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Discussion in 'Crazy-Awesome almost Dakar racers (950/990cc)' started by sakurama, May 5, 2009.
Seems like it has been a while between updates! Sorry about that but its been busy here and tough juggling all the balls I have in the air. At least i'm not as bad as my buddy Scott: http://kolblsr.blogspot.com/2013/12/1634-days.html!
Anyway, I've been busy here on lots of stuff, 2WD included. Some of the other stuff is boring but pays the bills (light brackets for a train station, etc) and some is secret (super important consumer gizmos) But it all has to eventually get done.
Soooooooo, it has been a while but i have not been idle on this project. I've made lots of chips, for chain housings...
And housing covers.....
and custom gaskets
and ignition switch mounts.....
and steering stops.....
Oops, no pictures of machining that but they look nice finished!
And after a few of the debacles on some of the aluminum parts had a nice adventure finding a new anodizer. I'm glad to have found them as they are in NJ and did a great job.
The frame also came out nicely in a metallic orange. The metallic is hard to see indoors but really jumps out in sunlight.
At last now I have everything in house in final configurations for a test assembly then pack up and ship out. I'm sure Joe and Tony are reading this in disbelief that they will finally be able to get the bike together! I can only say that poor time planning for these R&D type projects is my big weakness. But it does get done nicely in the end!
The steering stop and ingition switch mount bracket look tidy and retain the steering lock too! Keep all those jealous 1WD owners off!
I think for orange frames you get black housing and for black frames an orange housing. Thoughts?
Will put up another post in a couple of days (no, really, I mean it!) with the full assembly before packing and shipping.
Sorry again for the gaps in coverage but life sometimes gets in the way of life!
Dammmmmnnn. That looks nice and that frame is so fucking pretty. Holy shit is right.
Tony, Joe, I can't wait to hear your impressions.
Sacred faeces by all means
Well it looks as flash as a rat with a gold tooth but until its in my workshop and I can see it in person I won't let myself get to excited.
And black cover with orange frame looks good chris.
This past year has been really busy with trying to balance work with the work on the house and then family as well. If that wasn't enough I picked up an old Guzzi last year and finally rolled it into the garage to get it roadworthy enough to use it for the summer. And of course there's a build thread on that too.
Suffice it to say I haven't had the time during my short visits east to get all the way out to NJ to bust Chris' ass and try to get the bike finished. This last trip I made a special effort to get two days where I could get to the shop. When I spoke to Chris he said, "It's all done - it just needs to be put back together. Two three hours at most." You can see that Chris possess the same out of touch sense of optimism with bike projects as I do with house remodels.
Not in touch with reality.
So armed with my buddy Tommy I went out on Friday to put some time in. Tommy, look serious here!
Chris has indeed finished most of the machining and fabrication. He's made a very nice ignition mount for the triple clamp...
...and he's made up his own longer tubes for the drive shafts where they meet the triple clamps.
When I was there last Chris had notched a frame tube and asked me to make the cap for it. He never got around to welding it and so I tackled it tacking it in and starting the stitches.
After a while I ran out of skill for the crazy out of position welding that was needed for the underside of the tube. I claim that it was partly due to Chris' turn of the century welding helmet and non-pulsing welder but Chris proved it was simply lack of talent.
He welded it upside-down, laying on his back on a chair with his foot on the pedal. Yeah, I still have a long way to go.
In the end we made progress but there was a lot of test fitting, assembling, disassembling and reassembling which is to be expected but also takes time.
Also, since my bike was the test mule a lot of my parts needed to be adjusted or modified whereas the parts for Tony's bike were the final revision. Seeing Tony's frame and the parts makes me realize how nice his bike is going to be. All the parts and all the welds are perfect. My bike, and I cringe at the thought of it, really needs to be taken down to the frame and then repowdercoated and given a brand new wiring harness. It's showing it's age and the harness is starting to crack and fail from all the rerouting. I may just leave it for another year as the thought of taking the bike apart again is so repulsive that I can't stomach it.
The added complexity of the AWD is pretty apparent when you are putting together the triple clamps and drive shafts.
The chain run parts are very nice. There's a real level of sophistication to Chris' parts, a fantastic attention to detail.
I am still aiming at riding the bike out to Portland in the next month or so. I need to finalize a date but I have a few possible jobs that may happen that would take precedence. Motorcycle shoots always take precedence. Chris swears he's going to get the bike wrapped up in the next week or two. I will be sending my dirt wheels off to Woody this week as well as getting a second Christini front hub to lace up so that is happening at the same time.
My fingers are crossed that this comes together and I ride it west in June.
I feel more incompetent every time I look at this thread.
Correct me if I'm wrong but you have a rideable 990 if I'm not mistaken...
I thought of washing mine, too. But, after seeing where that led you, I thought better of it.
Chris might be an amazing machinist and fabricator but he's not a great one at keeping people up to date on progress. We talked about it and while he knows it he can't say why that is. Probably why we're friends - he makes amazing stuff for me and then I tell people about it.
Which brings us to what I found in my inbox this morning. Something people have been asking for for a while and it seems is now on my bike.
It seems Chris has paired up his lovely stacks with a plate system that works with the Rottweiler filter. Supposedly Peter's dyno broke so they're awaiting parts before they can test it but my guess would be it is maybe the same or better than the K&N's. This is obviously a prototype but it looks pretty close to final.
If anyone in the NYC metro area is planning on going to Rev'It!'s big party this Thursday Chris is going to bring the bike and we'll be looping our two wheeled burnout video on one of the TV's. Rev'It! throws a good party so either call them up or email them to get on the list. If there's a list - I'm not sure. I'll be there though so be sure to say hi.
Where / when?
It's this Thursday night. I understand it's a VIP industry party but I asked if I could bring some friends and that's fine. So, Tim, I'll PM you the email to RSVP to and if anyone else is interested either email me or PM me and I'll do the same.
That's almost funny, because I've just finished this...
The fit is not perfect, and the welding is not at all beautiful, but it does hide nicely under the SM tank and connect to Chris' velocity stacks.
Nowhere near as good a job as Chris. However, what I think we really need are the stacks to be modified to include a mounting for the plate. Should be easy enough if Chris can find the time.
It's interesting that you've managed to maintain the original throttle cables. For me the plate was bang in the way of the front cable mount. Maybe my plate is further forward to account for the smaller SM tank clearance at the rear? My solution was to rebuild the front mount to make the cable approach less vertical and make a linkage to join the throttle spindles of the front and rear carbs. Works a treat and with a much lighter throttle action too, now that there's only one set of cables!
Pictures to follow when I next take off the tank to install the new filter. Sorry, but the weather is way too good now to be spent in the workshop!! The squashed K&N filters will have to do for now...
Whats the status of the choke for the FCR?
I've tried to stress to Chris that most people are waiting for him to finalize the chokes before they pony up for a whole kit. He's not as convinced there's enough interest. In the end I'm bringing my bike back to OR in the next few weeks and so it will end up becoming my task as I'll have the only bike with the choke circuits. I know that they are doing something as they will kill the engine if put on while the bike is warmed. This tells me that it's an issue with float levels, jets or something and will simply take time to fiddle with. Time is pretty limited for me with the house and kids.
Which leads to me to a possible idea. Perhaps someone here has the time and interest to take either my carbs (I'll swap to the 41's) or have Chris do a second set (:ddog oser ) and do the ground work. I don't think you'd need to have dyno access but it might not hurt. Mine are pretty nicely set up for my 990. You would need patience and diligence. In return we'd give a good discount on a full setup.
I'll have to clear this with Chris but I can certainly box my carbs up and send them away.
I'll take you up on this... but it will need to wait until the end of the summer to be practical. It's just too hot here until at least September to need much of any choke. It's part of the reason I've made almost no progress with my external solution... Definitely not ideal.
You don't seem to have people queuing up to help. I don't know why.
I'm local to you and (as I said in PM) happy to help once I get my bike sorted. Hopefully that's before end of summer.
I'm one of those waiting...
Shipping costs to/from UK makes doing it in 2 bites financially impractical.
I can't remember why the Rottweiler filter project was started or who asked for it. Chris thinks that's how the whole FCR stacks thing got started but I thought it was someone who wanted it for an SE. Regardless, my bike was in the shop and so it became the defacto guinea pig for the plate mockup. Which means instead of putting my bike together I spent the weekend reworking the carbs.
It required a lot of reworking too.
To start the position had to be roughed into place which Chris had done with some marks.
And from there I attempted to drill through the whole thing to get it to bolt up on the marks. This is a rough mock up from a 3D printer and Chris made some alternate wedges as well.
From there we had to use a new throttle cable mount (to address your issue Tinwelp) because the plate and the current mount interfere.
At this point I was getting frustrated with the number of times I had to mount, unmount, remount ad nauseum for every single fitment and adjustment. To Chris credit I was getting tired of this after one day - he's been doing this for over a year and I can't imagine how sick of my bike he must be at this point.
And that is what happens when you get sloppy from being frustrated. Disgusted with myself I pulled the part and...
...became more disgusted with myself. Insult to injury...
In my head I could hear my father telling the teenage me, "If you're going to do something, do it right. If you're going to start a job, finish it!" and aside from the irony that these were my fathers greatest failings it is something that has stuck with me and a lesson I continue to learn to this day; there's never time to do it right but there's always time to do it over.
So I took a deep breath, sat down on the couch and chewed some gum.
Then I used that gum on the tip of a welding rod to fish out the screw that dropped into the intake.
Then I did it right.
I drilled through the TPS bracket and then sharpened set screws into points. Clamped the part in perfect alignment and screwed in the set screw to make a small mark.
I used the smallest center screw we had to be sure to keep things in perfect alignment and then center drilled, drilled, countersunk and debarred.
Unlike the original brackets these change the orientation of the throttle cables 90° and as such the bolts had to be changed to flat head screws. It seems like nothing but this took hours and hours because of all the refitting, test fitting etc.
Finally I got it perfect and then fitted and set the TPS.
Now I had to fit the throttle cables and after trying about 5 or 6 different routing configurations determined that the cables for the front carbs were about 4" too long for the new bracket. So then I had to shorten the throttle cables.
Which means I had to turn new ends from some brass stock, drill them out and then measure the slack for each cable and then shorten the housing by 4" for the front carbs.
A trick I discovered in trying to keep the cable end in place was to use some tape and then to fray the back side. Worked well.
Finally I was able to get the carbs mounted with the cables in a clean run with no bends. The action was actually the slickest it's been and very light. At this point I could see that the rear accelerator pump wasn't working so I had to take the carb apart to check that it wasn't blocked, clean the passages, remount and retry. It occurred to me that the 39's hadn't had the floats set and perhaps I'd only done that on the 41's.
So after many fittings and removals later I got the floats set to where the accelerator pumps were both working, the slides snapped shut easily, the cables were tight and the carbs synced. I was actually surprised when the bike started right up. It has become an almost inanimate object to me and to hear it burst into snarling life was surprising and exciting.
But that was the extent of the progress I could make. Chris needs to finish putting the AWD parts back together and then we can button it up. Oregon was nice enough to give me a temporary transit plate since my NY registration expired about three years ago. Good god. It should be back together on Wednesday for a final test and I'll be riding it back to PDX at the end of the month. Fingers crossed.