The ground up yz/wr/xt/tt adventure build

Discussion in 'Thumpers' started by yamahaman, Oct 27, 2010.

  1. duxrneet

    duxrneet Been here awhile

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    That's a beauty.
  2. yamahaman

    yamahaman wannabe bike builder

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    that would be awsome I have got some pictures of the rad sprocket carrier

    http://www.radmfg.com/Cush-Series-REAR-HUB-125-up-p/radh-eq-1r.htm (all pictures copyrighted so you will have to check out this web site)

    If you could include some mesurements that would be great

    :1drink:1drink:1drink
  3. LukasM

    LukasM Long timer

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    I've got a RAD carrier too, but it's for a 950/990 so the measurements are probably a bit different. The Haan Wheels one is machined with much more detail, so it's a lot lighter. I have never heard of one breaking either, even running them on 70HP big bore LC4 supermotos on slicks.

    I'll get you some pics of it next week, then you can tell me which measurements you need. Here are some of the RAD carrier:

    [​IMG]

    [​IMG]
  4. DANJET600

    DANJET600 Need 2 go bush ASAP

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    :clap nice work
  5. yamahaman

    yamahaman wannabe bike builder

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    [​IMG]

    So here we have an action shot on the rotary table, on the mill, having its fingers cut into it.

    [​IMG]

    And this is the finished product about to come off the bench to be de-burred. I put the carrier into a hub and its a snug fit but it works well. I prefered a slightly tighter fit to take into allowance for worn rubbers. I actually have a set of worn cush rubbers (still very servicable, from the wheel I copied) and they are not as tight but still firm to fit so I am very happy, and all this first hit I didnt have to have a second go at the sprocket carrier, all of my measurements worked well. I am quite pleased with the out come.

    Sorry about the crappy phone pictures I think you guys/girls get the idea.

    :1drink:1drink:1drink
  6. Mezo

    Mezo Banned

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    Top job that man. :clap

    Mezo.
  7. LukasM

    LukasM Long timer

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    Looks like you already have the carrier sorted, but here are the pictures I promised you.

    Haan Wheels 640 carrier on the left (622 grams) and RAD Mfg 950/990 carrier on the right (930 grams):


    [​IMG]

    [​IMG]
  8. yamahaman

    yamahaman wannabe bike builder

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    Lucas that haan carrier is so sexy but there is a limit to what you can practically do on a manual machine (ie no cnc) you can do the same work but it takes soooooooo long. So certain short cuts were taken.

    [​IMG]

    All I have to do is order some heavy duty spokes and 2.5 rim lock, lace her up and there is one less job done.

    [​IMG]

    Also going to have to trim sprocket bolts to the correct length so they dont touch the hub where the spokes attach to the hub

    :1drink:1drink:1drink
  9. brucifer

    brucifer Long timer

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    Excellent! :clap
  10. yamahaman

    yamahaman wannabe bike builder

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    Have been busy putting my yz back together so there has been a little stall on the project never mind the rear spokes arrived today and laced into the rear wheel I am not sure if they are the right lengths. Time will tell when I get the wheel to the wheel builders to tension up.

    [​IMG]

    Just put the wheel into the swing arm to work out the correct offset

    I also finish welded all of the structural welds on the frame, not much to see here just a few more to go and the whole lot is ready to go for a final fitment.

    Next I will be starting on making the fairing for this machine modifying this one to make a mould.

    [​IMG]



    :1drink:1drink:1drink
  11. yamahaman

    yamahaman wannabe bike builder

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    Here is the original mask whick I am going to modify to fit my bike (mabey make some for wr 450/426 as well) here I have got it ready to seal up over the MDF to and braced the whole thing to ensure the mold/plug is going to stay still and not flex.

    [​IMG]

    A little bit of sealing and some wax no worries should be able to reproduce quite easily.

    Cutting welding and machining are my speciality not composites so this should be fun

    :1drink:1drink:1drink
  12. Geoff D

    Geoff D Tenerista

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    Superb job :deal
  13. yamahaman

    yamahaman wannabe bike builder

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    Well I have made some infill pieces out of mdf/craftwood to fit into the head light hole to fill her up and get it ready to make a blank copy.

    [​IMG]

    The whole reason for filling in the hole was so I could install a current model wr 450 head light in the fairing to make the front end look a little more modern and I have a few plans to try to mabey develop a wr 450 kit if there is enough demand. Most likley because of the nature of these, it may be a bit expensive due to the bespoke nature of the job and they will be a bit expensive. But I digress back to the pictures

    [​IMG]

    With the right amount of blending it may look alright lets wait and see if it looks shit I will can it and go to twin vertical headlights.

    give us your opinion!

    :1drink:1drink:1drink
  14. pennswoodsed

    pennswoodsed lizards,bugs and me

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    I love these threads , only seem to come from Oz? I am jealous , and it was 26 F here this morning. Minus 2 c or something.
    Regards,Ed

    ps not that the skills are here(me) either
  15. tileman

    tileman Long timer

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    I am in. Where are you in melb, I have a project and have a wr450 front light for it so.....who knows
  16. xlv

    xlv Been here awhile

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    Anything new, love to read more about this cool bike
    /M
  17. yamahaman

    yamahaman wannabe bike builder

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    I have been very busy and havn't done any thing I ordered some fiberglass material from a e-bay supplier and they have sent the wrong stuff to me so I have sent it back and have requested the right item be sent to me.:baldy So all I have done is put some final touches to the fairing and searching for some answers to some fiberglassing issues.
    [​IMG]

    Will keep you all posted on the progress as soon as it comes to hand
  18. alonimus

    alonimus n00b

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    :ddog ola ?!
  19. yamahaman

    yamahaman wannabe bike builder

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    Hello Guys and Girls
    I have been quite busy with my pregnant wife and some other domestic duties to post so im sorry

    I have been quite busy with preperations for a heap of work so I have been getting so instuction on fiberglassing and a few other bits and pieces. I had a near disaster on my yz I came home from work early to go on a club ride and I found that my shock had leaked its contents out onto the bike bench due to a damaged shock shaft cutting the head seal. I rang chad ( www.chadsoffroadsetups.com.au ) and I made some quick plan changes and went to see him at his new factory and he rebuilt my shock on the spot for me, what a champ, he saved my bacon.

    So I decided to check the shock on my project bike and low and behold there are a few spots of rust and a chip on the shock shaft. I decided to pull it apart and send the shaft to get re-hard chromed and while I was at it I decided to get some fruit on the bike. I got the shock body hard anodised in black and the two caps in red. Yeah I know but the anodising was only 40 bucks so why not.

    [​IMG][​IMG]

    So when the shock shaft comes back I will be straight back to chad to get it revalved and rebuilt and ready for my bike!

    In the mean time I will be getting some fiberglassing done and get some more pictures
    :1drink:1drink:1drink
  20. CodyY

    CodyY ADVenture Capitalist

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    sexy