My 950 Refresh or Mission Creep...

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

  1. mookymoo

    mookymoo Mookish Mook

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    Either UK or Australia ...
    Do you have access to a big cool-room? :evil
  2. ramon

    ramon weezin' the juice!

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    Awesome project!!
  3. CosentinoEngineering

    CosentinoEngineering Been here awhile

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    >>Being wrong from the other side of the country isn't nearly as much fun as being wrong right there where I get the eye roll and the sardonic

    Isn't that what facetime is for? :rofl
  4. sakurama

    sakurama on an endless build

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    Chris is waiting on some parts but I got out there this past weekend to pay a visit, see the progress and take some photos. I recently decided to step up my personal photography - Sony has finally introduced a point and shoot (the RX1) that is on par with my professional gear and so from this point forward you will see a marked improvement in photography for this thread: both in the quality of the equipment and my intent. I hope you enjoy watching.

    So, let's take a look at the progress thus far.

    [​IMG]

    This is the countershaft drive. Chris will have to custom make this part but the important part is the location of the second sprocket just inches away. Locating the second one here will allow a long second chain run to the 90° gearbox.

    [​IMG]

    Here you can see the second chain run up to the head stock - this chain will run in an enclosed case and utilize a tensioning device similar to a cam chain. The bulk of Chris work is to perfectly place the gearbox square to the headstock. He will ream the headstock to accept the Christini bevel stem. The brilliance of this solution is that the frame only needs very small modifications and no external changes to the bodywork, tanks or running gear. It will require the modification or removal of the stock airbox but that is a small price to pay.

    [​IMG]

    [​IMG]

    Here are two views of the location of the bevel gear box. Christini has been extremely helpful with us and has given us a lot of proprietary information to allow us to build the very best adaptation to the 950/990.

    [​IMG]

    I liked seeing Chris' copious notes here scribbled on paper. There's a tremendous amount of math and measurements, both of distance and forces that Chris is making to adapt the parts to the 950/990.

    [​IMG]

    [​IMG]

    I hope you enjoy the photos. I think there's nothing more beautiful than an elegant solution and Chris is well on his way to completing this in the most elegant way possible. Stay tuned.

    Gregor
  5. DesertSurfer

    DesertSurfer Tail sprayin

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    The photos and play by play are additionally fantastic. This project quite simply amazes me! Great courage involved beyond the engineering sophistication. Elegant indeed and at the highest level. Hat's off to you all! I'm glued to this.
  6. SS in Vzla.

    SS in Vzla. Totally Normal? I'm not!

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    :clap:clap:clap
  7. Pete640

    Pete640 Long timer

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  8. sakurama

    sakurama on an endless build

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    Yeah, Chris has been really busy. I need to pester him for an update.

    Gregor
  9. Flanny

    Flanny Flanny-it-up!

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    Thankfully,you're an awesome Pestererer!
  10. Pete640

    Pete640 Long timer

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    Hows the house renos?
  11. The Doc

    The Doc Been here awhile

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    Hey guys this has been the best thread Ive ever read on ADV. awesome work!

    I've got a couple of questions.

    I presume the underdrive gearing is allowed to "happen" inside the front hub due to sprag clutches, if this is the case what happens when you want to roll the bike backwards?

    What is the gizmo on the output shaft of the 90* gearbox? It looks like a little clutch, whats its purpose and how does it work?


    Sand riding and muddy hills are going to be awesome
  12. CosentinoEngineering

    CosentinoEngineering Been here awhile

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    I better make a post.

    Unfortunately I've been a bit busy on another project the past couple of weeks. It is another bike project, more TZ cases. I was turning these:

    [​IMG]

    into these:

    [​IMG]

    and about 6 garbage cans full of these:

    [​IMG]

    I'm 1/2 done and should finish the lowers in the next week or two then I get to put some exclusive time back on the 2WD project. By that point all the parts on order should be here and can get in deep and won't stop until I can do an initial test assembly. It will all start to happen quickly from there.

    A little more patience and we'll bring this baby to fruition!
  13. CosentinoEngineering

    CosentinoEngineering Been here awhile

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    >>Hey guys this has been the best thread Ive ever read on ADV. awesome
    work!

    Thanks!

    >>I presume the underdrive gearing is allowed to "happen" inside the front hub due to sprag clutches

    Yes, you're right on it. the front wheel has dual sprag clutches in the hub and normally the wheel just overruns the FWD assembly until the rear wheel slips a set percentage. We'll initially be able to test out a range of underdrive ratios from 40-80% to get the best performance.

    >>if this is the case what happens when you want to roll the bike backwards?

    There is a FWD disable feature in the drivetrain that is activated by a handlebar mounted lever similar to a decompression lever. This lever must be engaged to roll the bike backwards due to the front wheel trying to now overdrive the rear wheel.

    >>What is the gizmo on the output shaft of the 90* gearbox? It looks like a little clutch, whats its purpose and how does it work?

    It is a torque limiting clutch to act as a safety 'valve' in case something goes wrong somewhere in the drivetrain. It is mostly to protect the drive components that could be overloaded, like the telescoping splined drive shafts. Its set for a fixed torque and is simply just a small version of a motorcycle clutch with a nut and belleville spring providing the fixed torque value.

    >>Sand riding and muddy hills are going to be awesome

    2 wheel roost, baby!!!!!:D
  14. sakurama

    sakurama on an endless build

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    I've gone from here:

    [​IMG]

    to here:

    [​IMG]

    As you might imagine from my obsessive build here I take details seriously and it seems with every turn I find more crap that's done poorly and needs to be fixed. At this point there's very little sheetrock left inside and I've torn out 90% of the wiring and 100% of the plumbing and I live in fear of running out of money in this halfway state.

    The good news is I'm having fun and it's going well but I'm exhausted at the end of every day. I now ask friends to intervene when I think about adding to the project. I want to be in by the end of June - I also wanted to be riding this bike about a year or so ago... :cry

    Gregor
  15. Ghostrider.

    Ghostrider. Adventurer

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    Excuse my language!
    But this is the craziest fukin build iv ever seen been done on a ktm!
    You sir have titanium nutts! :wink:
  16. sakurama

    sakurama on an endless build

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    Is that you Neil?

    Thanks. I look at the photos and right now I see how I took a rideable motorcycle and made it unridable and a livable house and made it unlivable. I'm hoping for validation and completion on both fronts soon.

    Gregor
  17. neduro

    neduro Addict Super Moderator

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    You might talk to a therapist about that... :lol3
  18. Ghostrider.

    Ghostrider. Adventurer

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    hehe no but i have a friend named Neil :D
    I understand what you say mate, I am same type of guy as you. I am never satisfied with things how they are, Perfection is only satisfaction!
    Im tearing apart my 2010 smc atm to make it "better" hopefully .
    But remember this , doing what you do is what gives you moral to live your life!
    Its what you enjoy doing, at least when it comes to bikes , not sure about houses heh.

    Just read entire thread! And its 2:30 here and i have work tomorrow fuk! But it was worth it
    Keep posting your a true inspiration :freaky
  19. DesertSurfer

    DesertSurfer Tail sprayin

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    Inspiration and vision go through various fazes before finally reaching ultimate success.

    What is most unfortunate are those who have nothing ventured and nothing gained.

    For you, it's simply the ability to work beyond your patience level.

    The talent is there.
  20. Katoom119

    Katoom119 Mmmm....Orange Kool-aid

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    Therapists are overrated. It's easier to find inner peace on a bike in the woods in the middle of nowhere.


    Good thing he's got that wee BMW. Unless he decided to pull it apart and figure out how to strap a JATO to it or something.
































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