Harrys R S/2 Conversion Build

Discussion in 'Airheads' started by black knight, Nov 1, 2020.

  1. black knight

    black knight Long timer Supporter

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    thumb_IMG_8030_1024.jpg thumb_IMG_8029_1024.jpg thumb_IMG_8028_1024.jpg thumb_IMG_8027_1024.jpg ~
    Taking Great Note, From Ados 's sweet /2's , yep on 3 that I've seen from him, I took to heart having a lockable Aux. Tool Box as a good thing. Showing his 2/3. ados vergison
    So I looked on fleesebay and finally found what I hoped would be a good acceptable candidate . It came w/o a lock and those are easy to find. - - - - Be sure that the lock is a ' DUST PROOF ' type . Add graphite to the cylinder for ease of operation. It was still many hours yesterday to adjust the cam lock bar so that it fit snugly. No bolt -on easy task, lots of fabrication -+- materials & shop time ~ ~ ~ ~ ~ ~ ~ ~ > Make Extra Keys !
    Some were $200- 400.oo range for original to specific bikes. Well that won't do @ all. I didn't pay near that for mine. I'm going to weld holes, attach anchor plates, seal it and when close to paint, seam seal the interior and body putty the exterior for looks & fabricate a back bracket. . . . . . . .
    Then paint & Pin stripe it at the correct time, long after I've handled it over & over.
    So here is the preliminary work and basic fitting. Since I don't have my Frame ... [ it's @ a shop getting checked over for trueness ]. ... I'll have to wait until it and the hybrid swing arm is back & fitted, before this work can complete.
    Yes, some may notice that the lock is down, it fits the frame better this way. Mostly found on Brit bikes, these aux. boxes are handy & useful. Depending on the aux. tool box you find , like Ados' the lock is up. There are ways to make sure all tools won't just dump to the ground when opened. It will be held to the frame by 3 round coupler nuts, which will be frame drilled / inserted/ welded in situ to the right side LooP . I have plans to add almost 16-20 coupler nuts for all that I will attach to this R50SS~80/2C machine . - - - see yellow tape on frame.




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  2. black knight

    black knight Long timer Supporter

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  3. Pokie

    Pokie Just plain Pokie.

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    If you are going to use the stock handlebar clamps, I wouldn't put the cross bar on. Mind you, the cross bar does give a good place to mount things.
    18415 likes this.
  4. black knight

    black knight Long timer Supporter

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    thumb_IMG_5084_1024.jpg thumb_IMG_5281_1024.jpg thumb_IMG_5282_1024.jpg thumb_IMG_5283_1024 2.jpg


    does this answer your statement . this is 1 / 10 special top plates made some 12-15yrs ago. this is the last uno. I have also made my own top plate cap screws.

    14B5ACB1-9AFF-4C34-8F75-62E5D90C44C5_1_105_c.jpeg
    .
    Pokie likes this.
  5. black knight

    black knight Long timer Supporter

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    16 11 4 080 165

    Gas Tank Tool Box Threaded Lock – SCREW
    $10.52…


    16 11 4 080 172
    SQUARE Lock Thumb - WRENCH
    $14.08

    Tool box key

    square  toolbox key  1  .jpg square  toolbox lock  1 .jpg thumb_IMG_6972_1024.jpg thumb_IMG_6975_1024.jpg
  6. black knight

    black knight Long timer Supporter

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    NOW ! ! ! ! ! !

    That My R50SS Frame is back home from the frame doktor & the Earles fork, getting a straightening check up, I am so ready to get started on her.
    I have this idea in the back of my mind ever since I started this build that the frame is Soft thin metal. She Sure IS ! ! !

    drilling a hole to ap a thread leaves one to wonder ~ This just AIN'T going to hold work shit 3months 3 yrs, 30 years from now. SO !! ! ! ! My ideas was using Coupler nuts. Belmetric makes the round type which is perfect .

    Buy the quantity an size needed

    b4 welding a blind hole - - - - - vs. a drill thru frame. you'll need to close off the end that's inside the frame. you DON'T want any water going inside the frame. I use a BB or a steel ball bearing that gets based to the end.

    Buy a precise # drill undersized and - Drill a hole. Clean the area that gets drilled. Remove the zinc plating off the coupler nut. Drill . . . . . . . . Hand [ rat tail ] file or ream it so that the inserted coupler nut is a tight fit. add a drop of weld then braze the rest. Clean the threads so they are clean.

    Now you have a point of attachment you never had before. In some cases , I'll only drill thru one side of the frame.
    In other cases , I'll drill thru the frame and have 2 points of attachment.

    I have planned 17-22 coupler nuts for my build.
    sizes 4mm , 5mm , 6mm , 8mm

    6 = fairing .
    3 = aux tool box .
    2 - 4 = Craven Luggage .
    4 = aux electrical offset panel .
    1 = ground .
    2 = seat shock base .
    2 = handle bars .



    Once the frame is blasted then painted or powder coated you really won't see these things at all.
    As for the fairing where the whole ideas came to be was ' HOW do I attach the fairing to the frame with OUT those ugly U brackets and vinyl tape bull shit.

    will the purists like me, I DGAS - I DGAF




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    I'm just gettin started .......... more later



  7. black knight

    black knight Long timer Supporter

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    Now moving along . . . . . . .

    the new Dual - 11.8" HD Rotors already mounted to the wheel ... waiting for a 'mock-up to apply to and with NissiN / Honda 2 pot calipers and my spare /6 19" wheel .

    I usually ' Pattern Make ' all brackets so this is another example of mark MK #, 5, 7 or 8

    3/16" strap - this is specifically made long so as to get welded past the AXLE piece not just the swing arm - arm.
    I sure don't want any failures there.



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  8. Pokie

    Pokie Just plain Pokie.

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    It's your bike, to do as you please. DGAFF for those that disagree!
  9. Arktasian

    Arktasian Feelin the BMEP

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    That cat seems to be going over your numbers, not sure it agrees with the changes.
    black knight likes this.
  10. black knight

    black knight Long timer Supporter

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    :ksteve:p3rry:jump

    It is ABSOLUTELY ESSENTIAL That the bracket extends forward and gets WELDED to the front axle Earles fitting so there are no Earles Fork Weld Failures

    :clap:clap:drif
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    Almost read to get the axle spacers made and turn down the axle as needed . make 4 more round spacers to weld to the 2 brackets to space the caliper correctly & squarely centered .



    .
  11. black knight

    black knight Long timer Supporter

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    FF372449-BF09-45E4-84DD-194FE0D344CD_1_105_c.jpeg 53768416-4405-4065-B984-60FF98FA9B76_1_105_c.jpeg :ksteve:p3rry:jump

    It is ABSOLUTELY ESSENTIAL That the bracket extends forward and gets WELDED to the front axle Earles fitting so there are no Earles Fork Weld Failures

    :ksteve:p3rry:jump

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    rat tail file a GROOVE into the bracket to fit the Earles weld



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  12. black knight

    black knight Long timer Supporter

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    00C40549-7533-41BB-BC07-93189FBF196B_1_105_c.jpeg HYBRID Swing Arm Welding & Drive shaft

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  13. black knight

    black knight Long timer Supporter

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    HYBRID Swing Arm Welding & Drive shaft
    All welded on a super Jig ....


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    .
    .
    A Jig was used to align the old style swing arm to the grafted later style FD piece. making sure all was aligned perfectly and has the correct length. welders know that there is movement during welding in the heated area vs. that which hasn't been heated. Since this takes multiple passes from different angles and the jig needs re-positioning our the welding, cooling start in.

    because it's held in the JIG the tendency for change is minimized greatly.

    .





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  14. Pokie

    Pokie Just plain Pokie.

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    Looks good! Keeping the rear axle and rear drive in the right place and square is the biggest problem.
  15. black knight

    black knight Long timer Supporter

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    .
    .
    A Jig was used to align the old style swing arm to the grafted later style FD piece. making sure all was aligned perfectly and has the correct length. welders know that there is movement during welding in the heated area vs. that which hasn't been heated. Since this takes multiple passes from different angles and the jig needs re-positioning our the welding, cooling start in.

    because it's held in the JIG the tendency for change is minimized greatly.

    . 9311A832-6DB2-433C-BD90-F165BAEE7A22_1_105_c.jpeg

    .
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  16. Arktasian

    Arktasian Feelin the BMEP

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    “Super Jig” - are you referring to the swing arm fabricating, or positioning of the U Joint caps for spot welding?
  17. black knight

    black knight Long timer Supporter

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    read above .....

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  18. black knight

    black knight Long timer Supporter

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    sometimes it just takes a revision. so back to my design drafting board in the shop. I went thru 15 versions of what ,ay be best for my needs.

    this is ................ MK #12 It really is important to have the bracket extend forward to weld to the Earles circle weld front attachment when attaching disc brakes to an old bike. it's added safety .

    When all is buttoned tight I will SS safety wire the 4 bolts to the F~4 brakes @ the tiny hole.


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  19. black knight

    black knight Long timer Supporter

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    1,028
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    Scott in Missouri likes this.
  20. black knight

    black knight Long timer Supporter

    Joined:
    Dec 2, 2009
    Oddometer:
    1,028
    .
    .
    Making a perpendicular twisty to a parallel twisty.

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