Mutilating an offroader into some sort of scrambler

Discussion in 'Some Assembly Required' started by Dino de Laurentiis, Jan 7, 2018.

  1. Dino de Laurentiis

    Dino de Laurentiis Working on it

    Joined:
    Mar 20, 2010
    Oddometer:
    558
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    I have the intention of finishing most engine and chassis parts in a finish for which I believe the technical term is “murdered out”. In that vein, here’s some more parts in matte black.

    A fairly stained stainless exhaust is getting bead blasted.

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    Some poor welds on fitting for a lambda sensor and EGT sensor (not my fault though could just as well have been) was cleaned up a bit. Not sure if the end result was much of an improvement, honestly.

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    The flange for attaching the exhaust to the head was bent, I’ve straightened it out somewhat. I have a mini oxy-torch which is very helpful for jobs like this. Still a bit tricky when it’s not possible to remove without cutting up the pipe but I think it’s better than before at least.

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  2. Dino de Laurentiis

    Dino de Laurentiis Working on it

    Joined:
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    Also painted it with high heat paint, but the curing will have to wait for another day (likely will use a propane torch for that, quickest way to do it).

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  3. Dino de Laurentiis

    Dino de Laurentiis Working on it

    Joined:
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    I got some things in the mail today. Huge box.
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    The actual contents was less voluminous though.
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    I’ve been meaning to get the rear fender for a while, so I can start finishing the rear end. The fender I got is really long at 1000 mm, but it was only 10 euro more than the 600 mm length, so I figured why not have the extra length if necessary. Needs to be shortened substantially in any case, as witnesses by my test fit. I do want it to look longer than what’s fashionable at the moment, both for the old school look and because it’ll actually do its job as a fender better that way... it may look too big now, it obviously the whole rear end will compress a bit with the engine in the frame, and the angle of the fender is wrong now, since it’s too long. Also, the final rear wheel and tyre will be chunkier than the temporary item which is on right now. It’ll look better in final form, promise.

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  4. Dino de Laurentiis

    Dino de Laurentiis Working on it

    Joined:
    Mar 20, 2010
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    Ultima Thule
    Also in that huge box was a new rear view mirror. I know mirrors are super uncool but I kind of like to see whether there are any coppers behind when out and about (speaking from experience here). It’s really nicely made, super thin and the same mirror fits either right or left. I intend to keep it on the left side but only had the right lever fitted. The mirror itself is rather cool as it’s a glass less design. Instead it’s highly polished aluminium coated with some silicon dioxide or some such.

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    Finally, I also got (very slightly) started on the diffusers for the front indicators. That is, it’s a piece of transparent acrylic which I’ll mount in front of the diodes to help spread the light a bit. Obviously not E-marked but then again, neither is much of the rest the bike... Couldn’t cut anything due to the lateish hour and because the garage is in the basement of a residential building with some rather noise sensitive neighbour right above our workshop.

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  5. Dino de Laurentiis

    Dino de Laurentiis Working on it

    Joined:
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    Chopped off a good sized chunk of the rear fender. I think something like this will be better, but I need to finish the rear hoop on the subframe before I start making attach points for it.

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    I also gave the indicator diffusers a go, but I think that the plastic isn’t acrylic like I thought but rather some other plastic, possibly poly carbonate since it’s very bendy. In any case I had trouble thermoforming it, I mostly got some nasty bubbles on the surface despite low heat on the heat gun, I couldn’t achieve much of a proper bend at all. Will get some acrylic instead and try more with that.


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  6. Dino de Laurentiis

    Dino de Laurentiis Working on it

    Joined:
    Mar 20, 2010
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    558
    Location:
    Ultima Thule
    Fear of Covid kept me away from the garage for a while but since Sweden is like he only country in the world not in full lockdown at he moment, in the end I couldn’t stay away.

    Have been working a bit on finishing the subframe. I wanted a hoop at the back, and it is possible to buy ready made hoops but not with the radius or thickness of the tubing that I wanted, so I had to make my own. We do have a pipe bender in the workshop but it’s kind of shit and not usable if one wants to bend a pipe to a certain radius since it’s not possible to fix the pipe in place, so had to jury rig it with a ratchet strap for it to work.

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    Not possible to make a complete 180 degree bend, so had to make two 90 degree bends (pipes filled with sand to keep tuve from buckling). First try I didn’t get bend that were even, but by marking the pipe and pushing through an equal distance each bend, I managed to get a couple of fairly equal bends.

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    Just loosely stuck in place here, but welded on later (absolutely awful welds, good thing the hoop is non critical).

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  7. Dino de Laurentiis

    Dino de Laurentiis Working on it

    Joined:
    Mar 20, 2010
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    558
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    Ultima Thule
    Although, it won’t be used for quite some time, I’ve also bought a new exhaust from China.im sure it will be perfectly suitable for a 790 cc thumper?! Predictably, it was shall we say, sparsely packed out of the box.

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    The perforated pipe ends before the reverse cone, so in an effort to get a little bit more noise dampening, I fabricated a perforated piece of tube at the very end. Start with one piece of sheet metal. Drill lots of holes in it.

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    Bend it by hand and end up with an uneven piece like this.

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    Massage it with the help of a piece round tube, and a mig welder and you get something a bit more presentable.

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    Finally, tack it onto the end piece of the pipe, like so, which also gives you a way to attach a dB-killer, as it’s not overly restrictive from the outset...

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    Finally, repack the muffler with Acousta-Fil (stock packing material show for reference...), and you get a hopefully more effective muffler. The acousta fil fabric is supposed to expand when heated, to fill the entire volume. I also stuffed some of that in the reverse cone part. Can’t hurt, right?

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  8. Dino de Laurentiis

    Dino de Laurentiis Working on it

    Joined:
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    For the longest time, I wasn’t sure how to go about making the seat pan, but in the end I settled for the simplest possible way, a flat sheet of stainless (which I got from a girl I dated a while ago, nice girl huh?). I’ll have it rest directly on the frame rails, with the help of some rubber cushions (rubber stock on order).

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    I also lowered the tank 20 mm. Not totally sure I like the result though, it gets a bit goose necky around the headstock. It does meet the subframe better though. Btw, I can’t really push the tank, as it the fork legs would touch if so. In fact, already as it is, I need to make a new steering stop.

    before:

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    after:

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  9. mentolio

    mentolio King of the island of unwanted toys...

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    Looking good...also loving that ol' Zephyr 1100 in the background. Great bike, that one!
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  10. Dino de Laurentiis

    Dino de Laurentiis Working on it

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    Ultima Thule
    So I made another piece. All done with an angle grinder and a hand file. Anyone care to guess what it is (not so difficult I would think)?

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  11. Gedrog

    Gedrog 1000 mile stare a 1000 stories to tell

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    part of a steering stop
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  12. Dino de Laurentiis

    Dino de Laurentiis Working on it

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    Indeed. This mounts on the lower triple tree and hits a protruding tab on the steering head. With the cx500 tank I now have on, i couldn’t use the stock laser cut stainless part so had to make this one in mild steel instead. At least this one has double the thickness where it hits the tab compared to the stocker. Will add some lightness to it too.
  13. Dino de Laurentiis

    Dino de Laurentiis Working on it

    Joined:
    Mar 20, 2010
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    Location:
    Ultima Thule
    So I’ve made some small things but nothing worth updating. Like, I needed to do some reinforcements to the front tank mount, I’ve also done up the little rubber cushions for the seat pan, and I’ve attempted to start doing the headlight brackets but never seem to get around doing anything concrete.


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    Mostly though, I’ve been obsessing with how to make the rear mount for the fuel tank, and having trouble finding a good solution that incorporated mount points for everything I needed to fit (seat, tank, electronics plate, all in the same space basically). Initially, I tried to preserve the stock tank mount of the CX500 tank, so I made a simple bracket of a piece of 3 mm steel “band”. I was never very happy with it though, both because it was crude and because it created a big space between the front of the seat and the back of the tank. I’ve been going back and forth and trying to come with various contraptions mock-ups, but none that seemed to make sense or to work at all. In the end, I started by cuttting down the bracket on the tank to make it protrude less. I’ve cut it down in several steps and now the only thing that remains of the stock part is the hole for fitting the rubber grommet. I’ve also made a new way to mount the electronics plate that is a little neater (counter sunk screws from the side, instead of have that somewhat awkward tab resting on the top of the old tank mount.

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  14. Dino de Laurentiis

    Dino de Laurentiis Working on it

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    Finally, the tank bracket was forward enough that I could create a bracket that is hidden completely under the tank, with only a small tab protruding. It also integrates quite nicely with the electronics plate and the the new attachment brackets for that on the subframe. Of course, once I was almost done with it, I realised that it no modification of it will make it possible to fit the CDI unit in its intended location so I’ll have to make a new one with a wider space between the pillars. At least now I know how.

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  15. CaptainUnsociable

    CaptainUnsociable Adventurer

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    Jul 18, 2018
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    Lincolnshire
    Your're doing a great job mate - My CCM 604 is now a road going tracker, been following yours for a while now!

    Your sub frame is loads better than mine - mine is aluminium bar bolted together.... Looks horrific :)
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  16. Dino de Laurentiis

    Dino de Laurentiis Working on it

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    Ultima Thule
    Thanks mate, much appreciated. It’s taking it’s sweet time to get this one done, but I’ve now sold off my Ducati SuperSport so until I’ve finished this one, I’ll have no ride. Hopefully will make motivated enough to finish this one! Still a “when it’s done” kind of project though.
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  17. Dino de Laurentiis

    Dino de Laurentiis Working on it

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    So with tank mount bracket Mk2, the CDI fits. As usual, when doing something twice the second time is not only fast but also better. Still some bits to finish though.

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  18. h0lger

    h0lger Adventurer

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    Tallinn, Estonia
    You should check on your dog he/she hasn't moved for a long time!
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  19. Dino de Laurentiis

    Dino de Laurentiis Working on it

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    Yeah, it’s ok. I keep him turned off when I’m in the garage.
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  20. Dino de Laurentiis

    Dino de Laurentiis Working on it

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    So some things have been done with the bike which I’ll get to in a bit but until then, i just wanted to share some photos from my vacation in Spain this summer (2500 km road trip, though in cage). Mostly by chance, we stumbled upon this motor themed museum in the northern end of Extremadura (which is beautiful btw), in the town of Hervás. I haven’t got much info about the owner but it’s a private individual which some very specific tastes. The museum is BIG, I think they have around 300 vehicles there, mostly from the 20s to the 70s. Motorcycles, cars, horse carriages, and even some vintage strollers in a pavilion themed “the first and last modes of transportation in life” (the other side of that pavilion was full of hearses ). The whole museum has a very peculiar architectural style,a bit of gnomish village feel to it… The town and its surroundings are also gorgeous and there’s even an abandoned medieval village nearby, with castle and stone walls and everything still intact. Should you ever find yourself in the neighbourhood, I totally recommend a visit.

    https://www.museomotoclasica.com/

    Attached Files:

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