R100RT chop hack and slice without remorse. Looming 56K death

Discussion in 'Airheads' started by digger440, Nov 27, 2012.

  1. digger440

    digger440 Adventurer

    Joined:
    Nov 26, 2012
    Oddometer:
    74
    Location:
    Very northwest corner of the USA
    formatting issues
    #41
  2. digger440

    digger440 Adventurer

    Joined:
    Nov 26, 2012
    Oddometer:
    74
    Location:
    Very northwest corner of the USA
    So the UPS and USPS person brought me some stuff for this abortion.
    [​IMG]
    [​IMG][​IMG][​IMG]
    [​IMG]



    Progressive fork springs grips, Bar End Mirrors and coils.

    I said earlier in this thread I had an idea for CoP ignition for this project and after a little searching I found an ignition module to handle "making of the sparkage".

    [​IMG][​IMG][​IMG]
    [​IMG]
    [​IMG]

    [​IMG][​IMG]
    [​IMG]

    [​IMG]

    [​IMG]
    [​IMG]

    It is an impressive for the cost (quite affordable) has a wide operational range and will handle up to 12 amps current draw.

    Here are the specs http://www.weaponxperformance.com/technicalPDF/Ignition Module Specs.pdf

    It is available through WeaponX Performance

    http://www.weaponxperformance.com/main/ignition_module.htm

    Stay tuned for more, I have ambition again
    #42
  3. bgoodsoil

    bgoodsoil Dare to be Stupid

    Joined:
    Jul 9, 2008
    Oddometer:
    4,673
    Location:
    Washington, DC, USA
    Man I love reading build threads. It's like building a bike yourself without having to go broke or get your hands dirty :D

    Love those shock mounts :thumb Can't wait to see the rest :lurk
    #43
  4. digger440

    digger440 Adventurer

    Joined:
    Nov 26, 2012
    Oddometer:
    74
    Location:
    Very northwest corner of the USA
    So I am transitioning back to nightshift and I have time to work on this damn thing again.

    I bought a battery for it, an Evo2, and I needed a place to hide it; so I set about thinking on how to build a box to hide it where the air box was.

    My only problem is that I don’t have any metal shaping tools, I would have killed for a English wheel, planishing hammer, roll, or even just a leather bag and a mallet in the middle of this.

    I started with what was going to be the base of the battery box (but ended up being the top in the end). I used the trans as a template and cut 2 pieces of Aluminum. Here is where I go all caveman, in order to get curves I had to tack the outside piece and form it to the base.

    [​IMG]

    [​IMG]

    [​IMG]

    Once I got it all welded up I found it fit better as the top




    [​IMG]

    [​IMG][/IMG]


    But as I said, I have no way of making compound curves so I had to get creative. A quick trip to the local Thrift store yielded a pressure cooker, a bundt pan, a Mr. Omlette and a Perfect Pancake cooker for about 14 bucks.

    [​IMG][/IMG]


    I cut up the Mr. Omlette as I was going to use it at a base for the box. But, I did not use it, the Perfect Pancake however was made of spun Aluminum so I put it in the bandsaw and started chopping. When I was done I welded it to the back of the box



    [​IMG][/IMG[/URL]]

    [​IMG][/IMG[/URL]]
    [​IMG][/IMG]

    [​IMG][/IMG[/URL]]

    [​IMG][/IMG[/URL]]


    I also drilled and tapped the trans ears to mount it



    [​IMG][/IMG]


    I then filled the gaps with other pieces of The Perfect Pancake machine to smooth it and give it a more rounded appearance

    [​IMG][/IMG[/URL]]

    [​IMG][/IMG[/URL]]


    Test fit!

    [​IMG][/IMG[/URL]]

    [​IMG][/IMG[/URL]]

    I then added some ears to the bottom to fill it out more Pancake parts

    [​IMG][/IMG[/URL]]

    And the fab work is done on this item, I just have to grind it smooth and get it powder coated

    [​IMG][/IMG[/URL]]

    [​IMG][/IMG[/URL]]

    [​IMG][/IMG[/URL]]


    The UPS man was kind last week and brought me turn signals and a tail light.

    [URL="http://imageshack.us/a/img197/5789/dscf1487d.JPG%5b/IMG"][/IMG[/URL]]

    [IMG][URL="http://imageshack.us/a/img4/2749/dscf1474x.jpg%5b/IMG"][IMG]http://imageshack.us/a/img4/2749/dscf1474x.jpg[/IMG[/URL]]

    [​IMG][/IMG[/URL]]


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    #44
  5. bill42

    bill42 Old-School BMWs

    Joined:
    Dec 20, 2011
    Oddometer:
    406
    Location:
    Long Island, NY
    FYI not one of your photos are showing up...
    But I was able to click the links and delete some extra IMG text after the .jpg, and hey, that is a pretty cool metal box you made there. I was thinking of making of finding a similar box like this to use as a storage area for tools on my bike as I have no place to hide stuff.
    #45
  6. digger440

    digger440 Adventurer

    Joined:
    Nov 26, 2012
    Oddometer:
    74
    Location:
    Very northwest corner of the USA

    Fixxxxxed:pissed
    #46
  7. digger440

    digger440 Adventurer

    Joined:
    Nov 26, 2012
    Oddometer:
    74
    Location:
    Very northwest corner of the USA
    So I had some ambition tonight, I measured for brake lines as I am ditching the under the tank routing. I finished mounting the exhaust (no pic though it was mundane enough I did not feel it worthy of photos.)

    As I said a while back I had an idea for COP ignition so I purchase a pair of Ford v-8 coils. Of course I mocked them up first

    [​IMG]

    Then I built a bracket to hold them in place

    [​IMG]


    I needed to mount the bracket to the head so I drilled holes in the first two rows of fins and installed threaded inserts.

    [​IMG]


    [​IMG]

    Installed inserts ahoy


    [​IMG]

    [​IMG]



    And here is the finished product coils bolted up and ready to go

    [​IMG]


    [​IMG]


    [​IMG]




    If you have been following along I built this battery cover in the last installment

    [​IMG]


    Well tonight I took a Scotch-brite wheel to it with extreme prejudice and it smoothed out nicely I am pleased

    [​IMG]

    [​IMG]


    I have air cleaner and brakeline plans next and I have a good idea for the fuel filter/crossover but I need some disposable cash first


    To be continued...
    #47
  8. Kt-88

    Kt-88 I like everything.

    Joined:
    Sep 9, 2012
    Oddometer:
    1,009
    Location:
    SLC area, Utah
    Neat!
    #48
  9. digger440

    digger440 Adventurer

    Joined:
    Nov 26, 2012
    Oddometer:
    74
    Location:
    Very northwest corner of the USA

    Thanks, but then again you like everything lol
    #49
  10. Kt-88

    Kt-88 I like everything.

    Joined:
    Sep 9, 2012
    Oddometer:
    1,009
    Location:
    SLC area, Utah
    I just stay out of threads I don't. ADV has enough armchair naysayers. Lol.
    #50
  11. digger440

    digger440 Adventurer

    Joined:
    Nov 26, 2012
    Oddometer:
    74
    Location:
    Very northwest corner of the USA
    Tonight I started the headlight mounting brackets. Last week I ordered a set of Dominator headlights and a Linx flyscreen from Jesterstrickbits.co.uk

    One of my favorite looks for a bike is the Speed Triple, I like the bug eye for some reason which is why I went with the Dominator setup.

    Anyhow since the lights are on their way I need a way to mount them and all of the "universal" 36mm brackets look cheesy so I will build my own.

    I started out with some 6061-0 1.75 ID pipe and cut it into 1 inch rings

    [​IMG]

    [​IMG]


    The first thing I have to do is square up the saw cut edges, turn all 4 to the same OAL and cut the outside surface to look nice

    [​IMG]


    After makeing the outside purdy I tried to get all four within +/- 0.005 (which is amazing for the crap ass lathe I am using)

    [​IMG]


    I then cut the ends off and shaped them using a vise and a 1.5 inch Ti billet as a mandrel. I had it floating around in a bucket full of Ti scraps (I plan on using the Billet to make rear bobbins later on)

    [​IMG]


    Here they are on the forks, I purposly made them wide to cover some rust pits in the area of fork where they mount.

    [​IMG]


    Hopefully me Lights and screen get here soon

    TBC...
    #51
  12. digger440

    digger440 Adventurer

    Joined:
    Nov 26, 2012
    Oddometer:
    74
    Location:
    Very northwest corner of the USA
    This last weekend my lights and flyscreen showed up at the post office, so last night I got on the ball and built the rest of the mounts. I started with some 1"X 1/8 aluminum stock and cut it to length.

    [​IMG]


    I then took the pieces and used a piece of Titanium billet to form the curve for the fork

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    Four done and they fit pretty well


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    Next step is to drill and tap the collars on the end

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    Once they were bolted up I drilled and tapped the other end. When I went to the hardware store this weekend in preperation I was running on 3 hours sleep for a 30 hour period so my math skills were not up to par, I got only eight of the 16 5x.80 bolts I needed. And at 11:30 pm there are not a lot of places open for hardware.

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    Since the factory gauges were meant to be used with the fairing they obtusely stuck up in the air like an erection at a nudist colony. So, I cut the factory gauge bracket down and welded it back together so the gauges were just off the triple clamp

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    With the gauges in place I drilled the fork clamps for threaded inserts and installed them


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    I then made some support brackets out of some aluminum in the odds and ends bucket. I had to tweak the ends to match the lights and when I put the ear in the vice I found that I had made the ears out of 7075-T6 it was a total bitch to bend

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    They are pretty plain-jane right now, but I plan on adding some lightening holes to purdy them up before sending them off for powdercoating

    In the below photo you can see how low the gauges now sit.

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    And here is the result, I am pleased with it. I know I am mixing a coupe of genres cafe racer/streetfighter but I like the attitude of the speed triple look with the classic tail and dual shocks of a cafe racer. Comments good and bad are appreciated

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    I also built the intake system last night. I did not want to run pod types and since the original area of the airbox is now the battery cover I had to get creative.

    I have always liked the look of external piping on turbo bikes and a longer intake track usually help smooth out the incoming air. so I bought a couple of these and chopped them up

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    I also bought this dual inlet K&N


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    Now if you remember I am using COP ignition and I have a little extra room under the tank where the stock coils bolted up. So that is where the airfilter was going. It did require that I remove a couple of the vent slats from the started cover to fit it though.

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    It fits much better than I expected and fills the relief cut fully. Next stop is to mock up the bends I cut from the original mandrel bend.

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    One of the things I had to work around was frame braces that I plan to install when the parts get here. On the left side of the bike I also had to work around the underseat exhaust I built

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    And here it is mocked on the left side

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    I welded them up and now I have to smooth them prior to powdercaot. the are not obtrusive and fill out the engine compartment. I like the "busy" but purposeful look and they add support for the carbs.


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    And lastly I was shopping at the local Goodwill thrift store a while back and found this for $19.99. My Kawasaki has no place for bobbins to use it but that Titanium billet gave me an iderrrr....

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    TO BE CONTINUED........:D
    #52
  13. digger440

    digger440 Adventurer

    Joined:
    Nov 26, 2012
    Oddometer:
    74
    Location:
    Very northwest corner of the USA
    So I have been a tad slow in updating, this week has been super busy at work and I just havent had time to post. I shouldnt be such a pussy, sleep is for the weak lol


    Anyway I got some threaded tube ends, rod end bearings and some pre-fab frame tabs because I wanted to make a set of frame braces.

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    They are pretty simple just weld in the ends, screw in the bearings and weld the tabs on the frame. My wife happened to be hanging with me in the shop and took some photos.

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    They fit well and dont touch the intake pipes or exhaust.


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    Next I bent some fuel lines from the petcocks to the fuel filter bolted to the back of the battery cover. I took a few tries even with the 2 or 3 different benders I have to get a reasonable mirror image, and that didnt have a big kink in the middle of a bend because I was a dumb ass


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    And here they are


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    With the intake pipes installed


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    I am getting a bit excited as I am closing in on making it run probably a month off or so. I am also looking forward to my next build. I was given another freebie unloved bike over the weekend which I have some cool ideas for. Just a teaser it is a 1200 cc V-4
    #53
  14. chasbo

    chasbo Long timer

    Joined:
    May 8, 2005
    Oddometer:
    2,187
    Location:
    Prescott Valley, Arizona
    That is really starting to come together nicely now!
    #54
  15. Airhead Wrangler

    Airhead Wrangler Long timer

    Joined:
    Mar 4, 2008
    Oddometer:
    6,821
    Location:
    Back in Seattle, FINALLY
    What's the reason for the accel coils out on the cylinders? Aren't they going to get cooked out there? Also, speaking of cooked, running the exhaust right under your seat pan is going to melt the seat pan if you use one of the later plastic ones or just cook the vinyl if you use an earlier metal one. I like that aluminum infill cover where the airbox used to live. Are you running a dual shock swingarm with a single shock?
    #55
  16. digger440

    digger440 Adventurer

    Joined:
    Nov 26, 2012
    Oddometer:
    74
    Location:
    Very northwest corner of the USA
    Thanks, yeah the image I had in my head is finally starting to show through. I cant wait to get it in paint!


    I used those coils for a couple different reasons, they look different not your standard airhead fare. And, since they are off a ford truck engine, in case off failure I can go to any Auto-zone or Kragen and pick one up on a Sunday. They also match the color scheme (they are purdy yellow).

    As far as addressing the heat the will be subjected to I am not too concerned about it. I dont know if you are familiar with Ford 4.6/5.4/6.8 liter engines but these coil sit next to the valve cover in direct contact with the head. They are constantly subjected to 130-150 degree temps and even higher in some locations (Arizona or the Mojave for example). I doubt they will fail but if they do I will just do something else (that is the fun part)

    If you scroll up or even go to the next page back you can see the seat mounted. It has a metal pan and I had planned to monitor it and if it got too hot I have room for a heatsheild

    As far as the shocks i am running duals I just removed the left side so I could weld on the tabs for the frame braces. go back in this tread and you will see both mounted up :D
    #56
  17. digger440

    digger440 Adventurer

    Joined:
    Nov 26, 2012
    Oddometer:
    74
    Location:
    Very northwest corner of the USA
    As can bee see from the first attempt on page 1 upholstery is not one of the things I am good at. And, after my last fail attempt I was convinced that I could not even do a temporary seat. Well with some patience and beer I lost my irrational fear of foam covering. I wanted a temp seat as I dont have a lot of disposible cash and I am saving up for brake lines so I just dont have it in my wallet right now to get a seat built by someone who knows what they are doing.

    I got these from the thrift store, the electric knife was $3.00, the floatation cushion was $3.50 and the yoga mat was $3.00. I already had glue and cover material kicking around from the last attempt.

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    I made a couple different layers separated with the yoga amt and glued it together. The case of oil is a glue weight

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    After gluing it and shaping it with the electric knife I started to put on the cover

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    After getting it stretched I bolted it up to the tail and put it on. Not a professional job but close enough until I blow it apart for paint.


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    #57
  18. digger440

    digger440 Adventurer

    Joined:
    Nov 26, 2012
    Oddometer:
    74
    Location:
    Very northwest corner of the USA
    So I finaly got off my ass and got time to post some pics. I have been working on a bunch of little things which take up a bit of time.

    A few posts ago I talked about making bobbins for a rear stand I found at the local thrift store. I had a 1.5" grade 2 Titanium billet in the odds-n-ends bucket so I cut off some chunks only to discover that they would not fit in my itty-bitty lathe. so I drilled a hole and used a bolt as a mandrel so I could turn them to about 1.25" diameter. I faced them and left a small shoulder on the bolt and shock sides. I also chamfered the edges and replaced the bolt and stud that mounted the bottom of the shocks with longer 12.9 prop class allens.


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    Here is a photo of them from start to finish. I started a couple extras as I will put them on my ZX6 too.

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    And here they are all bolted up


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    With that done I had to make real shift linkage to replace the temporary one I made to fit the exhaust. I used a 3/8 aluminum rad and turned it down on each end to 6mm, threaded it and bent it the correct shape. It look a ton better that the ready-rod temp one I built.


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    I had to plug the pulse air system so I took the fitting I had removed from the head, put them in the lathe and turned off the part that the tube attaches to. I then drilled and tapped them for an 1/8 NPT steel plug and staked it into place once I screwed it into the fitting.

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    For the rear lights I got some flush mount GSXR turn signal and a cat-eye brake/tail light. All have smoke colored lenses which blend into the tail, the brake light especially, with it off you can tell it's there (however the flash on my camera relects off the lens making it more visible than it is). but it is very visible while on. I removed the rear roundel and used a countersunk allen to bolt the bracket on that holds the light.


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    I have got the Battery mount and fuze/junction block mounted but I will put that in a new post
    #58
  19. globalt38

    globalt38 Swimmin W/Waterwings

    Joined:
    Apr 10, 2013
    Oddometer:
    1,043
    Location:
    Atlanta
    For some reason I'm very intriqued by this (incorporation of the ford v8 coils) - interested in seeing how it turns out!:ear
    #59
  20. digger440

    digger440 Adventurer

    Joined:
    Nov 26, 2012
    Oddometer:
    74
    Location:
    Very northwest corner of the USA
    Thanks I will let you know. I have this pet peeve with bikes that you cant get parts at any parts store. I already have a WeaponX ignition module but I do not think I am going to use it as I cant go get it at Vato-Zone on a sunday afternoon.

    I will keep you posted
    #60