300 Day Challenge to complete my Bultaco Roadster "Garbage Bike"

Discussion in 'Some Assembly Required' started by Tanshanomi, Jan 4, 2018.

  1. Tanshanomi

    Tanshanomi Your Favorite Uncle

    Joined:
    Jul 22, 2009
    Oddometer:
    1,970
    Location:
    Heart of America
    [​IMG]

    On October 25th, 2011, I posted this image as my first post in a build thread on the caferacer.net forum. I had gathered a salvage Bultaco Model 193 (1977 Pursang 370) frame, an '76 YZ125C monoshock swingarm and Suzuki wheels, with the naive notion that I could build a functioning motorcycle from whatever cheap, used parts I could scrounge online through Ebay and Craigslist.

    This was always intended as a strictly back-burner project — only getting whatever extra money and time was left over after all the other projects and demands of life were addressed. I did manage to make progress, if very slowly.

    By May of 2013, I had wheels attached to it:

    [​IMG]

    And a year after that, had collected the basic components of an engine. A Bultaco engine was always central to the project. I'd previously owned and loved three Bultacos, despite their general crudeness. I converted a Pursang 250 into a road racer back in the mid 1980s, and I've always been a big fan of the final Bultaco road bikes that were equipped with cast wheels and disc brakes, but none of my Buls were street legal, and I've always wanted a Bultaco road bike.

    [​IMG]

    And in November of 2014, a rear shock in place:

    [​IMG]

    Since then, I've done very little with it. The chassis has been in various states of disassembly since, and the engine never went together; it remains a collection of salvage parts occupying several shelves in my workshop. I did cut off the rear of the frame and experimented with seat and bodywork concepts...

    [​IMG]

    ...and decided to revert to a twin-shock design, replacing the YZ swingarm with one from a DT175.

    [​IMG]

    Which necessitated the purchase of a frame jig this fall, to ensure everything went back together true and square:

    [​IMG]

    This project will be seven years old at the end of October. In short, it's time to either make this happen or get rid of the carcass. I have decided that this project needs to become a higher priority. Therefore, I am giving myself the next 300 days get the whole thing together and running in some fashion (that is, started up — not necessarily running well enough to ride), or I am going to part it out and get rid of the evidence.

    There are more than 300 posts in the caferacer.net build thread that go into extreme detail about every minute consideration and blind alley along the way, but much of that information is irrelevant. I will still keep that build thread up to date, but that site has largely atrophied over the last seven years and ADVrider has a great deal more activity, so I figured I should create a thread here, too. And, frankly, some new blood and a fresh start is needed to help me renew my motivation to get this completed.

    EDIT: I should note that I'm not looking to create a great-performing, highly valuable bike, or even an especially attractive or practical one. This has been about learning all the skills of custom bike fabrication that I have wished to acquire. This is my coursework in the college of hard knocks.
    #1
    RCmoto, knudln, Nemosengineer and 9 others like this.
  2. r60man

    r60man Long timer

    Joined:
    Mar 14, 2013
    Oddometer:
    1,390
    Location:
    Robesonia PA
    Should be fun, I am in!
    #2
  3. flinders_72

    flinders_72 Long timer

    Joined:
    Apr 21, 2008
    Oddometer:
    1,642
    Location:
    Murtoa, Australia
    I gave myself 365 days to lose some weight. I hope this is more successful. Good luck! :)

    PS, the Bultaco Frontera is one of my favourite bikes, best looking enduro ever built IMO.
    #3
  4. Tanshanomi

    Tanshanomi Your Favorite Uncle

    Joined:
    Jul 22, 2009
    Oddometer:
    1,970
    Location:
    Heart of America
    Day T minus 299: making leveling legs for my frame jig.

    Trying to do something every weekday, even if it's just something small.
    #4
  5. TOsborn

    TOsborn Been here awhile

    Joined:
    Jun 21, 2013
    Oddometer:
    107
    Cool, a Garelli Rex tank. I had a complete one of those once, it was a fun project with loads of style. That tank will look sweet on yours.
    #5
  6. Tanshanomi

    Tanshanomi Your Favorite Uncle

    Joined:
    Jul 22, 2009
    Oddometer:
    1,970
    Location:
    Heart of America
    It's from an early-'60s, German-made KL30 or KL35, so technically pre-Garelli.

    http://www.bike-urious.com/1964-rex-kl35/

    silberrex.jpeg
    #6
    Jay_In_Milpitas likes this.
  7. TOsborn

    TOsborn Been here awhile

    Joined:
    Jun 21, 2013
    Oddometer:
    107
    Cool! Sorry to sidetrack, but thanks for the history lesson. I never really understood why my old bike was badged Garelli, and badged KL55 Rex.
    #7
  8. Tanshanomi

    Tanshanomi Your Favorite Uncle

    Joined:
    Jul 22, 2009
    Oddometer:
    1,970
    Location:
    Heart of America
    I believe that after Rex Moteren Werk went out of business (around 1964?), the U.S. importer contracted with Garelli to supply them with re-badged bikes, so they'd still have a lineup of bikes to sell.
    #8
  9. Tanshanomi

    Tanshanomi Your Favorite Uncle

    Joined:
    Jul 22, 2009
    Oddometer:
    1,970
    Location:
    Heart of America
    By the way, I stupidly stripped the paint off that Rex tank due to it being scratched up and rusted in a couple of spots. Big mistake. That paint was the toughest I've ever seen — multiple applications of citri-strip hardly touched it. Even the really caustic chemical stripper took several runs at it. If I had known, I would have just scuffed it up and shot primer over it.

    I'm sure I enhanced my lead levels in the process.
    #9
  10. Beezer

    Beezer Long timer

    Joined:
    Oct 26, 2004
    Oddometer:
    8,129
    Location:
    Anchorage, formerly Spenard (hub of the universe)
    yo Tan.... yer avitar looks remarkably B25S

    nice work on the Bultaco. I had 2 Alpina, a Matador, a Lobito, and a Pursang over a period of many years. got any use for a lighting coil?
    #10
  11. Tanshanomi

    Tanshanomi Your Favorite Uncle

    Joined:
    Jul 22, 2009
    Oddometer:
    1,970
    Location:
    Heart of America
    Round barrel B44.

    I’m probably going to just spring for a Powerdynamo electric setup.
    #11
    Beezer likes this.
  12. Beezer

    Beezer Long timer

    Joined:
    Oct 26, 2004
    Oddometer:
    8,129
    Location:
    Anchorage, formerly Spenard (hub of the universe)
    I had a few B44s... all square barrel, all Victor
    #12
  13. gavo

    gavo Slacker

    Joined:
    Jan 5, 2010
    Oddometer:
    2,674
    Location:
    Gympie QLD
    this is interesting because i've had a 350 Alpina cafe project languishing in the shed for 2 years. I want to see if a deadline works:lol3
    #13
  14. Nemosengineer

    Nemosengineer Hair Ball

    Joined:
    Dec 28, 2007
    Oddometer:
    1,624
    Location:
    Murrieta
    My kind of thread, your turning a motocrosser into a street bike, I'm turning a street bike into a motocrosser. Makes perfect sense, I'm in.

    Inspiration.
    [​IMG]

    : Mike
    #14
  15. knudln

    knudln Been here awhile

    Joined:
    Jul 29, 2014
    Oddometer:
    166
    Location:
    Saratoga Springs, NY
    :lurk
    #15
  16. Tanshanomi

    Tanshanomi Your Favorite Uncle

    Joined:
    Jul 22, 2009
    Oddometer:
    1,970
    Location:
    Heart of America
    I haven't done much work on the chassis, beyond finishing the jig setup and leveling it. I did, however, pick up some additional engine parts in the form of this Model 143 Frontera 370 bottom end. It has the larger cylinder opening of the big bore (326–363cc) bikes, the later ('75-on) left-side shift option, and the same wide-ratio gears as the Lobito 175 transmission I already have. I feel it was a fairly good deal at $199 shipped. The seller said the crank turns but feels gritty. We'll have to see what sort of condition it's really in when I get it in the next week or so.

    [​IMG]

    [​IMG]

    Since all the engine parts I have currently were purchased separately, a complete and intact lower end will also get me all those little extra bits inside the cases that I don't yet have. The extra kick from a 370 would be nice, but I will most likely end up sticking with a smaller motor, since I already have a Sherpa S 200 cylinder [VGC, but bent cooling fin :( ] and a NOS 2nd over Tarabusi piston kit for it.

    [​IMG]

    [​IMG]
    #16
    Beezer likes this.
  17. Rich B

    Rich B Long timer

    Joined:
    Apr 10, 2010
    Oddometer:
    1,699
    Location:
    Stone Creek, OH
    A 370 Frontera would be a torque monster for a road bike.......
    #17
    Beezer and Tanshanomi like this.
  18. Tanshanomi

    Tanshanomi Your Favorite Uncle

    Joined:
    Jul 22, 2009
    Oddometer:
    1,970
    Location:
    Heart of America
    Slowly making progress on the frame. Lots of measuring and nudging lately, not much fabrication. I did chuck up some aluminum in the lathe and made spacers that positively locate the swingarm pivot bolt in the jig horizontally and perpendicular to the center line. I then verified that the swingarm pivot is perpendicular to the steering stem axis and the frame is, indeed, symmetrical at the swingarm pivot — that is, the insides of the frame where the swingarm mounts are the same distance from the center line. I had strongly suspected that, but hadn't been able to conclusively determine that until now. That will simplify final installation of rear motor mounts and the swingarm.

    Now I can finally move on to getting the new seat supports and seat loop level and true, which was the task that prompted the purchase of the frame jig in the first place.

    [​IMG]

    [​IMG]
    #18
    flinders_72, Vince and JimVonBaden like this.
  19. Tanshanomi

    Tanshanomi Your Favorite Uncle

    Joined:
    Jul 22, 2009
    Oddometer:
    1,970
    Location:
    Heart of America
    I chatted with @Makr about my plans for Bultakenstein when he was a guest on the podcast, right after he bought his Alpina. Now, it pops up on Pipeburn turned into a monoshock, cafe-style roadracer. Coincidence? Probably, but I don't really care if it is. From now on, I am going to falsely claim that Bultakenstein was the inspiration for his bike.

    ...Mostly to hide my embarrassment that his went from concept to completion while mine changed....not a whole lot.

    http://www.pipeburn.com/home/2018/01/24/bultaco-racer-speed-of-cheese.html

    [​IMG]
    #19
    invisa-bill, Beezer and flinders_72 like this.
  20. Makr

    Makr I make my own rules

    Joined:
    Apr 28, 2010
    Oddometer:
    860
    Location:
    SL,UT
    @Tanshanomi Hehehe It was total inspiration, Peter!

    Get busy because now I am watching you.
    #20
    Tanshanomi likes this.