Rally 1200 Sportster! formerly The GO-SPORT adventure!

Discussion in 'Some Assembly Required' started by tobiism, May 26, 2016.

  1. tobiism

    tobiism Long timer Supporter

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    Screenshot_20210424-004658_Chrome.jpg
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  2. villageidiot

    villageidiot Long timer Supporter

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  3. AK650

    AK650 Long timer Supporter

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  4. JagLite

    JagLite Long timer Supporter

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    What are you going to build the rear subframe/seat/fuel tank out of?

    I don't have a spool gun to weld aluminum so I will have to use steel for my V-Strom project similar design.
    My plan is thin steel sheet over square tubes then coated inside with Caswell Sealer to (hopefully) keep the tank sealed when/if I dent it badly on rocks from a tip-over.
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  5. tobiism

    tobiism Long timer Supporter

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    That's pretty much exactly how I plan on doing mine! LOL I even have the caswell at home
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  6. JagLite

    JagLite Long timer Supporter

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    Hah! :beer
    I have the sealer also, but after reading in Steve's thread that Caswell has a shelf life and I thought I would be building it a couple years ago... :fpalm
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  7. tobiism

    tobiism Long timer Supporter

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    More like Car-dookie. Mine won't be anywhere near as nice as a carducci
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  8. villageidiot

    villageidiot Long timer Supporter

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    I’ve ogled the carducci bike a few times at the local progressive show. It’s insanity.
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  9. AK650

    AK650 Long timer Supporter

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  10. tobiism

    tobiism Long timer Supporter

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    Yeah the JD squared Bender is one of my favorite tools for sure. The Bendicator certainly helps LOL
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  11. tobiism

    tobiism Long timer Supporter

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    Received this shit show of a package from a seller in Canada. 20210429_184740.jpg 20210429_184712.jpg 20210429_184652.jpg 20210429_184640.jpg

    Unbelievably the 520 KTM forks were not damaged. The PDS shock and forks were dropped off to Futureshoxs in Phx to get rebuilt and revalved for trail riding.

    Fun tidbit, the KTM forks are a direct bolt in for the sportster neck.
  12. nostep

    nostep Been here awhile

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    Glad they made it relatively unscathed. I just received a 530 front end from a seller here on Friday. A Sportster is next on the project list for me too. Looking forward to seeing how yours continues.
    IMG_20210507_185815.jpg IMG_20210506_151917.jpg

    Also, from your mock-up pic, it looks like you're going with a single offset WP shock on the left side.

    That exact thing was suggested to me recently when I was discussing this. Our concern was making the swingarm resistant enough to twist without making it weigh a ton.

    The big benefit in my mind would be the reasonable price and tuneability of the WP shock, but also it would clear the way for a tucked in high supertrapp or two on the right side. I really like the looks, but the right side shock is in the way.

    What swingarm and hub are you using?
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  13. tobiism

    tobiism Long timer Supporter

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    Yes, mounting it on the left. I am going to redo the swing arm as a trellis Style. I'll use Harley adjusters that have already been bored out 20 mm. That way I can use a rear wheel with 20mm axle. Probably a Warp 9 RMZ250 non cush 18" with 2.5" rim.
  14. nostep

    nostep Been here awhile

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    Very cool. Are you going to put the bracing on the top or bottom of the arm?

    Rectangular tubing or round because you have that sweet bender?

    I was planning on leaving the stock subframe and oil tank, so I'll probably have clearance issues to work out with the upper mounting.

    I'm starting to look for aluminum swingarm swaps, but that would probably be for version 2 of the rear.
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  15. tobiism

    tobiism Long timer Supporter

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    Sorry for the delay. I'll be bracing underneath with round tubing. Probably build the oil tank into the backbone and neck.
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  16. nostep

    nostep Been here awhile

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    That's gonna be sweet. I'll be watching and learning.

    I'm hunting for one right now, but I'm hesitating because the Covid tax is in full effect out here. I really should finish the DRZ all the way before I get one, but I keep looking because I might miss the right sporty at the right price.
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  17. JagLite

    JagLite Long timer Supporter

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    Yep, you have to look everywhere, every day, and have cash on hand to get the super deals.
    Even then there is no guaranty, but you won't find one if you don't look. :beer
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