Guzzi Rig construction underway.......... at last.

Discussion in 'Hacks' started by toastmuncher, Jun 29, 2012.

  1. toastmuncher

    toastmuncher I be new round here! Ello

    Joined:
    Jan 3, 2009
    Oddometer:
    678
    Location:
    Chepstow, South Wales, UK
    Well, again, slow here as the painter is busy and housey stuff like building my lad a playhouse etc means not much happening. Anywhoo.
    In the bucket of fittings, the chair came from an identical bike, was a mystery plate. Well it turns out it was a bracket plate for the lower front mount, the eyebolt is located below the exhaust downpipe and the plate is secured by the front engine bolt. However, on removing MY engine bolt had a 12mm fine thread whereas the plate was tapped out at m12 x 1.75, quite a course thread. I managed to get a piece of 12mm bar which I had to file a taper onto, surprised how hard it was to get a course 12mm thread started, memory fails me from when I did this kind of thing regularly.
    [​IMG]
    This pic shows where I PLANNED to have the lower front BUT the double arm would not reach from its chair chassis mount. This is what lead to the plate identity discovery.
    [​IMG]
    Having the exhaust so close to the plate means a nut on the outside was not possible so cutting the bolt off and filing it with a taper gave a slight recess which could be filled with weld.
    [​IMG]
    The long bolt goes through the front of the crankcases and is notorious for seizing in place.
    [​IMG]
    This is now painted and in situ, shows how far away my assumed location is now obviously not where the LAST setup had it.
    [​IMG]
    Moved the swing arm onto the front holes, as per the recommendation of a chap on here.
    [​IMG]
    The 135-15 is now in the rear and the avon is now in the front. Waiting for the painter is driving me nuts so all wiring is now complete and tested, the dip and high beam is 30amp relay fed, I cannot mate up the bike and chassis yet as the rim is at the painters preventing me from getting the chassis height set. The fancy goodridge hose kit with SS ends etc is not long enough, I have taken the front lines to PIRTEK hoses who are duplicating them PLUS 200mm, hopefully the 8inch increase will suffice, I guessed 6 but best to be safe I guess.
    Now I wait. :cry
    #21
  2. cleatusj

    cleatusj Dirt floor engineer

    Joined:
    Dec 17, 2010
    Oddometer:
    1,252
    Location:
    Granbury, TX
    #22
  3. toastmuncher

    toastmuncher I be new round here! Ello

    Joined:
    Jan 3, 2009
    Oddometer:
    678
    Location:
    Chepstow, South Wales, UK
    Impressed last time I saw this, good job. Just struggling today to bleed/burp the brakes, the 8inch hose length increase was JUST enough. Phew. :clap
    #23
  4. gsd4me

    gsd4me 90% bluff

    Joined:
    Dec 11, 2005
    Oddometer:
    7,678
    Location:
    Brisbane, Australia

    I think you`ll find the Avon a much nicer tyre on the front than the Metzeler. I had an R80 mono w/- sidecar many years ago and found the Block K on the front was too stiff which made the bike very skittish to steer. I then fitted an Avon Mk11 and there was a lot of improvement. The Mitas E07 and Heidenau K60 Scout are also good strong tyres if you can get them in the size you need.
    #24
  5. Steve In Ireland

    Steve In Ireland Been here awhile

    Joined:
    Feb 1, 2010
    Oddometer:
    233
    Location:
    Northern Ireland
    I put a double banjo on the rear brake and ran the sidecar caliper directly from the rear brake master cylinder linked to the existing front and rear linked brake set up. The master cylinder has enough travel to cope with all three calipers and the brakes work well like this. I rarely use the front brake lever, the rear brake pulling the outfit up nice and straight. Might be worth a try first.

    #25
  6. toastmuncher

    toastmuncher I be new round here! Ello

    Joined:
    Jan 3, 2009
    Oddometer:
    678
    Location:
    Chepstow, South Wales, UK
    Ive now set the thing up as stock but will run the chair brake seperately. Thanks for input though, I assumed the rear MC would not cope with three.

    I have got hold of and installed the rear wheel/tyre, I have got the front brake hoses made up by pirtec in Avonmouth, not cheap but top quality Earles lines. All is wired but as Ive asked the painter to paint the chair wheel to match, I can do nowt now until the paintwork is done.
    Anyway.........Today I collected a great buy, a velocet fuel tank, not sure from what it comes but it fits on the carrier a treat and I guess holds approx 6 liters. I plan to splice into the fuel feed for the injection.
    [​IMG]
    [​IMG]
    Underside.
    [​IMG]
    I was thinking of additional capacity if we ever run onto the continent with it, so, at a fiver it seemed a gift, what do you lot reckon?
    #26
  7. Steve In Ireland

    Steve In Ireland Been here awhile

    Joined:
    Feb 1, 2010
    Oddometer:
    233
    Location:
    Northern Ireland
    Could be useful. I find the tank range on mine quite poor (about 120 miles before the fuel light comes on.
    #27
  8. toastmuncher

    toastmuncher I be new round here! Ello

    Joined:
    Jan 3, 2009
    Oddometer:
    678
    Location:
    Chepstow, South Wales, UK
    Good news, the painter APPEARS to have cracked on with my body, Anyhow, will hopefully be able to update with some progress soon. :clap
    #28
  9. Bobmws

    Bobmws Curmudgeon At Large

    Joined:
    Jun 6, 2005
    Oddometer:
    1,410
    Location:
    Same trailer, different park, FL
    Wow, you're a patient man!
    #29
  10. Hairyjohn

    Hairyjohn Hairyjohn

    Joined:
    Jan 5, 2013
    Oddometer:
    11
    Location:
    Coventry UK
    #30
  11. bmwhacker

    bmwhacker Still on 3 wheels

    Joined:
    May 6, 2009
    Oddometer:
    4,500
    Location:
    MONTANA NATIVE from NATIVE MONTANA
    :lurk
    #31
  12. toastmuncher

    toastmuncher I be new round here! Ello

    Joined:
    Jan 3, 2009
    Oddometer:
    678
    Location:
    Chepstow, South Wales, UK
    A little progress yesterday, dropped the gear oil while the exhaust was off, refilled transmission and re-fitted the exhaust system, for those unfamiliar with guzzis, the oil filter is INSIDE the sump pan, so I removed the sump to fit a new filter, a pain but it DOES make you clean the pan out periodically, the bikes been idle for 7-8 months and the oil had settled and the inside of the sump was in need of a good clean out. Put the sump back on with new gaskets.
    [​IMG]

    Had a good nose about while the sump was off, no evidence of prior blowups or bad repairs.
    [​IMG]

    Now, the front upper mount for the chair brackets is a bit tricky, the reg/rec is mounted just under the headstock, by drilling the mounting bracket I was able to relocate in 2'' over to the right.
    [​IMG]

    The ignition coils are another issue though.
    [​IMG]

    While it would have been far better to use a 'block' clamp, I just could not seem to get it installed without fouling the coil assembly, so, searching through my bracket archive :wink: I found a cast type clamp, I know this is less strong, but the other three are very tough and I am confident this wont cause me an issue, I have installed this as close to the headstock as I can and still clear the coils. You can see the issue in this pic. There is not enough clearance to relocate the coils over to the right, and no alternative site for the coils without major headaches, Ill have to run with this.
    [​IMG]

    Just heading back up to the workshop for a few hours, about three today hopefully, and am pleased that the bike is beginning to look like a bike again, just hope Im not waiting too long for the body after I run out of prep work with the bike. I am in a spot where, because I wanted the hack wheel painted up to match the body, I cannot do anything to mount the frame as the height of the chassis cannot be set.
    [​IMG]

    Although I am using the little GN 'Mighty Bullet' as my son calls it, to run about in this snow, alopng with my AJS 250 unit, I need this done..........I have a camper van 'Small RV' to build before the spring too. Some pics.
    [​IMG]
    [​IMG]

    the Camper, its gonna be a pain, but will open the door to more regular getaways, the Outfit will be dragged on its trailer along with us and used for running around once the van and its awning etc are set up. At the mo, its a blank canvass. 2.4 5 cyl diesel, non turbo, S L O W !
    [​IMG]
    #32
  13. toastmuncher

    toastmuncher I be new round here! Ello

    Joined:
    Jan 3, 2009
    Oddometer:
    678
    Location:
    Chepstow, South Wales, UK
    Methinks I may need a new camera too. :rofl
    #33
  14. Guzzista_Joe

    Guzzista_Joe Adventurer

    Joined:
    May 28, 2007
    Oddometer:
    34
    #34
  15. toastmuncher

    toastmuncher I be new round here! Ello

    Joined:
    Jan 3, 2009
    Oddometer:
    678
    Location:
    Chepstow, South Wales, UK
    Thanks Joe, bug has gone now unfortunately, it wasnt getting used enough so has gone to fund the camper which will benefit us as a family rather than be another toy for 'Daddy', wish I had that paint code info a while back, just came back from the painters and....................................... ITS DONE. Pics to follow. :clap
    #35
  16. toastmuncher

    toastmuncher I be new round here! Ello

    Joined:
    Jan 3, 2009
    Oddometer:
    678
    Location:
    Chepstow, South Wales, UK
    Right, just uploaded, off shortly to collect my lad from school so Ill get these up quick.

    Minor screwup, once the grey was on, they discovered they did not have enough gold pinstripe to go between the pearl and dark grey, so they have laquered it and are going to apply the stripe over the top. Again, not ideal but just glad to have it done. I had the jerry can done as I plan to carry fuel on a holder on the back corner of the hack, the guzzi sticker on this AND the eagles on the hack ARE laquered over. PICS................................... All of them.

    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]

    Hes put the grey on the wheel center too, I dont want to hear 'fault finding' Im just so happy its done and I can now get on and get this done. Clive who did the work is a mate Ive known for 20 years, hes done this pretty cheap and I gave him free reign to decide where the white went on the body, and how much to put on, I guess I may have had a LITTLE less white, but we'll see when its all together how she looks.
    One happy Ginger Bugger.
    #36
  17. Sidecarjohn

    Sidecarjohn Been here awhile

    Joined:
    Aug 29, 2008
    Oddometer:
    754
    Location:
    Yorkshire, England
    Blimey, know it's been a while, but some paint job. The project is going well.
    #37
  18. toastmuncher

    toastmuncher I be new round here! Ello

    Joined:
    Jan 3, 2009
    Oddometer:
    678
    Location:
    Chepstow, South Wales, UK
    Thank you John. Im hoping itll be a great outfit once finished. Hopefully It will match up and look the part too. :D

    [​IMG]
    #38
  19. Bobmws

    Bobmws Curmudgeon At Large

    Joined:
    Jun 6, 2005
    Oddometer:
    1,410
    Location:
    Same trailer, different park, FL
    Can't wait to see that all together, the paint looks great!
    #39
  20. TouringDave

    TouringDave Tri Moto Veritas

    Joined:
    May 17, 2005
    Oddometer:
    7,112
    Location:
    Frankston, Vic, Aust.
    Wow! very nice paintjob, colour scheme is brilliant! :clap
    #40