Retro Street Tracker ...with a 710cc DR Thumper..

Discussion in 'Some Assembly Required' started by Apocalipsis FZR, Jul 6, 2013.

  1. Apocalipsis FZR

    Apocalipsis FZR I´m too old for this....

    Joined:
    May 14, 2009
    Oddometer:
    85
    Location:
    Buenos Aires , Argentina
    Thank you for your kind words, Bambi.
    And nice BIG you have there...:clap

    OK..these last two weeks were hard..The job is killing me, so no left over stamina for the bike after 9 hours in the officce...
    The last weekends I´ve been working on my adventure bike in order to prepeare it for the Andes Heights, so less time for the tracker..
    To sum up, I´ve started a respectable construction work in my House in order to give more space and natural light to my wife´s design studio, and (although the Construction Contractor is a close friend and fellow rider) the whole thing is stressing for the Couple (as any house construction when you are living in the house with two young kids) and for the wallet (why contractors dont understand the concept of a close budget?? Jeez... :baldy).

    So now I slowly started with some ideas that will end up in a a lot of hand work with almost no special tools.
    Just a side Note, I already sent the top heads to the machine shop.
    One top head for only a combustion chamber refurbishing, and the other for a huge mod in order to have the first DR650 camshaft on roller bearings in history...

    Fisrt of all, head light protection design.

    The best one I ever used is the one that is mounted in the "Jurassic Rally" Adveture Bike. Just Transparent Acrilic .

    [​IMG]

    The most durable (because you can bend it to its more or less original shape after a hit) is the Wire net design,like the one that I have in my dailly conmutter (I call it " The CAT"...for Caterpillar).
    [​IMG]

    In order to follow the OLD roller idea, the wire net protector was selected...so lets go.
    First of all...I need the starting point , that is .....

    [​IMG]

    Yes, the thing that you have to use in order to retrieve the French Chips from the boiling oil...and I really have no idea how you call this in English...:D

    It will end with something like this, but with a Black finish:

    [​IMG]

    [​IMG]

    Then is the issue with the rear shocks and the Seat.
    Look at the following Pictures:

    [​IMG]

    [​IMG]

    I really dont like the position (almost vertical) and the height of the rear end. I need to replace my brand New, extremly cheap Chineesse twin shocks -made for the Chineesse version of the Yamaha YBR 125 (lenght 33 cm) - for something MORE CHEAP , preferably Chineese, of 27 cm....

    The other thing is the seat.
    I think is too tall, so Im in the doubt of removing some foam...this will end in a thinner and smaller seat...but also will reduce my butts comfort....
    Being a former Super sport young rider...I dont like the idea of suffer "AGAIN" a racing seat on my 40´s..
    What do you think??
    #21
  2. RedRaptor22

    RedRaptor22 Been here awhile

    Joined:
    Jan 24, 2012
    Oddometer:
    161
    Location:
    Louisiana
    Looks good so far, the potato chip strainer headlight guard is genius!

    For the seat I'd replace the foam with some more dense rubbery carpet padding foam and cut it thinner, maybe even taper it towards the back so it comes out more flat with the world on top.

    The more dense foam will give you the support you need and still be comfortable, never was a fan of fluffy seats, just not enough support there.
    #22
  3. Apocalipsis FZR

    Apocalipsis FZR I´m too old for this....

    Joined:
    May 14, 2009
    Oddometer:
    85
    Location:
    Buenos Aires , Argentina
    OK. sorry for the delay, but Im in the final countdown for my trip and I have no more free time.
    First week of sept I gotta be in Bogota (Colombia) for work, the following week I have to ship the bike to Jujuy (North of Argentina), and on Set 19th I gotta catch a flight to join my bike in Jujuy....after that, off road adventure ride until NAZCA (PERU) , so no or little time for the tracker and less for the Forum...

    Lets go to the updates:

    TANK painted, waiting for the final gloss (in fact Im waiting for the tank logos to be finished-my wifw is designing them-, so I can put the Poliurethane gloss on top).
    Painting was slowly, mainly because is winter here and I have no heated painting place.... (its a "father of 2 married man shelter", not an "open wallet wealthy single man machine garage")..:cry

    [​IMG]


    [​IMG]

    [​IMG]

    [​IMG]


    Final, Waiting for the logos and the gloss...

    [​IMG]

    I have a Compressed air painting gun, but...after making the math...it WAS CHEAPPER painting everything with Rattle can than buying the paint!!!!

    Rattle can does not mean shitty, it all depends on the quality of the job you make, and patience...


    Do you remeber this???
    [​IMG]


    OK, now is this:

    [​IMG]

    [​IMG]
    #23
  4. duckman

    duckman co conspirator

    Joined:
    Feb 1, 2005
    Oddometer:
    981
    Location:
    new york new york
    how about a pair of rubber knee panels from a late model triumph on that beautiful green tank.
    #24
  5. Apocalipsis FZR

    Apocalipsis FZR I´m too old for this....

    Joined:
    May 14, 2009
    Oddometer:
    85
    Location:
    Buenos Aires , Argentina
    Yes, I was considering that. :D
    The only issue is that Triumph isnt extremly available here.
    I have more options with NSU Speedmaster´s units or even Gilera´s , but I refuse to pay a LOT of money for a couple of rubber sheets...no matter what type of decals it has stamped on it... :evil
    #25
  6. Apocalipsis FZR

    Apocalipsis FZR I´m too old for this....

    Joined:
    May 14, 2009
    Oddometer:
    85
    Location:
    Buenos Aires , Argentina
    THIS:

    [​IMG]

    Now is this:

    [​IMG]

    Wiring si through the frame.
    BAse is made of stainless sheet metal.
    Its not pristine (came from ebay), but its a little bit nicer than the original set up.
    #26
  7. Apocalipsis FZR

    Apocalipsis FZR I´m too old for this....

    Joined:
    May 14, 2009
    Oddometer:
    85
    Location:
    Buenos Aires , Argentina
    AHH!!!

    And this:

    [​IMG]

    Its already assembled, with stainless spokes, safyty wiring between spokes (old school) and installed (shitty pic, sorry).
    [​IMG]


    Jeezz...its freezzing here...
    I´ll try to take some pic outside in the sun when the Final gloss of tha tank is ready....sorry
    #27
  8. davesupreme

    davesupreme grand poobah

    Joined:
    May 1, 2011
    Oddometer:
    1,796
    Location:
    palm harbor, fla
    i borrowed(stole, actually....:evil) 'yer idea for the fry basket headlight grille.... i had an old 8" one that fit my Baja Designs light perfectly on my KTM.... painted it up, ziptyed it to the light frame, fits like a glove... i should post a pic, but i dunno how here... great idea, i'll always give you credit....:evil
    #28
  9. Apocalipsis FZR

    Apocalipsis FZR I´m too old for this....

    Joined:
    May 14, 2009
    Oddometer:
    85
    Location:
    Buenos Aires , Argentina
    Nice!!!
    Post a picture!!!

    I´ll give you another idea for finishing it.
    A you have noticed, the wire net is too thin to weld (at least with something that is not a ¨point welder¨ -Im literally translating from spanish here, Im sure this type of welder has another name in technical english slang- so , in order to have a nice and neat finish for the complete assembly, what I do is the following:

    Y prepare the supporting frame for the headlight protection in aluminium.
    Where this aluminium frame encounters the fry basket , I perform several small holes.
    Then, using safety stainless wire,I sew the fry basket to the supporting frame, in across pattern , extremly tight.

    Then I use a general epoxi glue just to make it extremly tight, and in order to allow a perfect finish....then Paint and thats it!!

    TOURATECH is NICE....but I preffer to spend my money in other creations (big bore kits, advanced cams, etc...):evil
    #29
  10. Krasniewski

    Krasniewski I don't ride much.

    Joined:
    Feb 5, 2008
    Oddometer:
    1,264
    Location:
    LA - Lower Alabama
    Love this thread. Thanks for sharing! :freaky

    Looks like you really have some great skills. :norton
    #30
  11. Apocalipsis FZR

    Apocalipsis FZR I´m too old for this....

    Joined:
    May 14, 2009
    Oddometer:
    85
    Location:
    Buenos Aires , Argentina
    OK, remeber I wanted to install the camshaft on roller bearings?

    OK.

    The project is almost done.

    Of the 3 contact points of the camshaft, 2 of them are already done or waiting to be machined, but there is one point (the one in the middle) that needs a special solution and I CANT find the bearing I need.


    The left sliding point is done, hand machined by me..
    [​IMG]

    Here you can see it with the propper neddle roller bearing that will work there:

    [​IMG]


    The extreme right sliding point is waiting for being machined.
    Here you can see the selected bearing:

    [​IMG]


    MY PROBLEM is the MIDDLE sliding point.
    I cannot install a normal or standard bearing because I have the cams or the timming sprocket.

    This is the one:
    [​IMG]

    What I need is a SPLIT cage and SPLIT bearing type.
    Something like this:


    [​IMG]

    This is no INVENTION from my side.
    This is something that has been going on for a while in mechanical engineering.
    There are articles about this (read this one from NTN Bearings )


    HERE you have another article.

    I already sent an email to NTN and had no answer.

    I really need to have a 25mm Internal Diameter Split Cage roller bearing, but no one seems to know where I can find one.

    I guess my last choice will be to contact a Bearing MAnufacturer and see what I can find.

    The other choice was to buy an OPEN cage bearing, and then using a steel bushing, fabricate the external split race for the bearing ...

    I really DO NOT want to use steel bushings in this sliding point.
    The whole Idea of constructing this bike was to find alternative technical solutions in order to achieve more torque and durability....and the CAmshaft bearings are the Achilles hill of this bike...


    PLEASE, if someone knows where I can find this type of bearings, let me know !!
    #31
  12. Apocalipsis FZR

    Apocalipsis FZR I´m too old for this....

    Joined:
    May 14, 2009
    Oddometer:
    85
    Location:
    Buenos Aires , Argentina
    Forgot to mention:

    None of the machine shops I have presented the project (of installing Roller bearings in the camshafts) accepted it.
    So Im making it my self.

    I´ll hand made one (it will take me a long time), and once Ive done it, Ill use it as a model in order to replicate it...
    #32
  13. Apocalipsis FZR

    Apocalipsis FZR I´m too old for this....

    Joined:
    May 14, 2009
    Oddometer:
    85
    Location:
    Buenos Aires , Argentina
    Some updated pictures .... top head still missing...

    [​IMG]

    [​IMG]


    [​IMG]

    [​IMG]


    [​IMG]
    #33
  14. DRjoe

    DRjoe Long timer

    Joined:
    Sep 6, 2007
    Oddometer:
    5,333
    Location:
    Sunshine coast qld
    Lots of 2 stroke outboards use that style bearing for there big end.
    #34
  15. Apocalipsis FZR

    Apocalipsis FZR I´m too old for this....

    Joined:
    May 14, 2009
    Oddometer:
    85
    Location:
    Buenos Aires , Argentina
    Yes, I Im in contact with a bearing manufacturer now. They propose to use a YAmaha 75HP 2stroke marine engine bearing (only split roller cage),and I can manufacture internal and extrenal races.....
    Lets see what turns out...

    My life is a collection of NON Bolt on Mods....
    #35
  16. tileman

    tileman Been here awhile

    Joined:
    Mar 15, 2007
    Oddometer:
    886
    Location:
    Melbourne, OZ
    I'm based in Australia and travelling to BA in mid December so if there are some small items (you know customs there) I could bring them over for you. I'll be based in San Isidro.
    #36
  17. Apocalipsis FZR

    Apocalipsis FZR I´m too old for this....

    Joined:
    May 14, 2009
    Oddometer:
    85
    Location:
    Buenos Aires , Argentina
    Thanks for the offer!!!:clap
    I should have the bike running by December, but with trips and the job, you never know.:cry

    Ill let you know if there is anything I need from Australia!!:wink:
    #37
  18. Dyno

    Dyno Conquistador

    Joined:
    Nov 10, 2006
    Oddometer:
    1,903
    Location:
    Bottom of Lake Huron

    I suppose Harbor Freight isn't readily available either, but they have rubber safety tread with an adhesive backing. Cuts easily with scissors, might be a good choice for some knee pads. I've been using it for 2 years on the top of my panniers, it fades a bit but holds up amazingly well to sunlight.

    [​IMG]
    #38
  19. Apocalipsis FZR

    Apocalipsis FZR I´m too old for this....

    Joined:
    May 14, 2009
    Oddometer:
    85
    Location:
    Buenos Aires , Argentina
    Yes, its a possibility...although I can find a pair of these for 18 USD....
    [​IMG]

    [​IMG]

    :D:D:D:D
    #39
  20. Dyno

    Dyno Conquistador

    Joined:
    Nov 10, 2006
    Oddometer:
    1,903
    Location:
    Bottom of Lake Huron

    Nice!:clap
    #40