adjusters!!!
Damn nice work. Cannot believe you are fabricating this bike under a quickshade in the front yard and bolting it together in the lounge room.

Most excellent work Sir
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Old 06-11-2013, 06:42 PM   #69
clintnz
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Quote:
Originally Posted by XCgeek View Post
My welding still sucks but I can see improvement!
learning to TIG weld on small tubing is like a bloke learning to pick up chicks in a lesbian bar I reckon.

Nice work!

Clint
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Old 06-11-2013, 07:26 PM   #70
sailah
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Quote:
Originally Posted by clintnz View Post
learning to TIG weld on small tubing is like a bloke learning to pick up chicks in a lesbian bar I reckon.

Nice work!

Clint
Just start with the fatties first, the skinny ones give you all the trouble...

I was talking about tubes btw sickos
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Old 06-11-2013, 08:01 PM   #71
clintnz
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Quote:
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the skinny ones give you all the trouble...
But they are pretty satisfying when you get them nailed

I'm working my way down, made a couple of things out of .065 4130 tube, the most recent project was .049, will try .035 next

Looking forward to further updates on this build. I'd love to have a go at building a frame one day, & looking at XCgeek's 'workshop' vs what I have, I clearly have no excuses

Cheers
Clint
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Old 06-12-2013, 03:38 AM   #72
tileman
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Quote:
Originally Posted by clintnz View Post
But they are pretty satisfying when you get them nailed

I'm working my way down, made a couple of things out of .065 4130 tube, the most recent project was .049, will try .035 next

Looking forward to further updates on this build. I'd love to have a go at building a frame one day, & looking at XCgeek's 'workshop' vs what I have, I clearly have no excuses

Cheers
Clint
I tried to make some supertrapp copies. started with .028 (.7mm). The results were.....um.... not great.

But my 1.2mm .049 got heaps better!!!!!

Either way this thread and build is just inspiring. Since it seems that your mitre's are pretty close to the adjoining part maybe fusion weld it. I've had success with it. I admire what your doing and the updates are thorough and of major interest. Thanks for sharing.
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Old 06-12-2013, 11:22 AM   #73
MrPulldown
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Quote:
Originally Posted by smacka View Post
You made those snail cam chain adjusters!!!
Damn nice work. Cannot believe you are fabricating this bike under a quickshade in the front yard and bolting it together in the lounge room.

Most excellent work Sir
Porbably made those snails with a hand drill and a hacksaw/jigsaw.

Impressive indeed.
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Old 06-12-2013, 01:21 PM   #74
jesusgatos
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Doing more with less. There's a thread over on pirate4x4 about these metal fabricators in India that do some amazing work. In the dirt. In sandals. Love that shit.
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Old 06-13-2013, 05:45 AM   #75
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The weather here in Melbourne has sucked for the past couple of days. Well, it sucks if your work space is a 3 x 3 quick shade.

No matter, I set the exhaust up.

I bought a DRD exhaust that is specially made for hotted up XR100s like mine.



The DRD is manufactured to bolt straight up to an XR100 frame of which my frame bears no resemblance.

I also wanted to take the opportunity to try something different. I want to point the exhaust gases straight to the ground. There are probably some very good reasons why this is not done but I am really enjoying finding things out by trial and error.

My proposed setup is obviously going to be significantly different to the XR. I can’t use my tube bender to re-bend the exhaust tube because the bend radius is way to big. My bender will bend the header tube but the silencer tube is a bigger diameter which I can’t fit in my bender.

So, I bought some stock Stainless Steel bends.



I slightly modified the shape of the header with my bender. Worked OK.

I hacked up the DRD silencer and put this together. Fits pretty nicely.



The exhaust comes with a mesh spark arrester. I plan to add a second mesh screen just to be sure since I am going to be directing any sparks straight to the ground.

My hope with this setup is some noise reduction when on dirt. I expect it will be a good bit louder when in hard ground like concrete but this bike should not see a little concrete.

As an aside, I was planning to get an exhaust shop to build the exhaust for me but thought I would give it a go. The stainless is quite thick (this is Australia, we have limited product available) so it turned out to be pretty easy to weld as can be seen. I also ran a purge stream of Argon to the inside of the tubing to improve welding and longevity of the welds







I have also been working on some other bits; foot peg mounts, oil cooler mounts and starting the fuel tank.

More soon.
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