Trans Alp

Discussion in 'Some Assembly Required' started by justplainray, Feb 13, 2010.

  1. justplainray

    justplainray ucancallmeray

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    Ok, I finally got around to opening a SmugMug account, so here's my Transalp re-build report.
    In the beginning there was a well used '89 TA


    [​IMG] [​IMG] [​IMG]

    A shout-out to PATrans for parting with this beauty.
    Now I just have to figure out how to format the photos.
    Stay Tuned...More to follow.
    JustPlainRay
    #1
  2. andreakassi83

    andreakassi83 n00b

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    cool...
    #2
  3. B DIRT

    B DIRT Long timer

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    your moms house startn a small fire in her panties
    :thumb
    #3
  4. locorider

    locorider Loco, pero no estúpido!

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    Great! Post them at the Show your Transalp mod thread:thumb
    #4
  5. justplainray

    justplainray ucancallmeray

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    So five hours later, I arrive at home with my "new" motorcycle
    [​IMG]
    Let's have a look-see, rusty exhaust...
    [​IMG]
    Melted mud flap due to crappy SuperTrapp, this will have to go...
    [​IMG]
    Worn-out chain and sprockets....
    [​IMG]
    This will require improvement too...
    [​IMG]
    Well, let's get down to business...
    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    More to follow...
    justplainray
    #5
  6. Nightrunner

    Nightrunner Long timer

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    Looks like a fun project. Congrats. Clean up that 'trapp and put it on ebay. They discontinued that one long ago. Someone will buy it.
    #6
  7. justplainray

    justplainray ucancallmeray

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    I will post the "good" technical parts in both 'Translp mod' thread and here in parallel, as I don't want to fill the mod thread with useless fluff. This thread will be the whole story, fluff and all.

    Stay tuned...
    justplainray
    #7
  8. justplainray

    justplainray ucancallmeray

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    I'm going to post this and other extra parts in the For Sale thread here on ADV, that's where all the mental cases shop.

    Stay tuned...
    justplainray
    #8
  9. justplainray

    justplainray ucancallmeray

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    What do I intend to do with this bike?

    Well, I wish to ride it to the ends of the earth, or at least the ends of this continent. I want to ride the White Rim Trail, the Continental Divide Trail, Trans Am Trail, Labrador Highway, and every gravel/dirt road I can find. (this is starting to sound like a bucket list)

    This bike needs to be; reliable, comfortable, low maintenance, long range capable. Should be light enough to pick-up un-aided, yet be able to haul a lot of stuff. I want to have plenty of fuel on board, (no loose gas cans, thank you) and I want a quiet, US Forestry Approved, BLM compliant muffler. And I want a bike that is "different".

    Well, you can't get much "different" than a 20 year old TransAlp, in the USA that is.

    So, let the re-building/customizing begin.

    First off, a ton of thanks to Jeff@the Quad Shop for directing me to the French E-bay for the Afican Twin fuel tank. Thank You.

    [​IMG]

    Also, thanks to the un-known XR400 owner who sold his brand new OEM muffler on E-bay for cheap. As you can see above, it makes for nice mid-line exhuast system after I fixed the dented front pipe and replaced the up-swept exhaust collector with a parallel merge collector. See below for before photo.

    [​IMG]

    And after.

    [​IMG]

    Some Hi-Temp ceramic paint inside and out...

    [​IMG]

    Why a mid-line exhaust instead of an up-swept? Well I plan to install aluminum panniers and I can't stand that "WIDE LOAD" look that having a muffler between a pannier and the frame causes. This muffler will live underneath the pannier, while the pannier will be as tight to the frame as possible.

    Well that's enough work for one night.
    Stay tuned...
    justplainray
    #9
  10. wide

    wide Been here awhile

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    391
    Cool use of an XR4 pipe. Are you cutting out its baffle and using a VW Beetle tip
    #10
  11. justplainray

    justplainray ucancallmeray

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    Please explain....photos??
    justplainray
    #11
  12. Transalp Jas

    Transalp Jas Been here awhile

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    Corner Brook,NL
    Justplainray- Getting nice real fast!
    What type of paint did you use on the headers?
    #12
  13. Ladder106

    Ladder106 It's a short cut, really

    Joined:
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    Hi JPR,

    Very nice work. Here are a couple of comments from someone else who's done the AT tank and other Transalp mods.

    First I'd like to see some close-ups of your center stand. Looks good. Did you build it yourself?

    With the large tank, I'd strongly recommend replacing the bottom Transalp tank side-panel mount with this part (the black bit)

    [​IMG]

    It's a direct bolt-up to the frame. It supports the tank from the bottom. Full of fuel (about 7 gal) the tank is a heavy bugger. Given your design parameters of wanting a durable go-anywhere machine (same as mine), I'd strongly recommend this mount. They are pretty easy to find on eBay/Germany and not too expensive. When dealing with a purchase from Germany it's best to be certain the seller takes PayPal (it's becoming much more popular there) since an International Bank Transfer can cost over $30.00.

    Pay particular attention to your front high fender mount. There is some - but not alot - of space between the lower triple clamp and the front tire at full fork compression. Be certain the stand-offs you've used to make the front fender clear the frame does not jam into the front tire when you hit the Big Bump.

    I like your lower exhaust mount. I used a pipe from a DRZ400. The Transalp ran fine with this pipe without needing to rejet or feeling like it was restricted. The XR pipe should flow about the same. I think other guys are talking about hacking up the baffles......your choice.

    I'm envious of your shop......enjoy the project.
    #13
  14. wide

    wide Been here awhile

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    With an XR4 tail pipe the very end chrome piece comes off but would make the bike too loud so the end piece has a peashooter pipe that goes into a fine mesh baffle and is very restrictive. Cut off the baffle and take out the pea shooter pipe, I think held in by 2 small screws.
    Then get part 7/8 on this link. I would guess you have equivalent VW suppliers over there
    http://www.vwheritage.com/vwh/VW-Beetle-Parts/Exhaust-Heating/Exhausts/
    , its a VW Beetle chrome tailpipe that fits directly into the void left from removing the peashooter part. Put the 2 screws back in and voila a cheap free flowing nicer sounding exhaust. Especially on a V twin:evil
    #14
  15. justplainray

    justplainray ucancallmeray

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    I used POR-15 Black Velvet
    http://www.por15.com/BLACK-VELVET/productinfo/BVG/
    inside and out, baked on.
    Hope it is half as good as they say it is.

    The tear-down pictures date from Sept to Dec 09.
    I'm actually in the reassembly stage right now.

    More to come
    justplainray
    #15
  16. justplainray

    justplainray ucancallmeray

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    Thank you for the advice, I have actually read the entire Show Us your Transalp thread and knew about that bracket. I welded one up out of the orignal backet and some strap iron. You can see it in this picture.
    [​IMG]

    Don't ask about the cardboard....that will be revealed later.

    Oh and the centerstand...I can not believe that someone would sell a motorcycle without a centerstand. That too will be revealed later.

    Stay tuned...
    justplainray
    #16
  17. justplainray

    justplainray ucancallmeray

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    I will look into that VW tailpipe extension, I thought there might be something missing from this muffler. The two screws are gone and I figured there must have been an "inner pipe", other wise why have the two welded nuts in place.

    Thanks,
    justplainray
    #17
  18. justplainray

    justplainray ucancallmeray

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    [​IMG]

    Have a Nice Day

    justplainray
    #18
  19. justplainray

    justplainray ucancallmeray

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    Well, I don't understand why any manufacturer would build a bike without a center stand. It is just beyond me. So high on my priority list was to design, fab and install a center stand. Studing the TransAlp frame I noticed there is a cross tube at the lower rear of the engine cradle. This tube is capped on it's ends with real thin sheet metal. After chiseling this off, I could see that the tube ID was 25mm and the tube was un-obstruted. This is where the stand would pivot.

    Here is a JPG of the 3-D CAD model.
    [​IMG]

    Here's the same view of the actual installation.
    [​IMG]

    First I fitted nylon flanged bushings into the frame tube (1" OD x 3/4" ID). Had to turn the OD's down to fit. The main pivot shaft is 3/4" OD x 11 1/4" lg with a 3/8-16 X 12" lg hex head bolt thru the center. The center stand itself is a weldment of 1/2" black iron pipe and 1/4" inch plate steel.

    I had to mill a notch in the left foot peg/kick stand weldment to clear the left side pivot plate, I over did it a bit as you can see in this photo.
    [​IMG]

    The right hand pivot is threaded 3/8-16 to accept the thru bolt and hides nicely behind the exhaust collector.
    [​IMG]

    When the stand is folded up, the cross bar is resting against the Pro-Link frame bracket, visible in the first photo.

    More to come...Stay tuned.
    justplainray
    #19
  20. 100mpg

    100mpg Self Imposed Exile

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    :lurk
    #20