Operation: Battle Panda or: Getting the Airhead Ready for 2up Adventure

Discussion in 'New Zealand' started by igormortis, Jan 16, 2012.

  1. igormortis

    igormortis Long timer

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    OK, here’s some pics then.

    <a href="http://www.flickr.com/photos/58374333@N07/6866511753/" title="P1010920 by c00300875c487ce28b95948225d005e0, on Flickr"><img src="http://farm8.staticflickr.com/7197/6866511753_ba2e50efdc_b.jpg" width="1024" height="683" alt="P1010920"></a>

    <a href="http://www.flickr.com/photos/58374333@N07/6866512671/" title="P1010925 by c00300875c487ce28b95948225d005e0, on Flickr"><img src="http://farm8.staticflickr.com/7193/6866512671_99c1572fd4_b.jpg" width="1024" height="683" alt="P1010925"></a>

    Looks like I have just enough room with the KTM fork spacing, BMW x-spoke wheels, and a big caliper. Still figuring out the 320mm disc though.

    OH, and I said goodbye to this last week:

    <a href="http://www.flickr.com/photos/58374333@N07/6832620976/" title="P1030142 by c00300875c487ce28b95948225d005e0, on Flickr"><img src="http://farm8.staticflickr.com/7207/6832620976_82aaa72c34_b.jpg" width="1024" height="683" alt="P1030142"></a>
    #41
  2. msmckeon

    msmckeon Just ahead of the sweeps

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    Website is very old school (I liked it when I was still on dial up - up to last year!) but the product and the service is great.

    Michael
    #42
  3. advNZer?

    advNZer? Long timer

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    goodbye? or getting it rebuilt/valved/sprung??
    #43
  4. Padmei

    Padmei enamoured

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    A lick of paint & it'll be good as new.

    what are you gonna do with your wheels?
    I'm asking around experts about the advantages/ disadvantages of powder coating vs spraying them black. Black does look quite horny.

    Those brakes look good but the disc is a bit warped.
    What tyre is that on the front & do you find it ok?
    #44
  5. Box'a'bits

    Box'a'bits In need of repair

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    Might have gone a bit far cutting the springs...:huh

    That Brembo looks the goods. 4 piston?

    I found replacing it worked well for me (sold it off to some poor misguided soul)...

    So what are you going to do with your spokes?
    #45
  6. igormortis

    igormortis Long timer

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    Yes, only goodbye for now, because all of the above. I’m awaiting some magic from a certain Mr. Taylor.
    One way or another they will be black. Whether it’s powdercoat or anodised will depend on the condition of the alloy, I think. Ideally I’d prefer a hard anodise.
    That’s a Heidenau K60, which I rather like. Tubeless and the softer (I’m told) “Scout” compound, as opposed to the standard compound which I have on the rear. Strangely the rear has worn much more than the front, but I’m putting that down to being severely under-sprung on the rear. That’s after 3000km. Mostly tarmac, with some gravel and hard packed sand thrown in occasionally. I hear they’re quite similar to the Mitas E07, which I’ve yet to try.
    Yeah, but at least now I know that a disc will squeeze in there. I realised shortly after my initial measurements I hadn’t taken the upside-down-ness of the forks into account! D’oh!
    Yup. I’m still holding my breath a bit till it all comes together finally, but I think I’m getting there.
    #46
  7. igormortis

    igormortis Long timer

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    Trundled the mocked-up front end off to a friendly machinist to get the right bits shaved, sleeved, spaced and shimmed. Oooh-er.

    Came away with ideas about double plugs and stopped off for something French and oily on the way home.

    Pulling a starter motor out of a '90s French car reminded me very quickly of how much I dislike working on them. Merdé, merdé, merdé! Got there in the end, but man, it was a struggle.

    The raison d&#8217;être is that the smoke escaped from my &#8220;Valeo copy&#8221;. I think I&#8217;m just inside the warranty, but I&#8217;m not gonna trust another one of these I&#8217;m afraid. A dead one&#8217;s worth more to me for the following experiment. Valeo D6RA - found in Peugeot 306, 405, and several other PSA group cars...

    <a href="http://www.flickr.com/photos/58374333@N07/6981698905/" title="IMG_0001 by c00300875c487ce28b95948225d005e0, on Flickr"><img src="http://farm8.staticflickr.com/7209/6981698905_0029da06b7_b.jpg" width="1024" height="768" alt="IMG_0001"></a>

    French Valeo, left. Chinese &#8220;Valeo&#8221;, right.

    <a href="http://www.flickr.com/photos/58374333@N07/6981699311/" title="IMG_0002 by c00300875c487ce28b95948225d005e0, on Flickr"><img src="http://farm8.staticflickr.com/7054/6981699311_2dae9b7bfe_b.jpg" width="1024" height="768" alt="IMG_0002"></a>

    No comment on the branding.

    <a href="http://www.flickr.com/photos/58374333@N07/6981699653/" title="IMG_0003 by c00300875c487ce28b95948225d005e0, on Flickr"><img src="http://farm8.staticflickr.com/7060/6981699653_30ed8fe84f_b.jpg" width="1024" height="768" alt="IMG_0003"></a>

    Guillotine! Three allen bolts, a torx screw, and a couple of soft rivets to drill out.

    <a href="http://www.flickr.com/photos/58374333@N07/6981700203/" title="IMG_0005 by c00300875c487ce28b95948225d005e0, on Flickr"><img src="http://farm8.staticflickr.com/7187/6981700203_5b18890afe_b.jpg" width="1024" height="768" alt="IMG_0005"></a>

    Face, off! And on again.

    <a href="http://www.flickr.com/photos/58374333@N07/6981700469/" title="IMG_0006 by c00300875c487ce28b95948225d005e0, on Flickr"><img src="http://farm8.staticflickr.com/7180/6981700469_bce1654d5d_b.jpg" width="1024" height="768" alt="IMG_0006"></a>

    Since the car starter has the same number of teeth as the &#8216;Panda, I&#8217;m gonna see if it works as is. I&#8217;ll find out in the morning!


    And as an epilogue to todays French sojourn: ironically, or perhaps fittingly, the Peugeot 306 seems to have FUBAR&#8217;d its clutch release bearing. Sweet bliss. Maybe I&#8217;ll junk it and steal the starter motor...
    #47
  8. Padmei

    Padmei enamoured

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    Ok sorry IM but which is the one from the BMW (cue facepalm)?
    how much was the 2nd hand starter? maybe I'll find one & keep it handy...
    #48
  9. igormortis

    igormortis Long timer

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    The one that was in the bike is on the right in the pictures. Not original equipment, but a copy of the later Valeo starter.

    The starter was $50 from Pick a Part. I have one you can buy, it comes with a Peugeot 306 with a noisy clutch.

    If it wasn’t clear before, note that you’ll need the airhead specific alloy “nose” to swap on to the car starter - so this isn’t as practical if you currently have a Bosch starter.
    #49
  10. igormortis

    igormortis Long timer

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    Starter transplant was a success. And now further news...

    <a href="http://www.flickr.com/photos/58374333@N07/6999277337/" title="P1030295 by c00300875c487ce28b95948225d005e0, on Flickr"><img src="http://farm8.staticflickr.com/7204/6999277337_957d4f1313_b.jpg" width="1024" height="683" alt="P1030295"></a>

    Shock arrived back yesterday. Old spring, and hydraulic preload adjuster removed, and replaced...

    <a href="http://www.flickr.com/photos/58374333@N07/6999277589/" title="P1030296 by c00300875c487ce28b95948225d005e0, on Flickr"><img src="http://farm8.staticflickr.com/7247/6999277589_d88f52c108_b.jpg" width="1024" height="683" alt="P1030296"></a>

    ...with a much heavier spring matched to our travelling weight (pillion + luggage) and lock-rings for pre-load. The idea is that the hydraulic adjuster can fail over repeated abuse over rough ground. Pre-load probably shouldn&#8217;t change once we&#8217;re underway anyway, I suppose. It&#8217;s still adjustable via the lock-rings if required. More robust is good. All wear parts were replaced also, so I&#8217;m counting on it being a new shock practically.

    Not all is well however...

    <a href="http://www.flickr.com/photos/58374333@N07/6853153846/" title="P1030303 by c00300875c487ce28b95948225d005e0, on Flickr"><img src="http://farm8.staticflickr.com/7069/6853153846_e01b3b820e_b.jpg" width="1024" height="683" alt="P1030303"></a>

    <a href="http://www.flickr.com/photos/58374333@N07/6853154076/" title="P1030304 by c00300875c487ce28b95948225d005e0, on Flickr"><img src="http://farm7.staticflickr.com/6216/6853154076_74a53dd7a5_b.jpg" width="1024" height="683" alt="P1030304"></a>

    <a href="http://www.flickr.com/photos/58374333@N07/6999278439/" title="P1030306 by c00300875c487ce28b95948225d005e0, on Flickr"><img src="http://farm8.staticflickr.com/7058/6999278439_90b8d00eaa_b.jpg" width="1024" height="683" alt="P1030306"></a>

    The larger wire diameter required for the new spring rate, means that there is no longer clearance for the subframe.

    The idea is to strengthen the subframe anyway, but I now need to devise a way to clear the spring, as well as beef up the bracing in the same area.
    #50
  11. Box'a'bits

    Box'a'bits In need of repair

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    The spring length on Gus is circa 220mm. The spring wire diameter looks similar. The hydraulic adjuster sits level with the subframe.

    Is there potential to put more preload in to get clearance? Wouldn't need to be a great deal to get clearance. Remember this will move in an arc, not compress (that's the other end).

    Have you discussed with Mr Taylor yet?

    What happened with your pannier racks in the end anyway? See you have at least one side fitted.
    #51
  12. advNZer?

    advNZer? Long timer

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    a washer under the pannier rack would prolly move it out of the way
    #52
  13. igormortis

    igormortis Long timer

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    Haven&#8217;t tried with more pre-load yet. I&#8217;ll give that a go to see how much it would need. Obviously we still need to set the correct amount for or weight, presuming it didn&#8217;t already ship out with that dialled in.

    I've only had a brief exchange with RT so far - he reckons that a dent in the tubing is the fix. I&#8217;ll have to check what the movement through the arc is at that point of the spring, to see how big the clearance needs to be. May not be much after all.

    Regarding the pannier frames, yep they&#8217;re installed. I ended up with a new left side rack from Touratech. I still have the old one which may actually come in handy soon.
    #53
  14. igormortis

    igormortis Long timer

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    Paul, that’s the subframe in those pics. I tried to move that stay further out to see what it would take to space it away from the spring - quite a bit. More than I’m happy with at the moment, so I’ll try for another solution first.
    #54
  15. Padmei

    Padmei enamoured

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    Thats a bummer. I'm sure you'll come up with a suitable solution tho.

    When I went shopping for shocks I got the Wilbers with remote reservoir to help cool the oil as I'd read about the shocks failing due to heat from riding over repetitive undulations. The down side is the distance from the shock body affects damping apparently. I'm going for longetivity. I don't think you'll miss the hydraulic preload at all.
    #55
  16. Box'a'bits

    Box'a'bits In need of repair

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    Swings & round abouts. Nice to be able to quickly adjust preload if your load changes, ie differences between fully loaded & just rider & pillion. The C spanners are hard to use if you don't have easy access, ie the panniers are in the way.
    #56
  17. advNZer?

    advNZer? Long timer

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    my bad...i had to push the sub frame out of the way to install the ohlins,had the sub frame and pannier racks unbolted
    #57
  18. igormortis

    igormortis Long timer

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    Anyone have any ideas about how to put a “clearance dent” in the tube? I was gonna heat it up and smack it with a hammer.
    #58
  19. Box'a'bits

    Box'a'bits In need of repair

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    Might want to talk to an engineer first. You don't want to weaken the subframe, with consequences later in your trip. You could perhaps make a form to cradle one side & give some control to the 'dent'? Maybe use a hydraulic press instead?
    #59
  20. igormortis

    igormortis Long timer

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    :rofl

    Those were my thoughts too. Then I wondered if I was being over-cautious. Glad I posted before impatience got the better of me.
    #60