Overgrown Offroad Zombie

Discussion in 'Some Assembly Required' started by larryboy, Sep 18, 2011.

  1. Garthe

    Garthe ROCKS ARE YOUR FRIENDS...

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    You havn't seen my welding skills :rofl...

    My fix was selling the bike and buying another XRR :bubba.
  2. Nixels

    Nixels Face fears - live life

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    Issat the wrong way round? :dunno

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    Seems like there's a confusing mix of marques. :huh

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    What would Captain America do with all that space? :choppa :lol3

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    Remember boys and girls: The Venturi Effect causes twisting forces :eek1

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    :poser

    Hey larryboy! It was good hangin' with you today. :nod

    Quick recovery from the mosh pit! :super

    :gerg

    :razor
  3. larryboy

    larryboy Chopper Rider

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    Yeah Nix, was good just chillin' out and drinking some Benjava coffee!! :freaky

    Spent all day ripping an engine wiring harness out of an E450 with the 6.0 Powerstoke...we'll see if I'm motivated enough to work on the bike in the morning...

    I'd better get after it or I'm going to run out of time. :eek1
  4. Nixels

    Nixels Face fears - live life

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    :nod

    :*sip*

    Don't worry, I'll come over and help you with those welds. :kboom

    :poser
  5. larryboy

    larryboy Chopper Rider

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    Major progress today.

    The right flanges have arrived!!! Thanks to Chad at Sudco!! :clap

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    Now I can move on the airbox, I think I'm going to weld it into the frame with a lid under the tank.

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    Gonna have to cut down the idle mix screw on the right side. Very glad I got the remote choke option!!

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  6. larryboy

    larryboy Chopper Rider

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    Fairly productive day...

    Got my last tubes made and welded in, really happy with the strength and safety at this point.

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    Those little tabs are for the remote chokes. I've only had a torch for about six months and keep forgetting I have the thing...got to use it to shape the rear of the tube to match the curve of the subframe.

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    SFKLR came over and helped me swap the springs out of the forks. Glad he did as it took three of his hands and three of mine...these aren't simple KLR forks. Went with 15 weight fork oil as that was the heaviest I could find nearby.
  7. sailah

    sailah Lampin' it

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    Nice I was looking at the first pics thinking he needs a diagonal from the bottom of the Honda frame back to the transmission (??) point. Where the original tube lands mid tube isn't doing much, glad you figured and welded it in the 30 seconds it took me to scroll, man you're fast.:lol3

    Are those regular dirt wheels on the front? Only reason I ask is that I had Woodys build me a 950 front for my FZ. Heavy spokes, Excel rim etc.

    On my new project I'm wondering if I can get away with a standard dirt wheel. I have YZ450 wheels but man do the spokes look puny. Every wheel builder says I'm nuts to even think about using a 450 wheel. So I'm leaning towards spending the money again and getting a built wheel. I have to imagine your build is going to come in heavier than mine at #350. Is it not in the budget or are you simply going to run it and see if it breaks/upgrade later type deal?

    Just an FYI timing issue, I also had a hard deadline for the Eastern Rendezvous and thought I was well in hand. Nope. Pulled 48 hours straight no sleep and left still having not slept for the 8 hour ride. The little things you'll need to redo 14 times before you need to leave eat an enormous amount of time, energy and patience.

    I would also HIGHLY suggest you don't finish the frame before you go. Esp being in the dry climate like you are, it is nice to be able to reweld something or add a bracket/tab whatever without having to remove paint or powder.

    Does the front end of those biikes really weigh that much? By going my route on the new bike I'm taking it from #390 to I figure about 350 from losing weight in the wheels, plastic, tank, swingarm and going to an aluminum subframe and minimal creature comforts, no gauges etc. Just wondering where you got your figures is all.

    Looks good, nice coping joints on your tubes, I know those aren't easy to nail.:deal
  8. larryboy

    larryboy Chopper Rider

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    Yeah, it just had to have those extra tubes to tie it all together.

    Yup, XR650R front wheel...you know, the Baja 1000 winning wheel. :deal

    I'm seriously not going to be railing this bike like it's something it isn't. My stalled Bandit project got Warp 9 hoops and huge spokes from Buchannan, I plan to jump that bike and beat the hell out of it. It's kind of funny that the XRR spokes are within .2mm of the original GS spokes.


    Yes, serious time crunch here. Nice to see another fabber stop in and understand what the hell I'm talking about. I worship those chopper shows where they build a bike in 10 days with a 2 or 3 man team, it's much harder than it looks.

    I got my weight numbers by weighing myself with each part that I took off the GS, forgot to weigh the battery...I think the stocker is 14 pounds and the one I'm putting back in weighs 2 pounds 5 ounces...so I'm up to 160 pounds off of the bike or so. I will weigh the stuff going back on the bike to get a final number before fuel.

    I've been using the chop saw tube notching method, wish I had a lathe and one of those bits you see on TV.

    Like this: http://pirate4x4.com/forum/showpost.php?p=5256686&postcount=1


    I have to put paint on it, California has four seasons...San Diego doesn't, but that's Mexico. We've already had a couple of frog stranglers.
  9. larryboy

    larryboy Chopper Rider

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    Good progress so far today...


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    Gonna try to put in another 5 or 6 hours...
  10. sailah

    sailah Lampin' it

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    :rofl

    I hear ya!!

    Try and finish a week early, seriously. That way parts you'll need can get there in time for the departure.

    About the painting I was simply suggesting putting down some miles on the setup first then paint it once you're sure it's solid and nothing needs to change. I'm so glad I decided not to paint my bike yet (actually going to powdercoat the bike) and have ridden it all summer. There's a few things I'm going to move and redo. Course if you've done all the thinking ahead of time no reason not to strip it down and paint it.

    Good work on those rear tubes, that looks a lot better.

    When's the trip?
  11. larryboy

    larryboy Chopper Rider

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    Wasted some time on the crash bars, gonna put that off to the end if there is time, same thing with the custom muffler...I can slam the cat back on really quick for the exhuast if I run out of time.

    I don't think I'll have any do-over work, but I might forget a tab here and there, so I'm going with paint for easy touch up. The chance of rain and snow is very high for this trip and I hate cleaning up a rusty mess.

    I want to be riding it by Halloween...it is a Zombie afterall. :wink:

    Shake down trip by myself is set for Nov 9-13, this isn't an absolute must, but it is my goal. Main trip where I don't want to kill us both starts November 19th.
  12. larryboy

    larryboy Chopper Rider

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    Goofed around with the crash bars, much custom work will be needed to make them fit the new mods...gonna put it off until the end of the project.

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    Back to work on the battery tray and hold down.

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  13. Nixels

    Nixels Face fears - live life

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    Looks like that tube bender's earning its keep! :thumb

    Don'tcha think that battery color's a little off? :scratch

    :zilla

    :poser
  14. larryboy

    larryboy Chopper Rider

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    I haven't used the bender at all, used the bag racks that were left from my old Buell.

    I'll have to paint the battery, good point. :lol3
  15. Nixels

    Nixels Face fears - live life

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    :thumb

    :yikes I'd like to see the process of transformation. :lurk

    Knowing you, it took no time at all, and you didn't do a before/after sequence. :ddog

    :lol3
  16. larryboy

    larryboy Chopper Rider

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    I was planning to do a custom airbox from the start, but with the extra tubes on top my air filter doesn't fit. I think that by accident the stock airbox might still fit...it's time to rip the frame off the engine for final welding/paint and I can see if the airbox will squeeze in there.

    Kind of cool that I can still mock up the seats and tank to the frame when it's off the engine. Going to have to change where I was going to put the coil with the airbox back in the mix.

    Put an email into Motion Pro for the throttle and cables, I don't have time to build my own system from parts and I don't think it's a good idea to only use the stock pull cables, Mikuni advises to go push/pull all the way to the carb to prevent a high vacuum slide opening ie; hung throttle.
  17. mike54

    mike54 You don't get me

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    You're not really calculating airbox volume and tuning at this point are you?
  18. larryboy

    larryboy Chopper Rider

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    No room for those, Mike. They don't really like water anyways.

    I don't really "calculate".

    :freaky


    Sorry we missed you Saturday.
  19. mike54

    mike54 You don't get me

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    I'm seeing them on top of a snorkle. :D Actually I was thinking of putting them where the air box would go and running tubing to the carbs. They'd take less room than the airbox if you have trouble fitting it. Just a thought.

    Sounds like we probably passed each other saturday. I'm anxious to see this beastie. Looks cool in the photos. I'll have to wait 'til halloween weekend I guess.
  20. Garthe

    Garthe ROCKS ARE YOUR FRIENDS...

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    [​IMG]


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    Give me the short statement on why carbs...over EFI?