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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    I'm booked until the 11th in NYC which means two back to back 900 mile days - as the shakedown? I really don't know what to say...It bodes well that your Rotacular suffered no mechanicals last weekend. Perhaps this will work out okay.

    Okay, I'm punting the wheels to Woody. There's no way I'll find the time.

    Nice fixture, nice work. Work faster. :deal

    Gregor
  2. CosentinoEngineering

    CosentinoEngineering Been here awhile

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    Let's see what happens. I would have the bike tested before you leave. Or maybe I ride out on it a few days early and fly back. I'm an optimist these days.
  3. DRjoe

    DRjoe Long timer

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    Squeak squeak
  4. CosentinoEngineering

    CosentinoEngineering Been here awhile

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    Just got done with a bunch of millwork machining the transfer case mount that will be welded to the frame. there are a front and rear spar and a lower mounting plate that uses the original 4 Christini mounting bolts.
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    It's all 1/4" steel plate with milled pockets and looks pretty good.
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    The machining went smoothly, it was done with the vice mounted on the trunnion because that was the setup in the mill from making billet TZ cases.
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    The flat plate bolts to a shelf on the back of the drilling/welding fixture to ensure alignment with the pilot hole we just bored.
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    The front and rear spar sandwich the plate and were machined to fit snugly between the frame rails. Surprisingly, there was about a 2.5mm difference in the width of the top rails between Gregor's and Tony's frames.
    [​IMG]
    I have not removed the paint and done final fitting on Tony's frame yet. I want to get Gregor's all welded up and verified before hacking away at his. I do have all the parts made so the 2nd frame will go a lot faster than the first.

    Because of this big difference the transfer case mount parts had to be machined to be specific to each frame for the best fit. Not what I was hoping for in terms of repeatability but you can only work with the frames we have. If I do more conversions each mount will have to be fitted to each frame, so much for running a bunch of parts!

    Tomorrow I'll turn the bevel gear mount parts and weld the cartridge mount into the frame. At that point I will be able to test assemble the entire front end from the transfer case forward. Then its just making a chain housing and mount and then testing!!!!

    Its nice to see some good progress. Thanks for everybody's patience, especially Tony, Joe and Gregor. The wait will be worth it.
  5. DRjoe

    DRjoe Long timer

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    Nice work Chris.

    Its looking very special.
  6. DRjoe

    DRjoe Long timer

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    Forgot to mention it might be worth bolting in a spacer where the top shock mount goes.
    The frame can flex a heap when that top shock bolt is removed, also might be worth bolting in spacers at the engine mounts to mimic the engine width.
    Might solve your gearbox mount differences.
  7. rw4x4van

    rw4x4van East Coast Rider

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    This thread should be made into movie :beer :lurk
  8. sakurama

    sakurama on an endless build

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    Wow, Chris. Just wow.

    I'm now removed from this enough that it no longer seems like its my bike and I find myself thinking, "Boy, that's going to be a cool bike when it's done. Whoever owns it sure is lucky... Oh, wait, that's me!" It's going on three years off the road but I dare say this will make that wait worth every day.

    Hey Flanny, care to race your 150hp Duck? On gravel? It's not about how much power you have - its about how much makes it to the ground. Ha!

    Gregor
  9. Flanny

    Flanny Flanny-it-up!

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    Sure...Let's Race!

    How about tomorrow? Or maybe this weekend. Or how about next weekend? :deal :evil

    Remember...It's not about how much horsepower your bike will theoretically be able to have make it to the ground when it is eventually finished after two years of being on the workbench...it's about how much horsepower you can put onto the ground TODAY!!!

    I'll think about your bike in a million pieces on the bench when I ride my favourite twisties home from work on the Duc today...:1drink :D
  10. boxertwin

    boxertwin Long timer

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    That's just cold Flanny. Cold indeed.
  11. Flanny

    Flanny Flanny-it-up!

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    (And quite EVIL!)
  12. CosentinoEngineering

    CosentinoEngineering Been here awhile

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    >>I'll think about your bike in a million pieces on the bench when I ride my favourite twisties home from work on the Duc today.

    Enjoy it while you can because I plan on getting this done ASAP, more so Gregor can smack you down than for anything else! Joe, Tony: just kidding. Flanny: not kidding.

    >>Forgot to mention it might be worth bolting in a spacer where the top shock mount goes.

    The openings on your frame are not sprung more than about .01" but its a good idea to have it all bolted down solidly before drilling and welding. Good call.
  13. sakurama

    sakurama on an endless build

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    My bike will be done before your garage is painted red my friend.

    Honestly, ever since I test rode a Christini back in 2007 or so I thought it was a brilliant idea. I never thought I'd do it on a big bike but it makes the most sense for a bike that knows no traction off road. I like the Multistrada - it's a great bike for retired Adventurers...

    Have your fun now while you can.:deal

    Gregor
  14. 950smr

    950smr Adventurer

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    maybe i missed it, but did the chokes on the fcr's get finalized?
  15. Pete640

    Pete640 I hate sand.......

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    Not just yet - but when they are...:freaky
  16. sakurama

    sakurama on an endless build

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    Yes, they haven't and that's on Chris' plate as well - right Chris? If my bike is going to Colorado and then onto Portland that needs to be figured out ASAP so that whole project can be wrapped up for all the people waiting for cold start friendly FCR's.

    PM Chris if this is important to you - he likes to hear the squeak of interest. :evil

    Gregor
  17. Flanny

    Flanny Flanny-it-up!

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    Ouch! :gerg :muutt
  18. CosentinoEngineering

    CosentinoEngineering Been here awhile

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    I got some more parts made and now am ready to do welding on the transfer case mount and bevel drive in put mount.

    2 lathe parts had to be made: the welded in spigot and the screw in bearing cartridge.

    The welded spigot was turned to fit the hole that the hole saw made.
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    The 1 15/16" hole saw made a hole that was very round at a 1.943 diameter. After turning to size the spigot part was a light tap fit into the drilled hole.
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    The visible seam is the break between the front welded in spigot and the rear alignment spacer that located on the drilling/welding fixture.

    The fit and alignment are excellent. This should allow distortion-free welding which will keep the gear mesh properly aligned.
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    The gear cartridge part needs a hex to be milled on the end for wrenching. This part holds the 3 bearings for the bevel drive gear and a seal to keep dust and dirt out of the bearings. I am using sealed bearings but it never hurts to have a little extra sealing, especially for dirt and sand applications.
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    There is also an o-ring that seals this part into the welded spigot. Yes, I want to keep dirt out! We can use thin bearing shims at the clamping surface to shim the position of the bevel gears for proper meshing. And, yes, I like fine pitch threads.

    I'm going to weld these parts in this week and make another post in between TZ case machining and before a trip to Bonneville for the BUB Speed Trials. I'd recommend a trip to the flats to be on the bucket list for any speed freak. The feeling is hard to explain and out-of-this-world is an understatement. Its sunny, flat and dry with lots of loud engine sounds! And its one motorcycle event that is nearly guaranteed not to rain on.

    I'll be gone almost a week helping Scott Kolb get his BRB-engined partial streamlined 125cc LSR bike to 170+mph. I helped redesign his front and rear suspension systems to use some appropriately sized springs and dampers. We also got a full Atholon GPS Pro Cart GPS/data acquisition system from Fred Renz at Yoyodyne. The system will log GPS speed, engine RPM, EGT and water temp and also has a detonation counter. With this info we'll know more about what the bike is doing along the entire 5 mile run. From this data we should quickly be able to optimize both jetting and gearing to give the best speed through the measured mile.

    I'll be back after that intending to finish this thing ASAP and get it tested.

    That's all for now.
  19. sakurama

    sakurama on an endless build

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    Good luck in Bonneville. Say hi to the girls for me and hurry back and finish this bike. :freaky

    Gregor
  20. Pete640

    Pete640 I hate sand.......

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    So. Did you get some salt for the shaker?