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:
    561
    Location:
    Ultima Thule
    Among other things, I’ve been working away on the seat pan, but I think I inadvertently may have revealed the soul of my bike build in the process?

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    -Edit- i catn spel
    sruss67, Kai Ju, Fast Idle and 3 others like this.
  2. Dino de Laurentiis

    Dino de Laurentiis Working on it

    Joined:
    Mar 20, 2010
    Oddometer:
    561
    Location:
    Ultima Thule
    So, first things first. Initially, the idea was to keep it simple and make the seat pan out of some flat 0,8 mm stainless steel, and just have it rest on some supports between the subframe rails.

    Problem no 1: I initially had the rear tank mounting bracket in a different position (more to the rear) which with the new forward mounted bracket in place meant that there’s was a quite large gap between the rear of the tank and the seat pan. To cover this gap, I made an extension as an integral part of the seat guiding “pin”, which was also made out of the 0,8 mm stainless (because I had it around), attached with blind rivets. Of course, to get the shape right, I initially made a couple of CAD templates. Worked out ok.
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    Before attaching seat pan and bracket, I figured I’d bead blast both parts because XF the were by then quite stained from oil and grime and dirty paw prints (seriously, the steel industry marketers are so dishonest, it DOES stain!!!).

    Now this is when I realised that thin sheet metal and bead blasting doesn’t necessarily combine very well, so both parts came out of the blasting cabinet severely twisted. Turns out that the pressure of the bead works the metal and causes it to curve. Had no idea. The seat pan was basically impossible to make flat again but, sometimes when life gives you lemons etc. So, instead I used this effect by shaping the seat pan in a slightly curved shape, both giving me space for the fender and making the thin sheet somewhat resistant to bending. Seem to have lost most of my pics of that but the end result was something like this.

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    Now, the seat obviously needs some attachment to keep it in place, so I also made this bracket for the seat lock (the lock is off a Kawasaki W650), with a keyless opening mechanism. Of course, I needed to make one version as a sacrifice to the gods of metal.

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    The second version turned out better. The lock mechanism even seems to work, even though I had to make a second, correct version of the latch bracket after the first sacrificial version. The first version worked well enough but was welded on, so when in place on the bike, I couldn’t fit the actual latch. So, in Mk2 the latch bracket is now attached with a couple of bolts.

    Btw, the holes in the bracket parts aren’t because I’ve caught the same bug as waylongway but rather to accommodate a few plug welds (although in hindsight, the holes should’ve been a bit smaller).

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    finally a longitudinal stiffening bracket to make it more rigid… obviously also had to redo it once to get it right.
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    JimVonBaden, nuggets and BergDonk like this.
  3. Dino de Laurentiis

    Dino de Laurentiis Working on it

    Joined:
    Mar 20, 2010
    Oddometer:
    561
    Location:
    Ultima Thule
    other than that, I also modified the foot peg brackets to accept my 30 USD Chinese foot pegs (which seem REALLY good quality) instead of the crude stock pegs. Needed to cut off one side, fixate it with a long screw and a couple of nuts, and then applying lots of weld.

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    Now, maybe you’re wondering why one of the pegs are missing some of the pointy bits in the rear. Yeah, so was I but it turns out someone in China actually made some serious thoughts about that feature. It’s to prevent the sharp points from cutting into the brake master cylinder in the event of a very severe side way lean! And just by chance, it fitted my bike like it was made for it (it certainly isn’t, it’s for some small cc moto crosser I think).

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  4. Dino de Laurentiis

    Dino de Laurentiis Working on it

    Joined:
    Mar 20, 2010
    Oddometer:
    561
    Location:
    Ultima Thule
    Nothing much to report with the bike, we’re in the process of relocating the workshop in the garage so that it’s NOT situated directly under the ground level apartment in the residential building from which we rent our place (350 sq m space, 16 people sharing). It’s a bit of shuffling pieces around to make room for new construction, and refurbishing of some surfaces while we’re at it. Adding some sound proofing as well with double gypsum boards on one outwards facing side and OSB+gypsum board on the workshop side, so as to not have to find the exakt location of the wall studs (by trial and eror usually…) when mounting stuff to the wall.

    We’re all a bunch of construction amateurs but at least it seems the wall has stayed up. Still waiting for a double pane door to be delivered and installed.

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    Oh yeah, we also threw out some of plastic floor tiles we had used in some places (a kind of open mesh, perfect for trapping small screws, circlips and lots of gunk). So much oil underneath that we almost feared a US intervention, but a combination of lots of elbow grease, oil absorber and biological oil cleaner seem to have saved us. Whatever was left is now hidden under a shiny coat of paint…

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    I kind of like the look of the place now that all bikes are squeezed together btw.

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  5. Dino de Laurentiis

    Dino de Laurentiis Working on it

    Joined:
    Mar 20, 2010
    Oddometer:
    561
    Location:
    Ultima Thule
    I present to you my latest project; a race bike. This demon of speed pushes almost 50 km/h, and can almost stop when using the brakes (and yes, for once the lack of red tape was an actual annoyance).

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  6. Wildebeest90210

    Wildebeest90210 Long timer Supporter

    Joined:
    May 24, 2013
    Oddometer:
    5,606

    MOOSE ?
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