what do you get if you combine and RS 125 and a 640 LC4???

Discussion in 'Some Assembly Required' started by muttley92, Mar 30, 2013.

  1. muttley92

    muttley92 Adventurer

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    This a a build thread for a supermono road bike, it's been done before but I've never seen a proper build thread. Several people have asked me for this so here it is.
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  2. muttley92

    muttley92 Adventurer

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    I should start by saying that I am 20, I live in the UK, I'm studying a masters degree in Mechanical Engineering at Loughborough university and this is something I'm doing for fun in my spare time.
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  3. muttley92

    muttley92 Adventurer

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    The engine came from ebay 2004 640 LC4 from a duke II, the bike is a 2009 Apilia RS 125 that was a cat B write off and it arrived in bits.
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  4. muttley92

    muttley92 Adventurer

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    This engine looks like it was made to fit in the Aprilia frame! The mounts needed filing down by about 2mm to fit in the swing arm, and I had to take a little off the front of the swinger for clearance. The earlier engine is easier to get in the frame (you don't need to do anything to the swing arm) just the bushes. It's tight, but it fits :D
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  5. Kawidad

    Kawidad Long timer

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    From the LC4 thread and I'm in. :clap
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  6. muttley92

    muttley92 Adventurer

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    I cut down the standard RS engine mounting plates and modified them slightly
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  7. pennswoodsed

    pennswoodsed lizards,bugs and me

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    A frame twisting mind bending wet dream ,and that's before it starts ! Subbed on the title value alone..
    Go for it ,Ed !
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  8. muttley92

    muttley92 Adventurer

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    It's not the best but I made it, it's mine and it will work :D
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  9. pennswoodsed

    pennswoodsed lizards,bugs and me

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    Hi,
    Your 2nd post ,engineering student so maybe this is dumb ,the front mounts are single shear on a butt weld ,I would want to spread moment above and below weld. Maybe.
    regards,Ed
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  10. Salsa

    Salsa Been here awhile

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    Or overkill !!!!!!!!!!!!

    Don
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  11. Droptarotter

    Droptarotter Long timer

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    I'm no engineer, but have been around these thumpers for quite some time and the front mount looks like a crack waiting to happen.
    Did you make the mounts just for a temporary hanger? Redo them later?

    Good luck with this...........it looks like it will be a nice combination once completed!

    Cheers
    #11
  12. muttley92

    muttley92 Adventurer

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    That was considered. It's 3mm stainless 304 on both sides, since the engine deadweight is only around 40kg max and majority of the weight is on the rear mount I think it will be just fine. But I'll keep an eye on it and if it should crack I'll find a solution.
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  13. muttley92

    muttley92 Adventurer

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    And many thanks to the Loughborough University Formula Student team for letting me use the lab and the weld set!
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  14. muttley92

    muttley92 Adventurer

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    Once finished the exhaust was difficult to fit so i modified it simular to the stock pipe
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    and i knocked up some rad mounts from the remnants of the standard mounts.
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  15. muttley92

    muttley92 Adventurer

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    All the standard fairings fit fine over the new engine, would make a hell of a street sleeper if the left hand side fairings were still in one piece!
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  16. muttley92

    muttley92 Adventurer

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    Since the existing bike was cat B, the DVLA in their wisdom dictate that it cannot go back on the road without being renumbered and passing a single vehicle allowance test (£140) So I opted for a second hand frame (£75) despite being told they are identical, in actual fact the swing arm bushes are 2mm different so they didn't fit... I had to order one for the earlier shape bike and that worked fine
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  17. muttley92

    muttley92 Adventurer

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    After the frame change I sorted out some cooling hoses to get it running on.
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  18. muttley92

    muttley92 Adventurer

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    Since the standard bike uses the front frame tube as an oil resevoir and probably as a heat sink I though it necessary to have some sort of oil box to bring the capacity back up and dissipate some of the heat.
    this is a cardboard mock up to fit nicely in the frame
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    and the stainless version
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  19. muttley92

    muttley92 Adventurer

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    The bike with everything so far fitted, though the plastic tank inside the cover fouled on the engine so will have to do something about that.
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  20. muttley92

    muttley92 Adventurer

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    Got some bosses on the oil tank to suit the standard lines.
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