Yet Another Budget Ninja Mutant Build

Discussion in 'Some Assembly Required' started by draco_1967, Feb 5, 2019.

  1. draco_1967

    draco_1967 Spoon!

    Joined:
    Aug 16, 2011
    Oddometer:
    650
    Location:
    Salt Lake City
    I did some prototyping of the new peg location, and I moved the main wiring harness inside the frame in preparation for future welding.
    The new peg location is about 1 inch back and .5 in up from where I had it. The previous location was a little off, and this puts it a little closer to what others have done.
    20200212_214922.jpg
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    20200212_214849.jpg
    The brake MC is just hanging out there in this pic.
    #81
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  2. draco_1967

    draco_1967 Spoon!

    Joined:
    Aug 16, 2011
    Oddometer:
    650
    Location:
    Salt Lake City
    Some progress tonight. I don't remember from which build thread here I learned this trick to center holes that can't be done with a center punch, but it worked perfectly!
    Cut off the heads of two bolts, and chucked them up in a drill. Then ran the head of the bolt on a belt sander while spinning the drill. Screw those into the holes, line up the workpiece, and give it a little whack.
    20200215_210500.jpg

    Then I marked the hole centers for the peg mount, drilled, and cut out the shape.

    There will be a piece of 3/8 plate behind the 1/4 plate that should provide plenty of rigidity.

    Attached Files:

    #82
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  3. draco_1967

    draco_1967 Spoon!

    Joined:
    Aug 16, 2011
    Oddometer:
    650
    Location:
    Salt Lake City
    The right peg mount is together. I still need to do some cleanup work on it, but it works well. I transferred the template and holes to the aluminum for the left side, then my son woke from his nap. He's not quite big enough to help in the garage yet.
    20200217_134509.jpg 20200217_134513.jpg
    #83
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  4. draco_1967

    draco_1967 Spoon!

    Joined:
    Aug 16, 2011
    Oddometer:
    650
    Location:
    Salt Lake City
    Left side together too. I still need to drill/tap the hole for the shifter pivot, and get a longer linkage rod. I like the new peg location.
    20200217_221135.jpg
    20200217_221537.jpg
    #84
    16VGTIDave likes this.
  5. draco_1967

    draco_1967 Spoon!

    Joined:
    Aug 16, 2011
    Oddometer:
    650
    Location:
    Salt Lake City
    I'm getting close to done with the peg mounts. The shifter location is set, but I need a longer linkage. On the right side, the brake master cylinder is placed. That piece of aluminum will also tie in the Versys subframe supports when they go on. A similar piece will be added to the left side.
    20200222_213159.jpg 20200222_213210.jpg
    #85
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  6. moffy

    moffy foolish fool

    Joined:
    Jun 19, 2014
    Oddometer:
    39
    Location:
    Cle Elum
    Excellent! I'm doing some similar peg mounts plate mods to mine.
    #86
  7. 11motos

    11motos Feral Rider

    Joined:
    Oct 27, 2017
    Oddometer:
    2,201
    Location:
    On the Road
    It looks awesome. Great job! what thickness is that T6 plate?
    #87
  8. draco_1967

    draco_1967 Spoon!

    Joined:
    Aug 16, 2011
    Oddometer:
    650
    Location:
    Salt Lake City
    I used 1/4" and 3/8" sandwiched together.
    The outer plate is 1/4":
    [​IMG]

    And the inner plate is 3/8". This is the plate that the peg mount bolts thread into behind the 1/4" plate. Also, the brake pedal on the right side threads into this.
    [​IMG]

    I still have some edge clean up to do, and I plan to cut the 90-degree corner at the bottom-front edge off at a 45 like the top corner is.
    #88
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  9. draco_1967

    draco_1967 Spoon!

    Joined:
    Aug 16, 2011
    Oddometer:
    650
    Location:
    Salt Lake City
    Final assembly (I hope) of the foot pegs. I ordered a bunch of hardware so everything was the proper length and it all matches visually. I am still waiting on the rod for the clutch linkage.

    20200303_221310.jpg 20200303_221328.jpg

    Next up is fab the front brake caliper spacer and put the DRZ/DL1k front end on. Then the nav tower.
    I am doing some offroad ADV training in April, so the Dirt Ninja needs to be ready by then.
    #89
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  10. draco_1967

    draco_1967 Spoon!

    Joined:
    Aug 16, 2011
    Oddometer:
    650
    Location:
    Salt Lake City
    Progress! I finally got the Versys/DRZ/DL front end mounted up. It looks quite beefy. Next step is to figure out the lighting/dash setup.
    20200316_215330.jpg
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    20200316_215206.jpg
    #90
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  11. draco_1967

    draco_1967 Spoon!

    Joined:
    Aug 16, 2011
    Oddometer:
    650
    Location:
    Salt Lake City
    I forgot to post the brake caliper bracket pics. I did this Saturday.
    20200314_133921.jpg
    #91
    greasyfatman likes this.
  12. 11motos

    11motos Feral Rider

    Joined:
    Oct 27, 2017
    Oddometer:
    2,201
    Location:
    On the Road
    Awesome! looking nice.
    I was wondering what you did for the fork clamps since the original DRZ clamp is complicated and doesn't give much turn radius
    without hitting something first, that is the radiator in my 500 that is what I am dealing with right now.
    You thread is inspiring and I am liking the idea of a Ninja 650 for the next build.
    Also How much travel you think you can get from the back with what shock?

    Thanks.
    #92
  13. draco_1967

    draco_1967 Spoon!

    Joined:
    Aug 16, 2011
    Oddometer:
    650
    Location:
    Salt Lake City
    I used a Versys fork clamp with some spacers to fit the DRZ forks. Lock to lock steering is roughly the same as the stock Versys.
    According to JD's big V649 thread, rear travel should be about 8"
    The 650 really is a great bike. I like the engine a lot. It's really mild in the lower RPM range, but get it above 5k, and it is a lot of fun. I chose it originally because of JD's thread. It is basically a recipe book for building these.
    #93
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  14. 11motos

    11motos Feral Rider

    Joined:
    Oct 27, 2017
    Oddometer:
    2,201
    Location:
    On the Road
    Yes!! .. thanks for the reply! Looking for versys clamps right now to avoid machining new ones.
    ..you know something that we should have in this forum is a nice grafting database with all sort of data for dimensions and cross compatibility charts.
    Perhaps there is something already but I didn't find it yet. There are all sort of challenges but specially with swing arms, wheels for lacing, hubs and axles that are the worse things to track for possible donors.
    The front end tends to be easier excluding a 19" from wheel with spokes.
    And I agree thanks to JDs, yours, and others, it looks the recipe for the Ninja X is becoming a recipe for success. The T7 for the working man, but better. lol
    #94
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  15. draco_1967

    draco_1967 Spoon!

    Joined:
    Aug 16, 2011
    Oddometer:
    650
    Location:
    Salt Lake City
    I found a few scattered resources for different measurements. Most of it was front and rear axle sizes and fork diameters. I'll see of I can find a link or two in my notes.

    In other news, check your cables often! I just replaced the clutch on the Dirt Ninja tonight. It was looking a little frayed:eekers:yikes
    (ETA: I replaced the stock Ninja cable with a stock Versys cable. The throttle cables are on their way as well. The Ninja cables are just a little too short with the Verys bar position.)
    20200319_214646.jpg

    I'm also working on the dash/nav tower. I'm liking this "social distancing" thing. I can get work done during my lunch break, and run to the garage right after I log off the computer!

    20200319_132930.jpg
    20200319_132901.jpg

    Lastly, I got the shifter linkage together. I need to find a double threaded rod that is the right length, but this will do for now.
    20200319_132825.jpg
    #95
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  16. jdrocks

    jdrocks Gravel Runner

    Joined:
    Jul 6, 2007
    Oddometer:
    7,970
    R1 allows more travel than there is room above the tire, and the result is an interference issue with the fender liner/subframe. if ridden as designed, you will crack the fender liner. i broke 3 before i hit the delete button and went a different direction. 8" is available, and is adequate for this type of moto, you just have to make a few changes to get there. remember, you're also likely to run a tire that has a slightly larger diameter.

    if not ridden hard you might not break anything, but then you're seeing less travel. for a fact, i don't recall other reports of broken fender liners from riders who have made the popular R1 swap on otherwise stock bikes, but used the bike mostly on pavement with only occasional or no light off pavement use. the V649 style gravel runner bikes are a different animal, and tend to get run much harder.

    breaking a fender liner doesn't park the bike, it's more a nuisance...unless ya knock a big freakin' hole in it, then it can get very inconvenient.
    #96
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  17. draco_1967

    draco_1967 Spoon!

    Joined:
    Aug 16, 2011
    Oddometer:
    650
    Location:
    Salt Lake City
    More work on tower prototyping. I made the main struts out of 1/4" hardboard so it could be a bit more stable and I could get better measurements. The windscreen in the last pic is the stock Ninja screen. With a little trimming and a few holes, it might work.

    20200320_212234.jpg
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    #97
    scot_douglas likes this.
  18. draco_1967

    draco_1967 Spoon!

    Joined:
    Aug 16, 2011
    Oddometer:
    650
    Location:
    Salt Lake City
    I have no plans to race, but a nav tower setup seems to be the best solution for this build.
    I am doing mostly HDPE with a little aluminum bracketry.
    Tonight, as I was fitting things in place, I decided to shorten up the main frame. My original idea was just way too long.

    Original length:
    20200327_214619.jpg

    Shortened:
    20200327_215015.jpg

    3/4 view:
    20200327_214623.jpg

    Still a little bit of work to do, but working in HDPE is awesome! Cuts like butter.
    #98
  19. draco_1967

    draco_1967 Spoon!

    Joined:
    Aug 16, 2011
    Oddometer:
    650
    Location:
    Salt Lake City
    Good point, JD. I remember reading that part of your red/white build, plus the latest iteration. So far, I haven't had an issue. I'm a bit of a newbie on the dirt (well, it's been 25 years...), so I take it easy. When it does happen, I'll make some needed modifications there.
    #99
  20. 11motos

    11motos Feral Rider

    Joined:
    Oct 27, 2017
    Oddometer:
    2,201
    Location:
    On the Road
    It looks great! ... how elastic is HDPE? could it bend if you crash or most likely break?