72' R75/5 Cafe Build Thread - Leadnuts

Discussion in 'Airheads' started by Leadnuts, Apr 24, 2012.

  1. Leadnuts

    Leadnuts do-over...

    Joined:
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    Yeah I have them I will send you a message here in a few..

    Have a bunch of other parts if you need them.. those chrome side covers, fenders, airbox, etc..
    #21
  2. Houseoffubar

    Houseoffubar HoFmetalworks.com

    Joined:
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    Wow, looking good! I thought I was the only one who used a router in lieu of a milling machine. I never thought, however to use a template, very clever!:clap

    BTW, Leadnuts is a super cool guy, who was beyond patient waiting to get his swing arm back! Much appreciated amigo!:freaky

    Keep up the great work!
    #22
  3. Leadnuts

    Leadnuts do-over...

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    Too excited, got a pretty spectacular looking set of rearsets this morning from a guy I randomly met while getting some coffee and holding a magazine I found called BMW motorcycles or something like that.. saw I was reading it and struck up a conversation next thing you know I have a set of tarozzi controls.. He said he had used them, but they look new to me.



    <a href="http://www.flickr.com/photos/cabea_da_nuvem/6975529106/" title="WP_000622 by Nerfrobot, on Flickr"><img src="http://farm8.staticflickr.com/7199/6975529106_99f43bd0f7.jpg" width="500" height="375" alt="WP_000622"></a>

    Going to have to make some new brackets to hold them I suppose... ugh.

    Going to do a cable to replace te rod in the rear as well I think. Anyone have a spare cable I can borrow forever?
    #23
  4. Leadnuts

    Leadnuts do-over...

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    Ah, Houseo, didn't see you there..

    It was easy to wait, I just rigged up a cryogenic sleeping cask. Seemed like only minutes to me... but worth the wait.

    I have also stuck a bearing on a carbide burr bit for mild steel.... very scary! But worked all the same, did I mention it was a bit scary?

    Anyway, I can't thank you enough for the wealth of knowledge that is pooled in that head.
    #24
  5. Leadnuts

    Leadnuts do-over...

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    Does anyone know what the degree of travel the rear brake pedal makes for adequate stopping?

    thanks
    #25
  6. Leadnuts

    Leadnuts do-over...

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    here is what I'm thinking for the new brackets which will now hold the end of a brake cable..

    #26
  7. Leadnuts

    Leadnuts do-over...

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    here is what I'm thinking for the new brackets which will now hold the end of a brake cable..

    [URL="<a href="http://www.flickr.com/photos/cabea_da_nuvem/7122850527/" title="RearsetMouts by Nerfrobot, on Flickr"><img src="http://farm8.staticflickr.com/7108/7122850527_26821d19c4.jpg" width="500" height="279" alt="RearsetMouts"></a>"[/URL]
    #27
  8. Leadnuts

    Leadnuts do-over...

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  9. Leadnuts

    Leadnuts do-over...

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    Had some time today and made a new headlight bracket out of stainless. It hasn't been polished out but you get the point.

    Added a Bumm mirror for effect.. Got a new top brace from Mr. ToasterTan and some sweet clip ons, which neither of them have made it on yet but hopefully soon.

    Question... Someone mentioned there is something I need to do to the front forks to modernize the way they work but I can't for the life of me remember what it was called.. Bypass, or something... a kit of some kind??

    <a href="http://www.flickr.com/photos/cabea_da_nuvem/7391151626/" title="Headlight bracket by Nerfrobot, on Flickr"><img src="http://farm8.staticflickr.com/7105/7391151626_8eb02b0fcb.jpg" width="500" height="375" alt="Headlight bracket"></a>
    #29
  10. bpeckm

    bpeckm Grin!

    Joined:
    Apr 2, 2008
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    7,038
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    Road Island
    Oh man, between you and Houseoffubar.... sigh.... sick skills and design sense!




    :puke1
    #30
  11. Padmei

    Padmei enamoured

    Joined:
    Mar 12, 2008
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    4,099
    Location:
    Nelson New Zealand
    Far too much thought, patience, technology & workmanship for my liking - can you please post some pics of your cockups to make us lesser mortals feel better:lol3

    Seriously I like the way you are evolving your bike to your ideas.
    #31
  12. Leadnuts

    Leadnuts do-over...

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    Awfully nice of you guys.. thanks.

    As for cock-ups... I realized that bracket needs to be 5/16" and not 1/4" to look right with that mirror... so i will be doing that again i suppose, and those aluminum rearset brakets I'm going to have to make again due to the rearset brake set up changed 3x now... rod, to cable, back to modified rod... basically I have no idea what I'm doing..haha

    As for patience... the reason everything seems to be "3rd times a charm" for me is because I keep making parts before the thing that is connecting to it arrives... because I haven't got any patience.

    My motto is "I call Do-Over"

    Hope that makes you feel a little better Padmei.


    I do think Fubar takes the cake with fab parts though... the swing arm he did for me blows me away every time i look at it
    #32
  13. Leadnuts

    Leadnuts do-over...

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    Made some new rearset brackets last night.. this time made them out of steel. As the new improved versions wil be welded on not bolted as it solves a few problems I was having.

    One was that when the bracket was bolted onto a tab it pushed the rearset levers out to a funny looking distance which was becoming problematic to align the brake rod. The new one pushes the whole assembly in about 1/2".. which combined with a right angle ball joint linkage thingy all seems to line up pretty good. Alleviating the need to engineer/fabricate a cable brake system, so thats good, right.

    The other thing it does is allow me a platform for adding things that I haven't really thought about yet like exhaust supports, or a removable 2nd passenger foot peg bracket, and a mount for the brake light switch.


    [​IMG]

    [​IMG]

    next will be the making of an extension to the rearset lever or the fabrication of a whole new one... haven't decided which to do yet. Leaning towards an all new one for a cleaner look though...
    #33
  14. Boxer Metal

    Boxer Metal Mad Scientist

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    I think the way you have the cable set up your brakes will activate every time the swingarm moves up and down.
    #34
  15. Leadnuts

    Leadnuts do-over...

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    I was wondering that, was actually thinking of flipping the lever under so the rod is parallel with the swing arm.. think that might help? If not I do have an actuator I was thinking about installing right up near the arm pivot, came from a raask bmw set. but was hoping to avoid the extra part..
    #35
  16. melville

    melville Long timer

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    Looks like the pedal is free to float with the wheel moving up and down. Actually using the brake over bumps might feel a bit funny, though.
    #36
  17. Leadnuts

    Leadnuts do-over...

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    Was looking around and found this one, and its similar to what the final set up will be like on mine. I can't imagine it not working as its done by what looks like some pro shop.

    [​IMG]

    never mind i see the difference, pivot is aligned with the swing arm pivot... sigh, guess i have more work to do.
    #37
  18. mattcfish

    mattcfish R90X

    Joined:
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    497
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    Bellingham, WA RAIN or shine
    Just a bit of info, at least on some airheads, you can flip the lever over on the final drive so it points up and it still works when you pull it. Might give you a better geometry.
    Love the work you are doing.
    #38
  19. Leadnuts

    Leadnuts do-over...

    Joined:
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    So I made a linkage lever actuator thing in order to bring the pivot of the brake rod perfectly in line and as close to the swing arm pivot as possible... The part below is made of the cut off lever from the original brake lever the grease zert pivot and the tube in which the original pivot rotated in... At this point I'm going to say "pivot" oooone more time... pivot.

    [​IMG]

    Here is the assembled part.. The small arm was bit of metal I had around. Drilled a hole and slipped the axle bit through then welded around that flange area when I figured out the angle I needed.

    [​IMG]

    Then touched up the aluminum lever where I made the cut.. The key here was to be able to lock the arm in place on the axle. Ended up drilling and tapping a hole split half on the axle and half on the alum. lever which now has a set screw in it to form a key. I will stick a washer and nut over the end for good measure.

    [​IMG]


    So in the end I have a pretty nice looking actuator is I may say so.. The linkage rod is temp. just to see what I needed while i was making it. Also the foot lever is set in that angle just so you can see the parts.. Ends up taking a perfect amount of push to get that brake to engage... man that was a lot of work. Bet part is I can grease the axle, i guess.

    [​IMG]
    #39
  20. Leadnuts

    Leadnuts do-over...

    Joined:
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    Also got some part delivered today. Stuck them on to see what It will be like. Have a look.

    [​IMG]

    [​IMG]



    What sort of options do I have for alternative fork nuts? Also will be modifying that 7' tall tension knob....somehow.

    Thats a ToasterTan brace... You Jelly Bro?
    #40