My 950 Refresh or Mission Creep...

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

  1. wiseblood

    wiseblood Hall Monitor

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    Is it possible that there is a thread on another Internet forum for home owners, titled, "My New Home Refresh or Mission Creep" ? :D
  2. sakurama

    sakurama on an endless build

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    Yeah, that's funny. Kinda. I think it's my wife's fear so I'm really busting my ass to get it livable sooner - by the end of June. Unlike the bike where it's about time the house is more about money - if there was an unlimited amount it would be done but like the old saying goes: "Fast, cheap or good - pick two."

    Gregor

    PS I am doing a thread on Garage Journal about the garage build but not much is happening there as most of the effort is going toward the house. The garage is the test bed for warming up my skill sets - rusty on drywall? Do the garage first.
  3. Keith

    Keith Slabbing it

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    What about using a sanding sponge in the valleys of your cedar ceiling to get to the whitewash?

    The foam might conform to the varying angles and still get the job done?
  4. rw4x4van

    rw4x4van East Coast Rider

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    Man knows his "wood" tools too.. :lol3
  5. sakurama

    sakurama on an endless build

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    That's what she said!

    I'm not nearly as skilled on that front but I'm a voracious reader and learner. I owe a huge debt to my friend Ben for guiding me on the house project. He's given me a lot of advice, direction and help but also let's me figure it out on my own. It's much the same as the way Chris taught me machining. I'm really enjoying the work, it's immensely satisfying. He's a recent member of Orange Crush so ill be able to return the favor this winter.

    I can see the end but its taking longer than expected. Has anyone ever done a remodel or bike build and finished sooner? No. Don't think so.

    Gregor
  6. rw4x4van

    rw4x4van East Coast Rider

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    Well somebody schooled you well in tool selection, Grasshopper....:lol3

    We rode together in the first Pine Barren 500,.. you led a group and I was a sweeper... I'm friends with Jolly
  7. sakurama

    sakurama on an endless build

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    Was that the year of the epic rain? I remember one time it rained so hard we followed Clipper through some back woods trails to his house, ordered pizza and watched old races until it stopped. Yeah, we're hard core. :rofl

    I usually take a very casual approach to dual sport rides and so am often being chased by the sweep. If its not a race I do my best to be last and have the most fun. Just spoke to James last week too. Small world.

    As for tools - buying good stuff only hurts once. Buying cheap stuff pains me the whole time.

    Gregor
  8. TA-Zappa

    TA-Zappa Been here awhile

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    That's exactly what we said when we where doing the summer house, it took 14 years for the top floor to be finished.... But it looks good. :D We got faster after that and the kitchen took just 4 years, well almost 4 years we still have the doors to paint.

    But considering your skills with the bike your house will be stunning when it's done. IF not this one maybe the next one.. :evil

    Cheers,
    Zappa
  9. rw4x4van

    rw4x4van East Coast Rider

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    ....epic rain? ....I was thinkin' monsoon, but that's the one :lol3

    Good luck with the house [I'm a builder] :evil
  10. sakurama

    sakurama on an endless build

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    Chris has been busy - both with other work and doing CAD work on this project. I visited the shop Tuesday to check out what was going on and to kill some time I thought I'd break down my front wheel to prepare for the new hub. That didn't work out exactly.

    First things first. I was faced with removing my tire and I had the only tire machine in the shop which is now in Portland. All that we had was two Motion Pro tire irons. Necessity is the mother of discover here and I learned how to break a bead with these so I thought I'd share it here:

    [​IMG]
    Stack the irons just like this - one on top of the other.

    [​IMG]
    Press down. I was sort of amazed at how easy it was. I searched all over to see if that was the way they were designed and I couldn't find any info or instructions but I've owned these irons for years and never knew you could do this. In fact I've used the side stand method even though I've had a pair of these right next to me. So now you know - Motion Pro 16" curved irons make perfect bead breakers.

    [​IMG]

    This is a shot to use to remember the triple cross lacing. I'm going to attempt to build this wheel myself. I'll most likely get close and then frustrated and then send it to Woody but it's high time I learn to lace a wheel.

    Next up was to break it down. Typically you just use a bolt cutter and cut the spokes but I'm hoping to reuse the spokes since it seems the new hub is the same size. I cursed Chris' cheap Craftsman 7mm wrench which was loose on the spoke. 1/4" was too small as was 6mm. It was only after putting a caliper on the nipple and looking online that I discovered there was such a thing as a 6.8mm spoke wrench. WTF? Really? 6.8mm?

    [​IMG]

    So I managed to get out two spokes before throwing in the towel and ordering the right wrench. The GOOP held very well and came off cleanly meaning it will be easy to clean the wheel and seal it again.

    Last up is a shot of the end plates that Chris has machined for the enclosed chain run inside the frame rails. I hope he sees this post and follows up with a few of his CAD drawings because he's done some very impressive engineering to make this slick, clean and efficient.

    [​IMG]

    The long run will be fully enclosed with tensioners and run in an oil bath while the short chain shouldn't need tensioners due to the short length but he's still working on that. There's some really beautiful stuff that is going to grace this bike - it makes me wish the tank was clear as it's a shame to hide it all.

    Gregor
  11. wiseblood

    wiseblood Hall Monitor

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    I assume you'll have to periodically change that oil?
  12. sakurama

    sakurama on an endless build

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    Yes, I'll have to but it should be a token amount just in the bottom. I wanted a window to the level but Chris suggested just a drain and a fill at the correct level so it's like a normal transmission - fill it until it overflows and your good. He's right but I like windows - as evidenced by my garage thread...

    I digress.

    I went out yesterday to work on the bike but we ended up spending the afternoon working on a kickstarter project we're doing together instead. I was frustrated but glad at least one of my many projects is going forward. Once we get our prototypes together for that and we're ready to launch it I'll mention what it is but for now it's enough to say it's not bike related.

    I digress again.

    I suspect sometimes that it must be difficult to have a conversation with me because my mind wanders so much. Hard to believe right? Okay, back to the topic at hand. My ridiculously sprawling 990 project. Sigh.

    So when we last left off I discovered that the spokes were actually 6.8mm and I didn't have a wrench. I ordered a nice Motion Pro one and it showed up on Friday...

    [​IMG]

    ...only to end up being too small at 6.71mm. Thanks Motion Pro! Luckily I was at Chris' shop and the Bridgeport was just around the corner so I snugged that sucker down in the vise and skimmed it to 6.8mm. Which was still too small. Slowly I'm learning and I didn't remove the wrench until I'd actually tried to fit a spoke nipple in there. It needed to be 6.83mm to be snug and fit.

    [​IMG]

    6.84 might have been better but I went through the plating to the copper so I suspect it will wear in a bit and it's better to be too tight than too loose.

    Back to the wheel.

    [​IMG]

    [​IMG]

    I decided that I'd best tape the rim to prevent (let's be honest - reduce) any scratches as I took it apart. The spokes were under tension from the crosses as well and when I got the last nipple the wheel was still together and I sensed that my bravado in believing that I could rebuild this wheel might be quite short lived. Woody? Are you watching this?

    [​IMG]

    Once I got to this stage it occurred to me I should have just sold this wheel and bought a new rim and have Woody build it up. Umm, yeah, a bit late for that now. Well, that was all the time I had yesterday. This week I'm headed off to Mass to pass judgement on some photography students. Chris has promised an update to the thread but don't hold your breath - I've been bugging him all week to no avail.

    Gregor
  13. Woundflatout

    Woundflatout Been here awhile

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    Gregor,

    This is by far the most insane thread ever. I would have to say it surpasses my complete inability to keep a bike for more than 6 months type insanity. Keep it up!

    Jason
  14. sakurama

    sakurama on an endless build

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    Ha! Thanks man.

    It's basically your 6 month m.o. but I've kept the bike and continued to put time, money and energy into it. And money, did I mention that? I think I'm approaching what could have been my third 990 with this latest silliness. If I didn't love this bike so much it wouldn't have stayed in the garage so long.

    You'll get to ride her this summer I hope.

    Gregor
  15. Woundflatout

    Woundflatout Been here awhile

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    My 6 month M.O. Sickness is getting worse. I am searching for a 990 that I can afford.

    I've only had the XR for 3 months.
  16. Michel77

    Michel77 Backyard Badass

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    Hey Gregor,

    I just finished reading through this - crazy stuff, the good kind! We "met" on the Duc-forum when I was building my Hyper-Strada. Now that my house reno is about done and I too sold most everything on two wheels, I am slowly looking for another bike/build and I'm leaning towards the 950 Adventure as well :evil

    Love what you're doing, admittedly I would have been riding it a bit more before tearing it down again, but your on a pioneering and engineering quest here and I can't wait to see the outcome!

    Best of luck (with the bike and reno), hit me up for a beer if you're ever up near Seattle!
  17. sakurama

    sakurama on an endless build

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    Michel! Hey man how are you?

    I replaced my Hyper with an MV Brutale and then replaced that with a BMW R1200S and I just put that up for sale to fund the house reno. I'm hoping that I'll be able to skim enough off the sale to pick up an older 4th or 5th gen VFR which is one of the bikes on my bucket list and would be the 4th bike I've owned during this bikes construction. :eek1 The VFR can serve as cheap interim transportation.

    I was hoping this 990 would be done but it's taking longer than I'd hoped. Of course the name of the thread is mission creep but honestly I'd love to stop creeping for a while and ride. Can't exactly put the brakes on now though...:cry

    Gregor
  18. Flanny

    Flanny Flanny-it-up!

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    Phew...for a second there I thought you were going to put the rim in the mill and machine each spoke nipple down.. :deal :evil :1drink













    :hide









    :evil
  19. Apple Jam

    Apple Jam Forest Flyer

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    Sorry about giving you that 990 idea again at the Black Dog, Jason.....
    I have had my 990 a month shy of 6 years now: still awesome.
    I really have had no big hankerin' for anything else,
    ...and my long-term house renovation is still sucking up all extra funds except priorities like tires, gas, and oil.
    Monogamy is just fine with the just the right bike :evil
    It's an Adventure honeymoon that might last forever :norton
  20. CosentinoEngineering

    CosentinoEngineering Been here awhile

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    OK everybody, I'm back. Sorry about the huge gap in posts but I am having a bit of a business boom and had to bring a guy in to help. Yes, what a thing to complain about but I forgot how much time is involved in bringing someone up to speed on several projects on a temperamental lathe. Next month it will be a benefit to me but last month was not. This month was a wash. Anyway, he's now on track and now so am I. Oh, I can also blame Gregor for sidetracking me on another project. And have I mentioned how much effort it is to make decent posts? Dammit Jim, I'm an engineer, not a writer.


    The CAD

    I did a bunch of design and fab work on the project in some time gaps over the past few weeks. The mounting of the transfer case and enclosed chain run are now largely worked out. Here's a couple of images of where we're at.

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

    The CAD is more more than 90% complete. After some discussions with chain manufacturers I've decided to switch from a small oil bath to grease for the lubrication of the long chain run. An easy to remove section of the cover will allow easy grease refreshing. Since Christini uses grease lubrication in the 3 sealed chain runs in their system I think this should work fine. Discussions with them also helped make my decision to fix the short chain run sprocket center distances and live with the small amount of stretch that will happen over the chain's life. Due to the short chain the stretch will be negligible and the complication of an adjustable center is more than offset by the ease of chain replacement. Goes to show how KISS applies almost everywhere.

    Now that the CAD is well along I needed to get over my mental block of cutting Gregor's frame. Since I did not take the smart step of getting a test frame like CJ did I need to shoot straight on my first round. With that in mind I make the first cuts and so far, so good....

    A proud father (on haircut day) with his piloted reamer apparatus. There are guide inserts pressed into the headstock bearing seats to guide the reamer and mandrel shaft along the entire length of the cut for best results. the only reamer available in 47mm diameter was a shell style (with a tapered bore!) which necessitated the making of a mandrel shaft and the accessory parts.
    [​IMG]

    For some reason the cordless drill just didn't have enough oomph for this. Peter briefly stopped applying cutting oil to take this picture.
    [​IMG]

    So far so good, surface finish is nice and diameter is within tolerance.
    [​IMG]

    I need to go about 3 inches down from each bearing seat to create the space needed for my bearing setup.


    Now that I've broken the frame's cherry progress should be a lot faster. Especially if Gregor keeps calling me to see if I had any serious family emergencies causing me not to post.

    Extra thanks to Joe and Tony for their understanding of a malleable schedule.