Projekt Husaberg Återuppbygga - Swedish for "Only idiots rebuild an acceptably running moto"

Discussion in 'Some Assembly Required' started by canadius_maximus, Dec 3, 2017.

  1. canadius_maximus

    canadius_maximus Quaere verum

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    Final fit check before finishing the fairing mounting hardware points and the from-scratch quick release.

    I think they’ll work ...
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    #21
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  2. canadius_maximus

    canadius_maximus Quaere verum

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    Ok. Sticking a fork into it. The fairing and tower, that is (except for vinyl finishing). Fab work is done. Once the wiring harness arrives, I’ll finish the wiring.

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    Oh. And temporary ghetto labels will be replaced with a nice old school Dymo set. Need to find a buddy who still has one of those old raised letter label makers. A nice blue set, reminding me of how we’d mark equipment in my Cold War army days. Why not a modern label? Because. That’s why. :lol3
    #22
  3. canadius_maximus

    canadius_maximus Quaere verum

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    OK - it's been ages since I posted to the build thread. Project was shelved for a long time due to lack of time after work and other life priorities.

    But it's 99% done. Chased down and solved a host of electrical issues, including a rear brake switch that masked the issue as electrical, when it was really a worn/defective pressure switch.

    Redesigned a new cleaner, less convoluted fuel delivery system from the two tanks (3 taps total). Doesn't sound hard, but there's a lot going on around the carb by the time you've routed the carb hoses well clear of the exhaust, left enough room for access to the hot and cold start buttons, and reoriented the fuel inlet.

    The result looks good, though there's a few unavoidable "high" spots in the line, there should be minimum "dead" or unuseable fuel, at least compared to the original condition, where there was the fuel line to the rear / underseat tank ran quite high, and thus overcame the gravity feed at lower tank levels. The previous owner had a clever pressurization technique where the vent hose on the rear tank could apparently be used in reverse - he'd blow into it to push the fuel up and over the dead spot. I'll install a new vent hose and play with it.

    New fuel hoses:


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    Took it for a quick spin around the neighborhood. Here's Minion, after his first post-rebuild run, before being put to rest for the night.

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    I left a few things unmounted such as skid plate and side armour / guards to make it easy to check for any leaks. So far, so good. Will put last few bits of armour, handgaurds, etc. on later this week, I have new tires and tubes waiting to be mounted - likely over the upcoming weekend - and then sneak a few days of fall riding in before the season ends for good.

    cheers,

    cm
    #23
  4. canadius_maximus

    canadius_maximus Quaere verum

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    CBC0B1B2-4A76-47F0-85E9-CA04FDCA4B2F.jpeg 797D2D17-52D2-4742-B35E-1CE338AA5E30.jpeg BE7648CE-A5CE-4F8E-904C-293C853573C3.jpeg B99607B3-4E11-4E9A-A477-F0736A0F5DAC.jpeg CF9E9D0D-901F-47EC-A7CB-9A13DE1CD14D.jpeg A25A23B9-8D3E-47DE-ACF8-9DF3B9B6ED3D.jpeg E408D1B4-C455-4685-AFDE-9A428C721CDC.jpeg 509FE382-2F13-453E-9DBE-69F00F653E61.jpeg A couple more with all the remaining bits and bobs put on. Can’t wait till the weekend! :lol3
    #24
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  5. Laromonster

    Laromonster Lean, mean pacifist machine

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    Dymo labelmaker FTW!!
    #25
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  6. canadius_maximus

    canadius_maximus Quaere verum

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    :lol3

    Yup. My father-in-law had one in his attic. It was loaded with a thinner, newish looking (matte) style of label versus what I remember using when I was younger as a thicker material that was also glossier. That’s what I had hoped to use, but this will do.

    Replaced the drain plug and mounted the new tubes and tires yesterday ...

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    :rilla

    Science can’t explain why every time I put on a new set of knobbies, my legs shrink by almost an inch ...:dunno:lol3

    Will stop off at the insurance office on my way home from church and reactivate the policy so I can do a wee spin around town to validate things work properly.

    Needless to say, I’m stoked .... :happay
    #26
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  7. GezwindeSpoed

    GezwindeSpoed Long timer

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    Wow, great result. Thanks for finishing this thread.
    #27
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  8. canadius_maximus

    canadius_maximus Quaere verum

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    Got so stoked riding that I’ve forgotten to post.

    Barring a few small niggles, the bike is done and running superbly. A couple poor shots from a fun burn in the hills near where I live.

    I love Minion.

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    #28
  9. canadius_maximus

    canadius_maximus Quaere verum

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    A few more because. That’s why! :lol3

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    Forgive the ghetto fuel cap. Broke the vent nipple. That’s temp until the new billet cap arrives on back order. End of Nov. :dirtdog
    #29
  10. NoelJ

    NoelJ Long timer

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    This is an awesome result! You never mentioned the fairing itself - did you form it up from CF sheet, and if so can you share the process you used? Looks for professional all around!
    #30
  11. r60man

    r60man Long timer

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    Beautiful! I want one!
    #31
  12. tinwelp

    tinwelp Professional Idiot

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    Very very nice. A truly excellent job you've done there Sir! My FE400e looks very shabby by comparison, even though it's of a similar era.

    I see you had the same problem I had when trying to find a shock mud-flap to mount on the rear fuel tank. I ended up making two solutions. The first was as you've done, making an adapter to fit the standard Acerbis mud-flap to the bottom of the tank. Mine broke after some roosting around in gravel, ripping out one of the mounts in the tank. My second solution was to cut down the standard (OE) inner mudguard to fit around the tank, reshaping it to fasten into the tank mud-flap mounts too (after repair). With the Acerbis mud-flap on the bottom of this modified inner mudguard, all works well and I've yet to break it.

    Not a problem if you ride in soft dirt, otherwise that shock shaft looks pretty vulnerable.

    Did I mention your bike looks brilliant?

    Cheers... Paul
    #32
  13. canadius_maximus

    canadius_maximus Quaere verum

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    Hi - thanks for the kind words. You're right, I kind of glossed over the fairing, because it was the area of least effort. When I decided to go with a frame fairing two years ago, I looked at the various options and figured the Rally Moto Kit design (intended for the early 2010 generation KTM EXCs) would be the easiest to adapt. I reached out to them to see if they had any fairings left, but they were all out, as their kit run lasted only around 4 or so years. But in all the investigation and "door knocking", I bumped into an inmate here who had previously owned an RMK, and had made a carbon fiber version for himself as spare and never mounted it. So he sold me that set, which is what you see.

    I'm fairly happy with it, and reflecting what options I had (and making my own was not something I felt I had the time to burn on), I turned out pretty good. The only thing is that now, with the 2018+ KTM RFS screens having come out and readily / commercially available, I'd go that route if I could do it over. I'm keen on having a readily-replaceable fairing, and while my I have a line on the supplier who made this one, I'd rather just place an order for the $130-odd one from KTM and be done with it. Who knows, I may add a postcript to this project and knock something up based on that. I would be relatively easy, since I designed the brackets to be easily removeable / replaceable. All I'd need to do is fab up new brackets that tie to that screen.

    Thanks Paul - very kind of you.

    Yes, great observation, and it's one of the couple of niggly little details I plan to resolve over the winter. I have that hard Acerbis splash guard, but I think it's a disaster waiting to happen to mount on the auxiliary tank in its current form.

    The previous owner's route was a custom "sock" - kind of like some that folks put on their front forks, held together by velcro, fitting tight on the top and bottom of the shock, but loosely fitting over the coils. The trouble was it inevitably rubbed and got pinched, plus it seemed to trap a lot of moisture. I like to do a quick pre (and post) inspection after each ride, and I'd rather not have to remove something like that every time.

    I'm leaning to finding a piece of rubber - thicker than tube, but a bit thinner than tire sidewall, and fab my own little extender. I'm open to reconsider, and in fact would be grateful to see how you did yours. I already have that Acerbis guard unused, so if there's a way to use it, I'd be happy.

    Cheers all.

    cm

    EDIT - if you can post some pics and details of your customized shock protection, maybe over in the "1998-2008 Husaberg" thread, because I'm sure many owners would be interested in options. Just an idea.

    https://advrider.com/f/threads/the-1988-2008-husaberg-thread.640445/page-25
    #33
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  14. canadius_maximus

    canadius_maximus Quaere verum

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    An update I’m calling “Covid19 Edition”. :lol3

    We’re all healthy, but with a mix of Spring Break, vacations, and working from home, I’ve found extra time to do another round.

    I liked the RMK fairing, but at least on this bike, I found I had to really limit the handlebar sweep so they wouldn’t interfere with the side skirts. This bike already doesn’t have a great turning radius, so I figured a new screen would help. So I picked up a nice, barely used 2018 KTM rally screen and sold the other to an inmate.

    Of course, like most things in this project, that decision created cascading downstream consequences - lights sit way lower and further forward. So I needed to not only rewire, but also design a whole new subframe for them.

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    So while I was rewiring, I splurged on a treat I’ve wanted since day one of them hitting the market: a set of Blitz Buttons to drive my digital odo and future digital road book. All I can say is, workmanship is nothing short of superb. Chris (@rides2little ) is a prince to deal with, and this little tool will get loads of use.

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    New dashboard:

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    Attachments for the side skirts. Big shout out to @MotoChron, followed his lead and went with 1/8” ABS. Perfect.

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    Pic of the tower before the fairing is mounted. Wiring not fully sorted, but you get the idea.

    Another thing I wanted to improve was the turn signal mounting. Previous builds either had them sticking out of the fairing (dumb from a wear/tear point of view and annoying when needing to remove the fairing). My previous solution was to mount them below the fairing, but that meant more brackets to get the needed offsets. So here, given the fairing is clear, they’re hard mounted to the tower. Nice and high, but protected. And as an added bonus, the fairing reflects the light, so it’s a built in feature to advise you’ve left it on. I find with the Euro switch it’s easy to leave the signal on even if you’ve toggled it. The L/off/R position feel is quite soft/undefined, so this “feature” is nice insurance.


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    CM
    #34
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  15. canadius_maximus

    canadius_maximus Quaere verum

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    Fairing on and sorting out the small details:

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    All in all, I’m very happy. Maybe doesn’t look quite as snappy as the other faring, but I’ve gained buckets’ worth in function.

    A ride around the neighborhood revealed the screen is bomber solid. After I remount the decomp lever, I’ll take it out for a good long boot to test.

    cheers all and stay healthy,
    #35
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  16. BergDonk

    BergDonk Old Enough to Know Better

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    Nice :thumb
    #36
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  17. loganlexow

    loganlexow Been here awhile Supporter

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    Whoa, it's like you bought a new bike! That looks so good! Do you have details on your tower build?
    #37
  18. canadius_maximus

    canadius_maximus Quaere verum

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    Hi Logan!! :wave Nice of you to drop by - can't wait to see what you do with the fairing. :thumb

    If you go back to page one of this thread and look at my post#5 onward, you see the concept I created to attach the tower. I purposely avoided drilling the frame and/or welding, but those are other approaches that some have followed with success. This thread is also a handy reference I'd heartily recommend. https://advrider.com/f/threads/rallye-navigation-bracket-photo-thread.684282/ I've posted there over the years, and gotten great inspiration and ideas from some of the real rock stars in that arena. Recently, @tileman and @AUSSIEADV have worked on a design that focuses on the newer generation of EXCs like yours and FEs - I'd definitely read up on their experience and get ideas for yours (I believe you had an EXC and a 690, yes?)

    Little of what you see here (insofar as the actual attachment to the frame) in this thread will help when it comes to the 690, given its perimeter frame vs the EXC/FE's more traditional
    cradle frame. For the 690, you can check my earlier thread (linked on page 1) that featured builds using, and then later recreating my version of, Rally Raid and similar vendors' products. But if you're designing for your EXC, there'll be enough nuggets between page 1 here and the "brackets" thread to get you going. @GalacticGS and @gaspipe did some superb race bike builds that were very instructive for me.

    Feel free to post in that thread too, like I said, some really smart designers have come up with some clever ideas. They'll be willing to help. And idiots like me will cheer you on and pipe up with ideas. I watch that thread regularly, so I'll look for your there.

    I hope this helps!

    cm
    #38
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  19. loganlexow

    loganlexow Been here awhile Supporter

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    You're correct about the EXC. I have a 500 EXC that I'm building into a mini adventure unicorn. I also have a 640 that, for whatever reason, I can't seem to part with lol.
    I went the lazy route and ordered a Nomad kit for the 500, though, now I'm wondering if I'll ever see that, what with a threat level 3 from Europe. Partly why I'm nagging you about your setup lol.
    The fairing I bought from you is planned for the 640. I can't tell you how well that lines up with the large tank and funky lines.
    I did try and look through your previous posts, but, for some dumb reason the pics wouldn't load up. No big deal because I have been reading the nav tower thread too lol. I'm so glad I'm not the only geek for fairings lol.
    #39
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  20. canadius_maximus

    canadius_maximus Quaere verum

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    Ok. Sorry. You can ignore my 690 comment - I forgot your other bike was a 640. Similar frame considerations to the EXC, so you’ll be fine.

    Here’s to a cool “Logan’s LC4 rebuild” thread! :clap

    Edit - I’ll go back and see what the deal with the pics is. I see most of them fine (some were lost as part of the Photobucket fiasco). Let me look into it tomorrow.
    #40
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