My Bike Build

Discussion in 'Some Assembly Required' started by XCgeek, May 8, 2013.

  1. XCgeek

    XCgeek Adventurer

    Joined:
    May 2, 2013
    Oddometer:
    62
    We have a roller! Well almost.

    I finished painting the rear suspension linkages so I could assemble the frame fully (then I promptly damaged the paint!). Action is good but there feels to be too much rebound damping even when fully backed off. I have not set full air pressure yet though as the mounts to the frame are only tacked on.

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    I tacked on those mounts while fully assembled to ensure they ended up in just the right place regardless of weldment movement, heat distortion and shoddy workmanship. Worked out well.

    I have also started working with some aluminium. Made up a rear disk caliper mount that is press fit on one of the hub spacers and will have a spot of weld on it later once disassembled. It engages with a nut on the other side of the chain tension bolt to stop rotation

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    I also turned up the hub spacers (love using aluminium in the lathe) and made the snail cam adjusters.

    I then made up some new front engine mounts cause I was not happy with the stock Honda ones weight. Honda = +500grams. Mine = 108grams. I know that isn’t much mass savings but if I want to hit 55kg total, every little bit counts.

    Now I have the engine fitted so I can check chain alignment, chain slider position, will need a couple of chain rollers etc.

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    While I have it at this stage, I will also modify my exhaust and re-route it through the frame. Hopefully that will make the next post.

    Oh, and why only nearly a full roller? Just the rear axle. Currently there is just a length od threaded bar in there so I need to make up a rear axle.
    #61
    MotoPolo, smilin jack and Pezz_gs like this.
  2. Marco Moto

    Marco Moto Voyager

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    Nov 14, 2008
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    1,550
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    Tuscany and Michigan
    Want! Nice work!
    #62
  3. Honkey Cat

    Honkey Cat Tailights Fade!

    Joined:
    May 5, 2011
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    Sarasota, FL
    Omg, jealouse and ill take one.
    #63
  4. jesusgatos

    jesusgatos fishing with dynamite

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    on the road
    Looks great.
    #64
  5. Te Hopo

    Te Hopo Nomad

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    Sep 25, 2007
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    Marlborough, New Zealand
    Super super cool work man, it looks good and your objectives sound like a fun bike to me. :clap
    #65
  6. MitchG

    MitchG Iron Collector

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    Apr 21, 2012
    Oddometer:
    663
    Location:
    Fort Simpson, NT
    Love the build, but can't wait for the scale when finished!
    #66
  7. anonny

    anonny What could go wrong?

    Joined:
    Mar 20, 2007
    Oddometer:
    6,654
    Location:
    Beautiful Revelstoke BC
    Impressive! Whats the steering head angle? Mine will need to have room and mounts for a Sherco 2.9 motor :lol3
    #67
  8. smacka

    smacka Tripper head

    Joined:
    Oct 13, 2005
    Oddometer:
    58
    Location:
    Brisbane Bayside
    You made those snail cam chain adjusters!!!:eek1
    Damn nice work. Cannot believe you are fabricating this bike under a quickshade in the front yard and bolting it together in the lounge room.

    Most excellent work Sir:freaky
    #68
  9. clintnz

    clintnz Trans-Global Chook Chaser

    Joined:
    May 17, 2004
    Oddometer:
    4,801
    Location:
    Rotoiti, North Is, New Zealand
    learning to TIG weld on small tubing is like a bloke learning to pick up chicks in a lesbian bar I reckon. :lol3

    Nice work!

    Clint
    #69
  10. sailah

    sailah Lampin' it

    Joined:
    Aug 12, 2005
    Oddometer:
    7,075
    Location:
    Turning expensive metal into scrap
    Just start with the fatties first, the skinny ones give you all the trouble...:deal

    I was talking about tubes btw sickos
    #70
  11. clintnz

    clintnz Trans-Global Chook Chaser

    Joined:
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    But they are pretty satisfying when you get them nailed :evil

    I'm working my way down, made a couple of things out of .065 4130 tube, the most recent project was .049, will try .035 next :wink:

    Looking forward to further updates on this build. I'd love to have a go at building a frame one day, & looking at XCgeek's 'workshop' vs what I have, I clearly have no excuses :lol3

    Cheers
    Clint
    #71
  12. tileman

    tileman Long timer

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    Mar 15, 2007
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    Location:
    Melbourne, OZ
    I tried to make some supertrapp copies. started with .028 (.7mm). The results were.....um.... not great.

    But my 1.2mm .049 got heaps better!!!!!

    Either way this thread and build is just inspiring. Since it seems that your mitre's are pretty close to the adjoining part maybe fusion weld it. I've had success with it. I admire what your doing and the updates are thorough and of major interest. Thanks for sharing. :clap
    #72
  13. MrPulldown

    MrPulldown Long timer

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    Porbably made those snails with a hand drill and a hacksaw/jigsaw.

    Impressive indeed.
    #73
  14. jesusgatos

    jesusgatos fishing with dynamite

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    Oddometer:
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    Location:
    on the road
    Doing more with less. There's a thread over on pirate4x4 about these metal fabricators in India that do some amazing work. In the dirt. In sandals. Love that shit.
    #74
  15. XCgeek

    XCgeek Adventurer

    Joined:
    May 2, 2013
    Oddometer:
    62
    The weather here in Melbourne has sucked for the past couple of days. Well, it sucks if your work space is a 3 x 3 quick shade.

    No matter, I set the exhaust up.

    I bought a DRD exhaust that is specially made for hotted up XR100s like mine.

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    The DRD is manufactured to bolt straight up to an XR100 frame of which my frame bears no resemblance.

    I also wanted to take the opportunity to try something different. I want to point the exhaust gases straight to the ground. There are probably some very good reasons why this is not done but I am really enjoying finding things out by trial and error.

    My proposed setup is obviously going to be significantly different to the XR. I can’t use my tube bender to re-bend the exhaust tube because the bend radius is way to big. My bender will bend the header tube but the silencer tube is a bigger diameter which I can’t fit in my bender.

    So, I bought some stock Stainless Steel bends.

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    I slightly modified the shape of the header with my bender. Worked OK.

    I hacked up the DRD silencer and put this together. Fits pretty nicely.

    [​IMG]

    The exhaust comes with a mesh spark arrester. I plan to add a second mesh screen just to be sure since I am going to be directing any sparks straight to the ground.

    My hope with this setup is some noise reduction when on dirt. I expect it will be a good bit louder when in hard ground like concrete but this bike should not see a little concrete.

    As an aside, I was planning to get an exhaust shop to build the exhaust for me but thought I would give it a go. The stainless is quite thick (this is Australia, we have limited product available) so it turned out to be pretty easy to weld as can be seen. I also ran a purge stream of Argon to the inside of the tubing to improve welding and longevity of the welds

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    I have also been working on some other bits; foot peg mounts, oil cooler mounts and starting the fuel tank.

    More soon.
    #75
    smilin jack likes this.
  16. aposaric

    aposaric Garden mechanic ;-)

    Joined:
    Jul 6, 2007
    Oddometer:
    270
    Location:
    Zagreb, Croatia
    Well you really managed to centralize the mass of the bike with this setup. Where do you plan to put your fuel tank?
    #76
  17. XCgeek

    XCgeek Adventurer

    Joined:
    May 2, 2013
    Oddometer:
    62
    Fuel tank will be in the typical location up front. Have been thinking of running a duel tank setup with the second tank in the subframe but that wont happen on this first one. Fuel tank is not even 2 gallons so not so much weight.

    #77
  18. haystack

    haystack Just ride

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    :lurk
    #78
  19. cedric

    cedric Been here awhile

    Joined:
    Nov 7, 2006
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    278
    Location:
    Calgary
    Any hints on how to find that thread? I went searching but couldn't find it. Sounds interesting.

    Great project by the way, I'm following along with interest.
    #79
  20. MrPulldown

    MrPulldown Long timer

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    Curious how that exhaust turns out. Experience ( in cars) would lead me to expect more noise. Exhaust noted hitting the ground bounces back up and is loud and drones. Cod be different on a bike.
    #80