Sport Bike to an Enduro or Dual Sport

Discussion in 'Some Assembly Required' started by dunesnstars, Aug 8, 2010.

  1. dunesnstars

    dunesnstars Been here awhile

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    Lots!
    Keep in mind the picture had to be maginified 1000X to be able to see the extent of the damages! :rofl
    #61
  2. dunesnstars

    dunesnstars Been here awhile

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    Yes the front is mounted to the exhaust. I welded a small stainless steel tab to the header. This is another reason I'm a huge proponent of bolting, since aluminum and steel cannot be welded together.

    So then I was able to bolt the front of the guard to that tab. The rear of the pan is bolted to brackets I made which is then bolted to the original bolt holes where the oil pan brackets used to be. The brackets I made are actually bent in case I smack something hard enough, the brackets should bend and still protect the exhaust. At least in theory, that's how it should work. Hope this answers your question.
    #62
  3. dunesnstars

    dunesnstars Been here awhile

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    You can get Ninjas pretty cheap and you will end up with your very own unique bike. I'm too short for any of the dual sports out there, so I didn't really have a choice but the build has been a lot of fun. But you gotta enjoy this kinda stuff for it to work out well.

    Go for it! :clap
    #63
  4. Laughingdawg

    Laughingdawg Been here awhile

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    That can't be true, because every Aegis cruiser is an aluminum superstructure welded to a steel hull. It may be ridiculously expensive in comparison to the value of the bike. But it's definitely possible.
    #64
  5. mpowers

    mpowers Been here awhile

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    fwiw
    I did a quick search on the cruiser, but my guess would be they used explosion welding to fuse a alum and steel pieces (thus making clad steel), then welded the alum deck structure to the alum side of the fused plate. This is considered cold fusion, where welding stick, mig, tig, shor arc, etc is hot fusion.

    Other than that, there are a few solders out in the market that more or less glue the two together-not truley fused and have no real mechanical strenght. These are inexpensive, but would have failed with the first hit from a rock.
    #65
  6. dunesnstars

    dunesnstars Been here awhile

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    Yeah, what he said!:evil
    #66
  7. gvthnks

    gvthnks Been here awhile

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    yup, that's it.
    #67
  8. dunesnstars

    dunesnstars Been here awhile

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    Wow! New tires are mounted, racks and side cases are installed! Looking really good!!!:rilla
    #68
  9. dawgwhat

    dawgwhat No Earthy Idea

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    need pic's or it didn't happen :eek1
    #69
  10. dunesnstars

    dunesnstars Been here awhile

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    Why you don't trust me? I can't believe how good it looks. It's really looking like it should have always been a dual sport! :clap :clap
    #70
  11. dawgwhat

    dawgwhat No Earthy Idea

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    I do trust ya... :D

    but you have 2 put up some pic's or it didn't happen
    #71
  12. dunesnstars

    dunesnstars Been here awhile

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    On Thursday, the fittings came in for the coolant tank as well as another set of turn signals and the Givi sidecases.

    Yesterday, the Givi racks (thank you Grainbelt!) and tires came in. Within a few hours, the new Avon distanzias were mounted and balanced. This morning, the wheels were installed. And they look pretty damn good!

    Still not finished but here's a quick preview of ENja now...

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]


    Tomorrow is paint day! Everything gets taken apart, sanded, primered and painted. While waiting for the paint to dry, I need to mess around with the wiring a little and ENja should be almost ready to ride!

    Can't wait!
    #72
  13. Funkydevil

    Funkydevil Been here awhile

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    Lookin' pretty darn effin' sweet. I would ask about paint, but I'll just wait and see. Good Job!!! :thumb
    #73
  14. dawgwhat

    dawgwhat No Earthy Idea

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    Lookin good gf :lol3

    almost there :clap
    #74
  15. dhillr

    dhillr Long timer

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    Looks real nice:thumb :thumb

    Now let's hit some gravel & break that puppy in!!!:ricky
    #75
  16. dunesnstars

    dunesnstars Been here awhile

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    Painting is killing me! :hung

    Thank you dawgwhat for helping to watch paint dry!! :bore

    Funkydevil, dhillr... thanks for the compliments. Can't ruin it now by being impatient!!
    #76
  17. dunesnstars

    dunesnstars Been here awhile

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    Today has really tested my patience. All the custom fabricated pieces finally have all the layers of primer on them. The frame has not been touched. Tomorrow, another coat of primer (ok, almost all layers), some sanding and hopefully top coat. I should also be able to begin working on the frame and before the end of the night tomorrow, I hope to be able to apply the top coat as well.

    I did paint the two engine guard brackets with the Color Rite top coat and surprisingly, the paint matches very well. A little on the darker side but I think this is because of the darker primer used. I originally started with the lighter gray and ran out. Went back to the parts store and they had also ran out. I'll need to find another parts store that carries the lighter gray primer, hence the last coat of primer for tomorrow.

    In the mean time, here's the picture of the custom pieces with primer... are they dry yet??

    [​IMG]

    Check out the silver bracket in between the radiator guard and the gravel guard. It looks really shiny!!
    #77
  18. underkill

    underkill Horsepower Junkie

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    You really DO have more patience than I do Shiela! :eek1 It'll look totally SICK when you're done... projects like this never get done on time... so dont lose hope! y'all will just have to ride out to Washington for vacation instead of labor day weekend... :freaky
    #78
  19. dunesnstars

    dunesnstars Been here awhile

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    That would be cool! I wonder if two weeks will be long enough??
    #79
  20. dunesnstars

    dunesnstars Been here awhile

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    Frankenstein bike!

    [​IMG]
    #80