R100GS - Sreet tracker / scrambler thing....

Discussion in 'New Zealand' started by boxer odyssey, Aug 11, 2009.

  1. boxer odyssey

    boxer odyssey to excess and beyond

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    The beginings of a casting pattern.

    Attached Files:

    #21
  2. Padmei

    Padmei enamoured

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    Very impressed BO.
    Did you vacuum form the part yourself? Or get someone to do it. I take it you then took the part to the foundry where they created a sand mold off the part for forging & did the rest.

    How did they make the sand mold then get the part out?

    Is there a market out there to reproduce these parts to partially offest the initial costs & time?
    #22
  3. boxer odyssey

    boxer odyssey to excess and beyond

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    Hi Padmei,
    Yeh I vacuum formed the pattern myself using the machine at a friends work, then I did all the finishing at home.
    After that the foundery did the casting - I'm not sure how they made the sand mold exactly other than the fact that the pull was verticle.
    The cast part was as you see it in the top photo, very rough, when I got it so I milled and sanded and linished it before blasting it.

    Initially I was quite keen to make and sell these but I'm not happy enough with the finished size of this one as I slightly miss-calculated the shrinkage. It's ok for me but not to sell. There's also a lot of time in post finishing them. Maybe in the future.

    cheers.
    #23
  4. Kiwi Pete

    Kiwi Pete Adventurer

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    Very nice work there Ken, looking forward to seeing what else you come up with.

    Pete
    #24
  5. boxer odyssey

    boxer odyssey to excess and beyond

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    Another saturday arvo and another part fabricated for the bike. Today I made the steel mounting bracket for the rear cowl - it also holds the engine breather and the coil. After final finishing it will be powder coated and I will run an earth strap from the middle mount bolt to the coil.

    Attached Files:

    #25
  6. boxer odyssey

    boxer odyssey to excess and beyond

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    I'm yet to decide if the HT leads will exit through the top or side of the starter cover, probably the side I think.

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    #26
  7. Mark_S

    Mark_S Fair Weather Faggot

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    awesome stuff
    really enjoying seeing your progress
    #27
  8. boxer odyssey

    boxer odyssey to excess and beyond

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    Not much to show for this week end. But progress has been made in the form of decisions and more parts ordered.
    I've ordered a Brembo front master cylinder and matching (hopefully) dog led clutch lever and perch from Bevel Heaven (http://www.bevelheaven.com/stuff-for-sale.htm) who are awesome to deal with.
    I also scored a black alloy switch block for the lights, indicaters and horn from fleabay. So waiting for all that before too much more can be done on the bars. And a nice alloy throttle assy by Tomasselli with start and kill switches.
    Today I picked up a used '83-'84 R80RT wiring loom (Cheers Sean!) which will become the basis of the new and simplified elctrical system. Decifering it now and working out what to keep and what to chuck from it. I'll need to chop it up to fit the new requirements so figured it'd be best to put the origional one in the box, with all the other stuff i've removed, and start a fresh. There's way too much on the later looms for my liking - especially around the indicator circuits.
    I'll throw some photos at ya soon.
    #28
  9. Steve in NZ

    Steve in NZ scared/cheap

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    :lurk :lurk
    #29
  10. Padmei

    Padmei enamoured

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    Keep them coming :ear
    #30
  11. boxer odyssey

    boxer odyssey to excess and beyond

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    Here's a couple of shots of the finished airbox replacement and new location of the ignition coil. New HT leads are also fitted (and new plug caps).

    I've been working further on the wiring (and learning lots) and will post more about this soon. Including the new AGM battery I bought today, which I plan to fit up under the seat.

    Attached Files:

    #31
  12. boxer odyssey

    boxer odyssey to excess and beyond

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    OK, I've not posted anything for a while because I've been educating myself in the wonderful world of that black magic - wiring.
    I bought a much more basic loom off an earlier model BMW road bike as a source of wire and a starting point to base my new loom on.

    So I began by learning enough from my local auto sparky (L Alexander) here in Wellington and with some extra help from my mate Guz (who's just become middle aged!).

    Then I started the new diagram. I wanted to use a couple more relays and to add some protection in the form of more fuses. So the new diagram based on the 83-85 r80 but with these extra bits. I have left the charging and ignition circuits as they were.

    This image is the progress to date on the diagram. I'm updating it as I go on with building the actual loom.

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    • loom.jpg
      loom.jpg
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    #32
  13. boxer odyssey

    boxer odyssey to excess and beyond

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    Spaghetti anyone?

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    #33
  14. Padmei

    Padmei enamoured

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    Had a good look at an old GS the other day to see what you were doing to yours.
    Having the twin delorto (?)carbs & losing the airbox is a fantastic idea. Compared to the original setup it looks very clean & what I would have thought would have been a great factory option if available! Any differences tuning the carbs without an airbox - rejetting for more air flowing thru?
    I would look at simplifying the wiring if you can. A lot of stuff there looks pretty superfluous.

    Thanks for the updates.
    #34
  15. boxer odyssey

    boxer odyssey to excess and beyond

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    The Bings apparently run best with the airbox I think. Although someone said recently that removing the trumpets from inside the airbox (not the outside ones) is good for a few hoses. Havent tried it myself.
    I'm using Mikunis. Should give me better throttle response but probably not a lot more outright power - oh and they win on the wankfactorometer too!

    Theres nothing I don't need left in the loom now. In fact the loom I bought is only useful as a source of wire realy.

    good to see someones looking - cheers dude.:freaky
    #35
  16. Mark_S

    Mark_S Fair Weather Faggot

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    he's not the only one

    those of us with limited mechanical skills watch in awe

    please keep it coming

    BTW have you seen this
    #36
  17. Eddieb

    Eddieb www.AdventureRidingNZ.co.nz

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    I had a R80G/S some years ago with the trumpets removed. It made it very peaky. It had a huge surge in the mid range and right at the top end but was a bit flat in between. While it felt faster and more interesting to ride, when it was put side by side with a friends R80 G/SA it didn't go any quicker.
    #37
  18. boxer odyssey

    boxer odyssey to excess and beyond

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    Interesting. I think that's the case with a lot of carb mods. Often the only thing changed is the way the power is delivered rather than the amount.

    Cheers for the info
    #38
  19. Oscar

    Oscar Curmudgeon

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    Why don't you change that sig. line, ya weirdo?
    And where's my feckin' map book?
    #39
  20. Steve in NZ

    Steve in NZ scared/cheap

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    i like the sig line or r ya tryin to change ya image.:lol3

    i sent ya about 6 emails re ya map book and even put some posts up on threads ya had subscribed on and no reply.

    Geez i even went to ya work in Hillsborough tce and they said ya be gone from there. i don't see ya in the phone and I dont use the work computer for unauthorised actions.

    I was gunna list it on "turd me" but never got around to it. Its been sitting in the back of me 4x4 since Rod gave it to me way back at easter and I finally took it out a couple of weeks ago. Bloody thing has down about 5000kms in me 4x4.

    giz us an address and I will drop it off, in town or ya home.
    #40