CB desert sled

Discussion in 'Some Assembly Required' started by Luke, Sep 6, 2012.

  1. Luke

    Luke GPoET&P

    Joined:
    Aug 25, 2004
    Oddometer:
    4,259
    Location:
    Beaverton, OR
    Rick had a really good idea for where to put the coils. They won't fit in the stock location because the gas tank's tunnel is too narrow, and I was just going to stick them near the stock location but below the tank. Convenient for them, but in the way of other things. Instead, they're going to go on top of the battery box. There's enough room to move the air filter up a couple of inches to accommodate them.


    Step one was to cut out a top for the box. The coils are attached to some pre-fabbed gussets which are welded to the top of the box.

    [​IMG]


    [​IMG]

    The battery box lid is larger than it needs to be because it will also be the bottom of the shroud for the air filter.

    Unfortunately adding a lip to the lid ruined it. The sheet warped and adding a rib to stabilize it made it worse. The original warping itself wasn't that bad, but pushing on the middle of the lid would make it pop from convex to concave like a jam jar lid. If the lid was popped the wrong way the coils wouldn't fit on the mounts. The rib was supposed to fix it, but just made it bad in a different way.
    [​IMG]
    That was about five hours of work I gave up on. :cry

    The nice thing was that the next one went much faster. :D
    Instead of making a sheet metal lid I'm going for plastic. A couple of brackets that each hold an individual coil each go on top of them.

    [​IMG]

    [​IMG]
  2. LC Garage

    LC Garage On Any Sunday

    Joined:
    Mar 18, 2011
    Oddometer:
    788
    Location:
    Columbia County
    Starting here. I never get tired of this view.
    [​IMG]

    So your an ass man? :lol3
  3. TwinDuro

    TwinDuro Befuddled Adventurer

    Joined:
    Jun 10, 2007
    Oddometer:
    356
    Location:
    Pac Nor-Wet, WA
    :photog

    It is a darn good view... :D
  4. Mr. Fisherman

    Mr. Fisherman PROUD 2B Riff Raff!

    Joined:
    Oct 8, 2006
    Oddometer:
    10,957
    Location:
    Drinking from the Stanley Cup!
    Wait until the truth comes out about the Lint chastity belt...

    Oops, I've said too much.

    No pics, didn't happen... move along...
  5. Kootenai Rider

    Kootenai Rider Gentleman of Liesure

    Joined:
    Nov 2, 2008
    Oddometer:
    2,276
    Location:
    Hillsburrito
    [Verbal handgrenade]Question..... Are you going to have a spare custom swing arm, you know, just in case? Or are you bringing a TIG?

    [\verbal handgrenade]
  6. Luke

    Luke GPoET&P

    Joined:
    Aug 25, 2004
    Oddometer:
    4,259
    Location:
    Beaverton, OR
    The swingarm is about the last thing I'd expect to break. Other stuff, like the frame, worry me more. Hauling a welding setup down there would be a pain, especially TIG. My small acetylene setup might go though.
  7. MrPulldown

    MrPulldown Long timer

    Joined:
    Aug 18, 2009
    Oddometer:
    3,685
    Location:
    Truckee
    Over the years I have taught myself how to weld with two car batteries. I now have a small set up I bring on 4 wheeling trips.
    This is currently my only welding set up. I have almost bought myself a little buzz box several times, but it is hard to justify when I have a neighbor who is a professional welder that works out of his garage across the street.
    Enjoying the build. Keep at it.
  8. oregoncoast

    oregoncoast Racing Like a Noob

    Joined:
    May 15, 2007
    Oddometer:
    4,544
    Location:
    Duh!
    Did some proper internet research on the 3 car battery welding system and I gotta say....what a freakin cool idea for emergency repairs! :freaky
  9. Mr. Fisherman

    Mr. Fisherman PROUD 2B Riff Raff!

    Joined:
    Oct 8, 2006
    Oddometer:
    10,957
    Location:
    Drinking from the Stanley Cup!
    It is a fairly common tech for old school off roaders and 4x4 clubbers.

    I have heard of coat hangers being used as rod in a pinch.
  10. RedRaptor22

    RedRaptor22 Been here awhile

    Joined:
    Jan 24, 2012
    Oddometer:
    163
    Location:
    Louisiana
    Yep, have seen that done on a broken fourwheeler a-arm about two hours out on a trail, surprisingly it held the whole way back and broke about 50yds from the campground lol.
  11. Luke

    Luke GPoET&P

    Joined:
    Aug 25, 2004
    Oddometer:
    4,259
    Location:
    Beaverton, OR
    A few little things today:


    Quick and dirty wheel spacers. The washers are 1/8" thick but it's a pain to get them all in the right place when installing the wheel. The swingarm width is also not an even number of washers, and is too stiff to bend in to the next smallest number. So I welded a stack of washers together and then sanded down the face to get it right. Ugly, but much faster than using the lathe.
    [​IMG]



    Next up was a bracket for the clutch cable. It's attached to a motor mount plate just like the stock cb550 setup, but it's in a slightly different place to deal with the different airbox. It's not done in the picture; there's another support for the plate which is attached near the cable.
    [​IMG]



    My new favorite things. Weld nuts. I bought a box of them from Mcmaster in different sizes. They're awesome. Drill an oversized hole for the bolt you want and then weld them in. They're unplated so there's no prep required, they have a ridge on them so they align right in their hole, and they're much wider than regular nuts so there's plenty of material to dig into with the welder.

    These weld nuts are for holding the lid onto the battery box.
    [​IMG]
    [​IMG]

    [​IMG]


    Finishing up the battery box lid, I put some screws in the mounting holes to transfer the hole pattern to the lid. Easier than measuring.

    [​IMG]




    Lid (with coils) attached. I also made a bent pipe for the air filter. Far from ideal, but it'll have to do until I modify the airbox inlet.
    [​IMG]





    I also installed the chain. The slack is set by moving the swingarm up so that the front sprocket, pivot, and rear axle are in line. Make sure there is just a little slack there, and it should be looser everywhere else.
    In line (roughly). The chain slack was set here.
    [​IMG]

    Compressed.
    [​IMG]

    Extended
    [​IMG]




    It's going to need chain rollers and a guide, but even without those the chain slack isn't horrible anywhere.
  12. Mr. Fisherman

    Mr. Fisherman PROUD 2B Riff Raff!

    Joined:
    Oct 8, 2006
    Oddometer:
    10,957
    Location:
    Drinking from the Stanley Cup!
    Another solid day of progress :clap
  13. DustyRags

    DustyRags Idiot

    Joined:
    Nov 27, 2012
    Oddometer:
    958
    Location:
    The Beast, California
    :eek1 It's gonna be a beast!
  14. oregoncoast

    oregoncoast Racing Like a Noob

    Joined:
    May 15, 2007
    Oddometer:
    4,544
    Location:
    Duh!
    She is going to be a big girl, that is for sure. But as Luke has told me...just think of it as an adventure bike (GS/990/etc) more than a dirt bike. Then the shear girth and weight become much more palatable. :D


  15. Jayrod1318

    Jayrod1318 Poster

    Joined:
    Jun 14, 2011
    Oddometer:
    1,642
    Location:
    Here and there and stuff.
    Quick question, What are you using for fasteners metric or Merican?:D
  16. kellymac530

    kellymac530 motorcycle addict

    Joined:
    Feb 4, 2010
    Oddometer:
    1,052
    Location:
    so. cal.
    While you were testing the chain tension with the shocks off, did you take a measurement so that you can always set it correctly?

    Even something as simple as picking a specific spot where 2 fingers fit between the chain and swingarm or a spot where 10mm or 20mm gap works?
  17. Luke

    Luke GPoET&P

    Joined:
    Aug 25, 2004
    Oddometer:
    4,259
    Location:
    Beaverton, OR
    All metric. All the donor parts are metric and mixed fasteners are an abomination.

    I bought a fastener kit that has the nice OEM style hex head fasteners. Expensive, but still cheaper than the hardware store.
  18. Luke

    Luke GPoET&P

    Joined:
    Aug 25, 2004
    Oddometer:
    4,259
    Location:
    Beaverton, OR
    Not yet. Adding the rollers and guide will change that.
  19. LC Garage

    LC Garage On Any Sunday

    Joined:
    Mar 18, 2011
    Oddometer:
    788
    Location:
    Columbia County
    In my Dad's body shop is was not uncommon to use coat hangers, we also did a lot of brazing. When we got a stick welder, we were in heaven! :D
  20. LC Garage

    LC Garage On Any Sunday

    Joined:
    Mar 18, 2011
    Oddometer:
    788
    Location:
    Columbia County
    Yesterday was a long but productive day in the shop for the Outta Sight team. Luke and Al arrived about 9:30, Paul got there about an hour later. Danny was there to greet them, hoping for a treat.
    [​IMG]

    This old fellow stopped by for a few hours, made himself at home and then later just disappeared.
    [​IMG]

    Luke and his helpers;
    [​IMG]

    Luke spent many hours fabricating an entire wiring harness. Once built he hooked it up and tested, everything seemed to work just fine.
    [​IMG]

    Corey arrived about 2 PM and went right to work, here Al captures him working on the seat project.
    [​IMG]

    Al was a big help all day, in addition to working on the bike, we also reorganized the out buildings to create a little more shop space.
    [​IMG]

    Paul painting his cage;
    [​IMG]

    Paul liked the progress on the SL350! :D
    [​IMG]

    Corey developing the seat shape;
    [​IMG]

    [​IMG]

    Seat roughed out with dense foam;
    [​IMG]

    Luke likes! :lol3
    [​IMG]

    Corey was designated to set base timing as he had worked with this system before.
    [​IMG]

    [​IMG]

    [​IMG]

    A jump start from the Paul's Subie brought the big sled to life! :clap
    [​IMG]

    A great way to end our day in the shop, with an unmuffled 650 four cylinder roaring! :D