DisTech's DR790 build

Discussion in 'Thumpers' started by DisTech, Mar 16, 2013.

  1. DisTech

    DisTech Been here awhile Supporter

    Joined:
    Sep 3, 2008
    Oddometer:
    658
    Location:
    Seattle
    Custom tubing bender mandrel cutting jig!
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    Tubing bender in action, start with unbent tube.
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    Finish with bent tube!
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    Yup.
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    Perfect circle! :norton
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    #61
  2. chasbo

    chasbo Long timer Supporter

    Joined:
    May 8, 2005
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    Prescott Valley, Arizona
    Fak! Brilliant idea to bend the tubing!
    #62
  3. Te Hopo

    Te Hopo Nomad

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    Excellent work, I'm enjoying watching your ingenuity.:clap
    #63
  4. Greg Bender

    Greg Bender Long timer

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    Oct 22, 2007
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    1,801
    Location:
    Cave Creek, Arizona, United States
    I'm 99% certain I have the correct replacement male terminals you'll need. If you want some, ping me off list, we'll verify, and I'll get you hooked up.

    Regards,

    Gregory Bender
    #64
  5. Mikey Boy

    Mikey Boy Been here awhile

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    May 9, 2011
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    Kalifornia
    Subscribed. This is such a great build. :clap
    #65
  6. DisTech

    DisTech Been here awhile Supporter

    Joined:
    Sep 3, 2008
    Oddometer:
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    Seattle
    Thanks guys. Thanks for the offer Greg. I have the correct connectors it's just the temporary splice where I used the crimp-on spades. When I know the actual length the pigtail needs to be they will be removed.

    Oh how I lust for a mill. Sawed/filed half slots on the edge and then welded these tabs together.
    [​IMG]

    Welded the circle together and looking at how the slotted tabs will connect.
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    #66
  7. DisTech

    DisTech Been here awhile Supporter

    Joined:
    Sep 3, 2008
    Oddometer:
    658
    Location:
    Seattle
    After some welding & grinding, welding & grinding, welding & grinding and more grinding the headlight frame is the shape I want it to be.
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    Side shot to see how the proportions work out, hard to tell yet.
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    Took the headlight frame to Seattle Power Coating today, get it back in a week.
    #67
  8. Boojum

    Boojum I Miss the PartyBoss

    Joined:
    Jan 7, 2004
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    Location:
    Ringgold, Ga.....Saaalute!
    Cool build Distech.......That bike is gonna be kick ass! :thumb :clap :slurp


    Boojum
    #68
  9. Dalmatino

    Dalmatino Been here awhile

    Joined:
    Nov 21, 2008
    Oddometer:
    672
    Location:
    Prison Planet Earth
    Shit, hurry up will ya...waiting is painfull :D

    Great build and fabricating skilllz man.
    It will be my turn next winter but in the mean time keeping an eye on these 790 builds. So far they seem kats ass...
    #69
  10. DisTech

    DisTech Been here awhile Supporter

    Joined:
    Sep 3, 2008
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    Seattle
    Yea, figuring out what the top bracket is slow business.

    But, hey! Seattle Powder Coating surprised me today when they called and said the headlight frame was done!
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    Gloss black, looks good!
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    #70
  11. ER70S-2

    ER70S-2 Long timer

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    SE Denver-ish
    Me too. :nod :D

    Ya know that once ya put pics on the internet, a photo pirate mite post 'em some where else, right? :augie
    #71
  12. Rainier_runner

    Rainier_runner Heh..?

    Joined:
    May 31, 2011
    Oddometer:
    376
    Location:
    Yelm, Washington
    How's the Renazco racing seat? I'm currently running the seat concepts, but am strongly considering the upgrade.

    And the project is looking awesome. Can't wait to here your opinions on the 790!
    #72
  13. deathu

    deathu Adventurer

    Joined:
    Oct 1, 2011
    Oddometer:
    77
    Location:
    Bucharest
    Hi,

    Thumbs up for the rebuild, I only hope I'll be able to do a similar project someday.

    Can you please explain how does your tube bender actually work? It seems very simple but I can't figure out how that model actually bends the tube, the principle...
    #73
  14. DisTech

    DisTech Been here awhile Supporter

    Joined:
    Sep 3, 2008
    Oddometer:
    658
    Location:
    Seattle
    I have a Sargent seat on my R11GS that is pretty nice, probably equal to Seat Concepts and put a Guts Racing tall foam and cover on the DR455 that is pretty good for the money, but the Renazco on the DR790 is the best seat I've got. Not sure how practical a choice black suede was, but I love it! Chris is in Ravensdale so I just drive my seat pans out there. :thumb

    Sure, what's probably confusing is the 2x4 attached to the side. It's only there to counter the leverage being applied to the vise while bending the tube. The tube was only 1/2" EMT, so really I am the tubing bender. I clamped the mandrel in the vise, stuck the tube between the bottom of the mandrel and jaw beam, wrapped the tube up around the mandrel with one hand and held the 2x4 with the other hand to keep the vise from tearing off my work bench. :lol3
    #74
  15. DisTech

    DisTech Been here awhile Supporter

    Joined:
    Sep 3, 2008
    Oddometer:
    658
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    Seattle
    Hrrmm... a hand brake would sure be nice.
    [​IMG]
    #75
  16. DisTech

    DisTech Been here awhile Supporter

    Joined:
    Sep 3, 2008
    Oddometer:
    658
    Location:
    Seattle
    I know everyone is probably sick of the nav tower, but I finally committed to drilling the spacer holes!
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    GPS platform.
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    #76
  17. Te Hopo

    Te Hopo Nomad

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    I'm not sick of it mate, I'm one of those guys who likes to read and see pics of every detail, especially when it comes to work as tidy as yours is. :clap
    #77
  18. Jimmy the Heater

    Jimmy the Heater Dirt Farmer

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    Location:
    Eastern Washington State
    Mistakenly thought this was the other 790 build that I had already seen. Opened it to make sure and presto, all sorts of wonderfulness!

    Excellent build and don't worry about overposting about the nav tower. Want to see everything that it takes!

    :clap
    #78
  19. AustinJake

    AustinJake DR650 - Versys

    Joined:
    Aug 20, 2010
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    6,642
    Location:
    Austin, TX
    /\ Those guys said it for me, I even subbed to your thread, thanks for taking the time to post your work!
    #79
  20. DisTech

    DisTech Been here awhile Supporter

    Joined:
    Sep 3, 2008
    Oddometer:
    658
    Location:
    Seattle
    Well aright then! Thanks for the encouragement. And now more nav tower!

    Gardgets attached!
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    Naked cockpit (that sounds so dirty)!
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    #80