My 950 Refresh or Mission Creep...

Discussion in 'Crazy-Awesome almost Dakar racers (950/990cc)' started by sakurama, May 5, 2009.

  1. sakurama

    sakurama on an endless build

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    So I'm back in Portland and I signed up for a welding class at the local community college. Since I'm not doing a "course" so to speak I'm not tied to a course structure which is really great. Basically I'm doing Tig practice once a week for 8 hours. This should help.

    My instructor helps me get set up on a mammoth Lincoln and I do a few fuse welds which are simple and solid so then I start with adding filler rod and keeping track of my amps.

    [​IMG]

    And I keep welding coupons...

    [​IMG]

    Until finally, for one glorious inch and a half, I get it right. Not sure exactly what I did but I learned a few things. I think I'll ask over in the welding thread. Anyway, here's my success:

    [​IMG]

    Of course it's way harder to do that on tube. I think I'll be ordering my own tube out here and my project for this class will be a collector. That should keep me busy.

    In other good news I'm very happy that I ordered my carbs through KTM Twins as Ron is helping hustle my carbs through the red tape that is SUDCO and there's an off chance I'll get them by next week when I'm back. There's other stuff to do if that doesn't happen. I could start sanding the bodywork...

    Anyway, trying to keep progress moving forward.

    Gregor
  2. Pyndon

    Pyndon Long timer

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    I like it....Bingo!

    I too have considered a Tig Welding class, just about to buy my own kit so I can do my own bits and pieces.

    The thing that's worrying me is welding the thin stuff, when you can weld a coke can you've cracked it apparently!

    :deal
  3. sakurama

    sakurama on an endless build

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    Actually if you're using the new square wave inverters the Coke can isn't quite as hard as it used to be. I have a Dynasty 200DX which is about all you'd ever need for a motorcycle. 200 amps is way more power than anything on a bike requires and most of the time you're around 70-100 amps so you can even run it on 110v (it switches automatically) and that was a big part of the appeal.

    Here's a video of the holy grail:

    <iframe width="640" height="480" src="http://www.youtube.com/embed/2X6RgJoXfZQ?rel=0" frameborder="0" allowfullscreen></iframe>

    I say do it Pyn - it's one of the most amazing skills ever to be able to just join two pieces of metal. Since my class is open I'm going to switch up about halfway to work on my aluminum skills and I'll see if I can do the Coke can. After the exhaust is a monocoque aluminum subframe/gas tank. That is way over my skill level so it sounds just about perfect.
  4. jonnykilo

    jonnykilo Traveller

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    Great words and pictures of your processes Gregor - you are a true artist. Hope the bike comes together in time for June :)
  5. adiablolex

    adiablolex Lost again

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    that's good news on the course, I've been messing around with a cheap chinese TIG/Plasma combo and I must say it's more difficult than it looks.
    The funny part is that I can weld any thickness of steel at any position with stick or MIG but when it comes to TIG the only thing I've accomplished so far is joining with no filler.
    Staying tuned for more pointers :D
  6. sakurama

    sakurama on an endless build

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    No real progress to report. I am in NYC again and got some time to head to the shop and since I don't feel ready to start welding the exhaust I just put in some hood time to practice the things I've been learning.

    [​IMG]

    That is my new torch head. It's a pyrex cup around a gas diffusion lens that is supposed to help with better gas coverage. The gas is argon, which is used for tig welding, and stainless is more susceptible to contamination so the lens helps to cover the weld area better. If the arc is exposed to air the weld becomes brittle and contaminated. When I start welding the exhaust for real I'll also have to fill the tubes with argon so the back is protected. I'm also using a thinner tungsten (the center electrode) so the actual arc is smaller and more focused. I whipped up the torch stand last night as I was getting sick of holding it in my lap and I don't want to break that pyrex cup.

    [​IMG]

    Anyway, the top weld is my last one. I feel that if I wanted to I could do a passable job of welding the exhaust now but I'd like to practice more. At this point I have a lot of time and cash into it and my perfectionist nature would like me to be patient. My riding nature would like me to hurry the hell up. We battle frequently.

    I have some time today and tomorrow depending on how my retouching goes and I'd like to get something done on the bike so we'll see what I come up with.

    Gregor
  7. Katoom119

    Katoom119 Mmmm....Orange Kool-aid

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    Those two on the bottom look better than the ones on some parts I've ordered before. I'd say you're ready to go.
  8. adiablolex

    adiablolex Lost again

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    good looking welds man, well done
    I say on with the exhaust too
    :D
  9. sakurama

    sakurama on an endless build

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    So I actually got another day at the shop before I had to leave for Italy and since I couldn't move forward on the exhaust without more bends to make the "X" pipe I thought to myself, "How can I did myself a deeper hole? How can I really paint myself into a corner on this build more than I have? Is there anyway that I can make sure I won't have a motorcycle to ride when it's nice and warm?"

    And then it hit me! I'll strip the paint off the bodywork with no real plan of what I'd do next! Genius!

    [​IMG]

    Yes, that's me grinding on a gas tank. I asked my friend Kenny to take this since I wasn't sure if I'd live through it. Sure, I'd flushed the tanks with soapy water a few times but you never know. Anyway, the reason for the grinding was those stupid embedded nuts for the tank guards - one was spinning. I ground off the head and then dug the bitch out.

    [​IMG]

    Not sure what genius thought a plastic tank would hold that forever. Not sure how I'll fix that yet either.

    I found a Valentine radar detector buried in foam in one of the side panels - wondered where that went.

    [​IMG]



    Teachable Moment!


    And since I had to remove the front blinkers I figured I'd try to add something useful (for a change). I'll teach you how to take these things apart. Yes, I bite my nails and have horrible cuticles. You would too if this were your bike. Here's the little connector:

    [​IMG]

    This is what you want to do - remove these leads without breaking them. This is the "top" of the clamp.

    [​IMG]

    Here it is with one lead removed. See that little tang on the bottom? Bottom means the opposite from the two rolled edges that form the little clamping blades. That tang holds this bugger in the plastic.

    [​IMG]

    You remove it by inserting a very small, thin piece of metal (a saw blade isn't recommended but it's what I had on hand) in-between the "bottom" of the clamp/lead and the plastic and disengaging that tiny tang while pulling (gently) the wire on the back side.

    [​IMG]

    This gets the guy undone so it can be threaded through the holes of the body panel or wherever it goes and then put back together. It's one of those things no one teaches you and it's hard to figure out on your own. Hopefully that will be useful to you someday.

    And back to our regularly scheduled destruction...

    I'll admit it. I think Flanny has done some great stuff to his bike. You have to when you ride so slow. One of the things he did that I liked was to cut open the side panel. Since that is where my "X" collector will reside I figure I'll open mine up as well so there's more pressure on me to make it look good.

    [​IMG]

    Then I start the process of no return:

    [​IMG]

    And this sucks. No, it seriously sucks. I can't tell if the stickers are cleared over or just incredibly thin or both. Finally, after trying numerous solvents and curse words I came upon this method of removing the stickers: heat gun aimed just ahead of a sharp scraper.

    [​IMG]

    By "sharp" I mean this:

    [​IMG]

    Grind a flexible paint/putty/drywall scraper at 90° lightly on a grinding wheel to make a sharp burr on both sides. That burr, not a knife edge, will do a good job of pulling up those (fucking) stickers.

    And that brings me to here:

    [​IMG]

    So, now it's basically spring and I have a bike with no carbs, no exhaust and no bodywork. I'm a freaking genius!

    Back in Portland this week I did some more welding - getting closer!

    [​IMG]

    So I'm back to NYC this coming week and I've ordered more tube to build the crossover. I aim to get the bodywork primed and the crossover built and the back of the exhaust fabbed and tacked.

    Gregor
  10. Deadly99

    Deadly99 Fast and Far

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  11. sakurama

    sakurama on an endless build

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    Your bike, by the way, has turned out great Deadly. Between you and Flanny there is a high bar set for rebuilding these bikes. I think if we just didn't ride them so much or so hard we'd save a lot of time/money!
  12. Katoom119

    Katoom119 Mmmm....Orange Kool-aid

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    "Dad! I just bought a 2031 KTM Adventure. Want to go for a ride?"

    "Sure, I'd love to! Let me see if I can find a bike to borrow. Mine is still in pieces since I decided to machine my swingarm out if depleted uranium."













    :hide
  13. Flanny

    Flanny Flanny-it-up!

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    Ha!

    Isabelle asked me today if I'd like to have the kids looked after by grandma so that she could go out on her Ducati Monster, and I could ride one of my 3 KTMs. My response? Sorry, none of my KTMs run right now.

    950 down to the frame to fix base gaskets, 450 undergoing Rally build, and no electrical. 300 has no suspension on it right now....

    It's just as well.. Riding the bikes just gets in the way of precious shop time....
  14. sakurama

    sakurama on an endless build

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    That is funny and sad. I used to ride so much - used to ride about 25,000 miles every summer. Then I progressed to racing and it was merely thousands but hundreds on the track. Then I started building bikes and it just became hundreds. That's the joke around our shop - we're sooooo into motorcycles we don't have the time for riding. :eek1

    Well, I aim to finish this thing in June one way or the other and then ride it back to Portland. I'm not about to miss a good Portland summer without my favorite bike. My methods are just to light a fire under my ass to do this project right and not halfway.
  15. neduro

    neduro Addict Super Moderator

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    I might have you beat. I've got 9 bikes in the garage right now. Three are operational- the Superduke, the Montesa, and the Dakar bike, which is more or less perfect.

    But, the 950 is still going back together from my G$/Flanny/D99 inspired rebuild, several 450s are lacking me having the time to finish various maintenance projects, and my new 500 doesn't run for some computer inspired reason.

    Sooo into bikes. :lol3
  16. Flanny

    Flanny Flanny-it-up!

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    Maybe - but not on a percentage basis. I'm 100% out of commission! :norton
  17. sakurama

    sakurama on an endless build

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    So Flanny, who is it that makes your base gaskets? I'd like to buy some stock in that company. It seems like when you go for a ride it's, "Fill 'er up with base gaskets and check the gas!". You should do what I do - just replace the engine - gaskets are just trouble I tell you. :wink:
  18. Deadly99

    Deadly99 Fast and Far

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    Min runs and it's dirty :1drink
  19. Pyndon

    Pyndon Long timer

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    I love these threads, so I'll chip in too. I can't wait to see this thing finished, it's over a year ago when I sent that engine over for the project, hope it runs because the warranty period has expired now :rofl

    I only have 7 bikes right now but I think I might have the largest range. At the lower end there's the CBR125RR, cost me a grand, top speed 85mph (with some mild tuning) but returns 104mpg (when driven respectfully). Yes, I look a complete tw*t on it!

    Then at the other end there is the 450RR which in itself is equivalent to four bikes just because of the shear cost of the thing :lol3 .....worth every penny!

    The best thing is, they all work, they are all serviced up and they are all 'ready to ride or race' anytime. I mean two of them are still dirty from their last rides but that's a minor thing!
  20. VertigoCycles

    VertigoCycles Been here awhile

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    Nothing to add, but if you're looking to get this done by June, I assume there will be more frequent updating :evil I like where this is going.