Project Full Circle:Ninja 650 gets a makeover

Discussion in 'Some Assembly Required' started by sailah, Nov 9, 2012.

  1. 16VGTIDave

    16VGTIDave blame Reaver...

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    Could you shim the master cylinder so that it is in alignment? It doesn't look to be too far out...
  2. sailah

    sailah Lampin' it

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    It's not at a 90 degree angle concerning the rotation. The parts are all in line, or close enough but I may have to trim that spacer. I made it quickly and ballparked it. If you are looking at the braking setup from the side you can see the master is raked backwards. Without recutting the rearset and redrilling the holes I can't fix it. But again it's not that big a deal. I just noticed it when I cycled the lever.
  3. PineyMountainRacing

    PineyMountainRacing Oops....

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    You should have all the bugs worked out by the first weekend of October. Not as big as Ricks RDV, but same core group of inmates :D


    http://advrider.com/forums/showthread.php?t=878511
  4. sailah

    sailah Lampin' it

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    Hey stranger!!

    I'd love to but that looks to be the same general time as we have for a local riding crew to head to Rock Run for a dirt bike campout/steak eating fest.

    I'm so pumped for this thing to run, hopefully it will be sooner than I think but I know better:lol3
  5. PineyMountainRacing

    PineyMountainRacing Oops....

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    Yeabut Nottarally is a nottadirtbikesteakeatinganbeerdrinkingfest :D

    The nottaNinja would fit right in! It's looking very sick. You missed your calling, or maybe not...
  6. sailah

    sailah Lampin' it

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    exactly:D

    Got lots done today.

    Cut the left side rear set out on the waterjet and bent the bottom. I had to remove the kickstand tab with the plasma so I'll need to figure that problem out.

    [​IMG]

    Here's the side I'm tackling. Worked on the shifter arrangement and think I designed it well enough. Spent a couple hours with calipers and bearings to get a good pivot point and solid shifter action. I have metric rod ends coming from McMaster to finish it off.

    [​IMG]

    Should finish shifter and can weld in the rearsets for good. Then on to the plumbing for fuel and some odds and ends.

    Also redid the radiator guard again and it looks sweet.
  7. sailah

    sailah Lampin' it

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    Finished the subtank today. I made the fuel pump flange twice. I started making it on the mill using a boring head but it ended up not being the right size. So I recut the 3/8" plate and chucked it up in the 4 jaw and made it again on the lathe.

    I drilled the holes for the pump and tapped them blind, M6. The holes are not symmetrical so I used a transfer punch to prick the holes then drilled them by eye.

    This version got tossed.

    [​IMG]

    Made up the fuel bungs for the tank, the inlet is 1/4" NPT and the vent is 1/8" NPT. Made those up and then had a big welding party on the tank and finally sealed it up for good.

    My McMaster order didn't come in in time so I couldn't work on the shifter. Hopefully tomorrow.
  8. sailah

    sailah Lampin' it

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    I know I said I would update daily so my apologies. Been working feverishly to check things off my list. What I have noticed is that I put things on the list, big things. But then I get them done and replace the list with smaller things. So it's a good sign when the 15ish things on the list are relatively small and easy to do.

    One thing that has been on the list forever is to thread the swingarm bolt for an M16 nut. Now this might not sound like a big deal to a machinist but I hate threading. Mostly because I do it once a year maybe and have zero confidence. As such I have been putting this job off for months. I finally ordered the nut and used my lathe at home for the task as it has the correct gearing for metric threading.

    I turned a piece of aluminum down to 16mm and ran a test. Worked awesome and I got a perfect thread, zero slop. OK only downhill from here

    [​IMG]

    [​IMG]

    So I chucked up the swingarm bolt and went to it. This shaft is pretty hard so I was taking light cuts. If you've never done threading, especially metric like me, this is a very stressful lathe operation. Fortunately I have a brake on the lathe and can stop it instantly.

    [​IMG]

    Nailed it. Another perfect thread, now I can relax for the rest of the year. I swear I would rather fabricate anything, ANYTHING instead of threading.:lol3

    On other bike news let's see...

    Swapped out the low fender for a high mount, like it much better looks badass

    Pressed out the stem I made and machined a spacer to space the lower triple clamp away from the steering tube as it was a little close for comfort.

    While I had the stem off I also machined a groove for a snap ring by grinding down a tool to 6mm. Reassembled.

    Changed the rearsets around by moving the rear master cylinder to the back of the plate. Had to weld up some holes and retap for the new holes. Works better as the MC is protected.

    Welded the rearset plates to the frame. I also braced the ends back underneath the frame crosmember to triangulate it. It's massively rigid, zero flex.

    Welded a tab for the exhaust can clamp to attach to.

    Welded the subtank completely including all bungs. I am not going to end up using that AN fuel line, it's too bulky and won't take the right bend to get up to the tank and I don't want to be putting stress on the fittings esp the aluminum tank. I bought some Buna-N hose from McMaster and some NPT barbed fittings and will use those.

    I got the rod ends from McMaster to start the shifter linkage. I plan to try and use the shifter I originally had made for the CBR as I had an extra. If the mockup goes well I will make a new one on the waterjet. The plan is to run double bearings with a shoulder bolt to a rod end linkage to the original shifter (which is reversed like a sportbike). It'll make more sense when I post up pics tomorrow:lol3

    Here's the sorta final project list, most of these are fairly simple straightforward things. I BELIEVE I have gotten all the hard tasks out of the way, the stuff that causes you to walk away from a project and mothball it for a couple months. Hopefully I can get to the wiring his weekend, maybe fire it up next week...:freaky

    Finish shifter
    Weld tank bungs (Main tank)
    cover and refoam seat
    Hook up the trail tech to bikes wiring
    Seal the case crack with loctite
    Weld swingarm bosses
    Make rear fender
    Brake pedal adjuster
    Steering Stops
    Weld angle to subtank
  9. yokesman

    yokesman Been here awhile

    Joined:
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    Oddometer:
    556
    when I ran cnc,they used a spotter before the drill,like a countersink with the same angle as a drill(126degrees I think) so when you drop your drill in there it just sets up (centers the hole)nicely,they are cheap from Enco .
  10. sailah

    sailah Lampin' it

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    I've got center drills is that what you mean? I've seen spot drills but don't have any.

    Alright, mid day progress report. And coffee break:D

    Finished the shifter. Very happy with how it came out. I have 2 sealed bearings in the shifter, pressed in. The pivot axis is a 10mm shoulder bolt. The actual shifter was one of the 2 I had made last year for another bike. I polished it up with a scotchbrite pad on the grinder. The linkage to the stock shifter is 1/2" aluminum rod tapped for M6 rod ends. Which are bolted on to their respective perches. I drilled a bunch of holes on the stock shifter 12mm apart to see what the "action" was. Fortunately it was the last one I liked best so I kept it and cut the rest of the arm off. It's a nice crisp shift. And the shifter is very solid, barely any wiggle.


    [​IMG]

    [​IMG]

    Got the subtank bolted in. I had to angle it slightly to gain some clearance with the shock. Drill and tapped into the frame. I have some thin neoprene that will go between for cushioning.

    [​IMG]

    The new brake location. Not sure why it looks like crap, maybe the camera. Looks much better in person.

    [​IMG]

    Latest shot of the bike with the high fender

    [​IMG]
  11. sailah

    sailah Lampin' it

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    Finished a bunch of little things, and some big ones too today.

    Got the shifter done and tested.

    Started on the wiring. Going to have to relocate the FI computer so I bought a bunch of wire and will lengthen the connectors to place it elsewhere on the bike.

    I think all the other wires and components will fit nicely.

    The original fuel line from the throttle body won't work so I'm figuring out a solution for that. I posted up the problem the Garage section if anyone has any hot ideas.

    Finished the radiator guard and installed.

    Added about 20 new things to the list :bluduh
  12. PineyMountainRacing

    PineyMountainRacing Oops....

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    That seems about right LOL!

    Your shift lever is a work of art. The whole build adds new meaning to the word "custom". Custom, it don't come in a box
    😎
  13. MadM

    MadM Dreamer

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    Slovenia
    Looking very sexy, my kind of a bike in a future :D Keep the pictures comming :freaky
  14. sailah

    sailah Lampin' it

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    Thanks guys. The finish line keeps retreating on me, every time I think I'm finally going to set a date for the first ride I think of 20 things I need to do for it to be ready. Need to push through.

    I feel like Chevy Chase in National Lampoons Family vacation in the desert scene:lol3

    [​IMG]
  15. Roadracer_Al

    Roadracer_Al louder, louder, louder!

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    You're dating yourself. Nobody under 25 even knows who Chevy Chase is. :rofl

    Looking good! I'm having "project finishing envy"! I'm busy making luggage racks for our upcoming trip to Alaska. I keep having nightmares about cold lap and weld inclusions failing in the middle of the arctic tundra. :cry
  16. sailah

    sailah Lampin' it

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    I'm a spry 35, hard to believe I was 27 when I joined here...

    Working on the tank hold down. More sheet metal:puke1 but I need to get it done.

    BTW I remember when that movie came out and I saw the pool scene with Christie Brinkley. I think that's when I became a man:lol3
  17. sailah

    sailah Lampin' it

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    Built the tank bolt down in the rear as well as the seat latch. I cleaned up the welds a little, I was using the MIG to tack it and started goobering until I stopped and TIG'd it.

    [​IMG]

    Also welded in the tank bung in the main tank. I thought I had it lined up perfectly and welded it solid. Put in the NPT barb fitting and it was hitting the fitting from the subtank. So I had to grind it off the tank and start over. Fortunately the welding went great and I got a good looking weld. No pics though.

    I test fit the tubing from the main tank to subtank and it routes fine. The Buna-N tubing is a little too flexible and I had to get it just right or it would kink. I might get some real fuel hose instead.

    Got the new MSR clutch perch in. Also ordered a 130 link chain as I have no idea how many links are required for this and I'm too lazy to count with an old chain:lol3. Got new sprockets too.

    Ordered some POR 15 tank liner and plan to do both tanks. I know the steel tank has some pin holes and the aluminum one may as well. I figure it's good insurance, especially if I put gas in it and it leaks and I have to clean them out to line them.
  18. Keith

    Keith Slabbing it

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    Sahweet!

    What about tygon for fuel line?
  19. sailah

    sailah Lampin' it

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    I have tons of tygon, I just never thought it was real fuel line. When I got it from McMaster I thought I got the wrong stuff. I used it on the CBR but that bike just has a lift fuel pump. It has worked fine, and it is SUPER flexible. Almost too flexible as it can kink easily.

    I ended up buying the fittings from Dorman on the suggestion that they look exactly like automotive nylon fuel line fittings. I also bought the nylon tubing. I'll give it a go making one up and sheath it in tygon. If that doesn't work I'll call in the professionals...

    Reworked my list of things to do and also bought everything but seat foam to *hopefully* get this bike on the road. My guess is 2 weeks and I'll be pulling wheelies.
  20. Keith

    Keith Slabbing it

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    I used it on my DS7, when I used an aftermarket fuel petcock and it worked well, holding up to the fuel/oil mix in direct sunlight, but you're right it it a little prone to kinking with tight radii.

    Maybe fuel injection hose? It should have a braid inside and be less prone to kinking[/thinking out loud]