Project Full Circle:Ninja 650 gets a makeover

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

  1. sailah

    sailah Lampin' it

    Joined:
    Aug 12, 2005
    Oddometer:
    5,823
    Location:
    Turning expensive metal into scrap
    Guess I have the ratio calculated incorrectly, see below. I'll report back with the new number

    Thanks. Just so I'm clear you meant 117/335mm=35% right?

    Will do. As I have found there's a big difference in designing in theory and actually getting out there and putting a bunch of miles on to really decide what works. Because the suspension is so critical to everything else, it's not like footpegs that can get relocated easily. I really want to get this right the first time. As always, I'll give the +/- when I ride it.

    Spent an obscene amount of time drawing, measuring and drawing and remeasuring to get the frame mounts and crossbars mapped into my CAD program so that I can draw the suspension mounts to have them waterjet cut.
  2. sailah

    sailah Lampin' it

    Joined:
    Aug 12, 2005
    Oddometer:
    5,823
    Location:
    Turning expensive metal into scrap
    Nice and productive today. Designed out the frame tubes so I could design the shock mount in CAD. Printed out a couple tests then I made one on a manila folder. I think I will have my waterjet guy cut these out and tack them in place to give it a full cycle. The circles on the body are for 7/8" tubes that I will weld across both plates to get the correct 24mm distance that the shock needs.

    [​IMG]

    [​IMG]

    It was hard to hold everything in place to get the pic. Hope it makes sense. The arm will be similar to what I made on the CBR but will also pick up the lower tube to prevent any rotational stress on the top tube. I think welded together it will be very strong and help tie the original frame together

    [​IMG]

    Then I decided to tackle the subframe. As you may have noticed, the Ninja subframe is not symmetrical due to their shock being on the extreme right side. I decided to make it sorta symmetrical by replacing the top tube with one I made, and also making a diagonal from the main frame back up to the subframe. Should be much stronger than the original. I need to put in some gussets and also there is a cross bar I haven't done yet.

    I was pleased with how the bends came out. I rolled the back half on a tubing roller, then went to the tubing bender to make the recess for the shock reservoir. I did not see a clean way to butt the tube into the frame so I decided to make a scarf joint instead and get a long weld bead on it. that joint is in tension anyways and I might brace it later.

    Here's what it looked like before I cut it

    [​IMG]

    And after

    [​IMG]

    [​IMG]

    Need to complete this tube across. The wall thickness of the tubing they used is retarded thick. They could have made the whole thing so much stiffer and lighter by using thinner wall and larger diameter. Oh well.

    [​IMG]
  3. Salsa

    Salsa Been here awhile

    Joined:
    Dec 12, 2006
    Oddometer:
    435
    Location:
    Arizona, Alaska, Kalifornia
    "Thanks. Just so I'm clear you meant 117/335mm=35% right?"

    I think Jar944 meant the measurements were at the shock. "typically KTMs run about 37/115mm"

    37 mm sag of shock travel out of 115 shock travel. But I am guessing.

    Don
  4. sailah

    sailah Lampin' it

    Joined:
    Aug 12, 2005
    Oddometer:
    5,823
    Location:
    Turning expensive metal into scrap
    Makes sense thx
  5. jar944

    jar944 Been here awhile

    Joined:
    Aug 2, 2010
    Oddometer:
    752
    Location:
    Chantilly VA
    Yes sorry.
  6. jar944

    jar944 Been here awhile

    Joined:
    Aug 2, 2010
    Oddometer:
    752
    Location:
    Chantilly VA
    115 race sag
    37 static sag
  7. sailah

    sailah Lampin' it

    Joined:
    Aug 12, 2005
    Oddometer:
    5,823
    Location:
    Turning expensive metal into scrap


    Btw your bikes are sweet, I remember a year or two ago reading about the rfs conversion then saw your sig line. Nice:wink:
  8. Pulasky

    Pulasky Been here awhile

    Joined:
    Oct 15, 2007
    Oddometer:
    245
    Location:
    Poland
    :lurk:lurk:lurk I like this thread.
  9. sailah

    sailah Lampin' it

    Joined:
    Aug 12, 2005
    Oddometer:
    5,823
    Location:
    Turning expensive metal into scrap

    Thanks man appreciate it:1drink I like doing it so it's a win-win.

    Worked a little yesterday and bent up some aluminum channel to hold the Rotopax 1.75G fuel cell.

    Finished my shock mounts and getting them waterjet cut, next step is to tack them on and recheck the suspension numbers. I really hope I didn't screw it up because that was a lot of thinking and my brain can't handle any more:lol3

    I've entered the Ninja in the ALCAN 5000 for 2014 http://www.advrider.com/forums/showthread.php?t=777051

    I really hope it has a bunch of miles on it before then so I can be confident it will make it. Hell the way I building these bikes I'll probably have a couple more done by then:evil

    Work will be slow for the next week, folks are coming to town and I don't want to start thinking fuel system until the shock mount is done. I have some radical ideas for the fuel tank (s) but it might be too much work, I'll explain when I get there.

    Merry Christmas gearheads!!:freaky
  10. sanjoh

    sanjoh Purveyor of Light

    Joined:
    Feb 13, 2007
    Oddometer:
    5,397
    Location:
    Mountains of Central Florida:)
    Merry Christmas:freaky

    Help me understand how you are setting sag numbers with a good 40lbs of stuff (never mind the gearhead holding onto the bars) not on the bike, is this SWAG:D
  11. sailah

    sailah Lampin' it

    Joined:
    Aug 12, 2005
    Oddometer:
    5,823
    Location:
    Turning expensive metal into scrap

    I was on the bike setting sag. I purposely sat on the pillion seat to weight it even further. I also wore a really heavy jacket and put a 25lb dumb bell on the frame. I'm probably within 10% of the final weight, but yeah SWAG:wink:

    Missing tank, battery, some plastics, lights. which is probably close to the dumbbell weight. I just want to get in the ball park, can always throw in a heavier spring or more preload.
  12. Roadracer_Al

    Roadracer_Al louder, louder, louder!

    Joined:
    Aug 5, 2007
    Oddometer:
    1,729
    Location:
    Oakland, CA
    I hope good ole Sandy Claws stuffed your stocking with lots of Sawzall blades, abrasive cutoff wheels, and TIG filler rod. :rofl
  13. sailah

    sailah Lampin' it

    Joined:
    Aug 12, 2005
    Oddometer:
    5,823
    Location:
    Turning expensive metal into scrap
    :D ain't skeered.
  14. sailah

    sailah Lampin' it

    Joined:
    Aug 12, 2005
    Oddometer:
    5,823
    Location:
    Turning expensive metal into scrap
    anyone here have a header?:ear
  15. Fishnbait

    Fishnbait Adventurer

    Joined:
    Sep 10, 2010
    Oddometer:
    43
    Location:
    Queen Creek, AZ
    This build is way beyond my skills, but very interested in seeing it come together. Great job. Subscribed.:lurk
  16. 13.1

    13.1 Shaken not Stirred

    Joined:
    Oct 6, 2006
    Oddometer:
    393
    Location:
    Way up in the White Mountains of Arizona

    Hey Pete

    yeah, yeah, yeah, I know you did all that funky stuff and a 25 pound weight, etc


    BUT


    .....you did FLIP OFF those flip-flops and slip on your riding boots when you set the SAG---right????:evil

    HappyRiding !!
    Thomas
    .
    .
    .
  17. sailah

    sailah Lampin' it

    Joined:
    Aug 12, 2005
    Oddometer:
    5,823
    Location:
    Turning expensive metal into scrap
    Mine too:D
  18. sailah

    sailah Lampin' it

    Joined:
    Aug 12, 2005
    Oddometer:
    5,823
    Location:
    Turning expensive metal into scrap

    Uh no, I have to ensure OSHA compliance at all times so the open toed footwear stays. I did eat a 16" hoagie for lunch so....
  19. sailah

    sailah Lampin' it

    Joined:
    Aug 12, 2005
    Oddometer:
    5,823
    Location:
    Turning expensive metal into scrap
    Did some work on the subframe, mostly small tube work and a few gussets.

    [​IMG]

    [​IMG]

    [​IMG]

    Bent and welded a cradle for the rotopax. I also bought a Rotopax mount but I figured this would be more secure and will mount to the back of the pannier hoops that I have yet to build. I bought the rotopax that was close to the size of the Wolfman saddlebags so it will tuck in right behind. I figure it will be about the same width as the exhaust on the right side. It's 5052 0.080" aluminum I bent, cut the 45 degree miters and welded. I'll secure the tank with an Ancra cam buckle.

    [​IMG]

    [​IMG]

    Sent the CAD drawing to my waterjet guy and dropped off the 3/16" plate I got from my buddy free as a drop. Should have them back next week and can tack them in pace to drop the shock in.
  20. sailah

    sailah Lampin' it

    Joined:
    Aug 12, 2005
    Oddometer:
    5,823
    Location:
    Turning expensive metal into scrap
    Got my shock mounts back from the waterjet guy, they came out great.

    [​IMG]

    Get these tacked up and see how it looks.

    Ordering a new set of wheels from woodys, rad billet cush hub, big spokes superlaced and excel rims. I'll use my current wheels as backup for the rally.

    Decided to build my bag mounts from aluminum so I got a couple sticks of 1" 6063 which I have found to take a nice bend. Also got the aluminum for the rotopax redo and surge tank.

    Lots of progress need to keep plugging away