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andym |
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andym World Chat Champion
Joined: 16 Nov 2010 Karma :
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Posted: 17:45 - 27 Oct 2017 Post subject: Project bodge-it |
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Aka: Project death trap
Aka: Project cheap b*stard
Warning: this is going to be a slow project.
A few weeks ago I bought a Chinese dirt bike from gumtree for £100, my plan is to bodge as much of it as possible with the aim of having something to take to the 2018 bbq that is on par with the drunken log walking.... or testing my homebrew.... on a budget of what I spent originally on it, or less.
This was the heap when I bought it:
https://imgur.com/rwkGdTC.jpg
https://imgur.com/5dLoGJI.jpg
It seems every time I look at it I find new problems, but sod it.... I'm up for a challenge.
One of the things I noticed when I got it running was the exhaust was blowing, so I thought I'd have a go at welding it... unfortunately the problem was worse than I thought:
https://imgur.com/sqrWklR.jpg
https://imgur.com/FRBo8lo.jpg
I'd removed it previously and gave it a bit of a scrub then painted with HT paint.... will still have a go at welding it though.
I decided to have a go at fixing the wiring so I could have it starting off the button (because I'm crap with kickstarts), because the terminal on the starter was rusty as f*ck, I thought I'd just remove it to make things easier, I found it wasn't even bolted to the engine, but wouldn't budge.... so to make sure it wasn't being held inside the engine I removed a cap and found there was a gear missing:
https://imgur.com/FMUzCir.jpg
Since I had the starter out I stripped it down to check inside, also tried to loosen the rusted bolts :
https://imgur.com/j56vBgN.jpg
Brushes were a bit worn, but still more than enough life in them:
https://imgur.com/ItzKtK3.jpg
I seen a video ages ago with a tip on how to rebuild a starter... it involved using a socket to hold the brushes back etc.... after about 20 minutes of fighting with this method I decided to try my own way:
https://imgur.com/cKTUswS.jpg
The starter was rebuild a couple of minutes later
After a failed attempt at fixing the rear brake master cylinder I had high hopes for a temporary front one:
https://imgur.com/2aB97lz.jpg
Trying to pressurise the system with a technique that has worked so many times in the past:
https://imgur.com/jiOCZmi.jpg
No luck there either.
Finally decided to have a look at the wiring:
https://imgur.com/XmP8qBS.jpg
https://imgur.com/PPRPZA7.jpg
https://imgur.com/H7tqDP8.jpg
The only positive from today is I found there was a loose connector on the kill switch circuit.
I'm already starting to hate this bike |
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DRZ4Hunned |
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DRZ4Hunned World Chat Champion
Joined: 15 Apr 2014 Karma :
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Posted: 18:01 - 27 Oct 2017 Post subject: |
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Looks like a right heap, good luck with it ____________________ DRZ400-SM
FZS600 |
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andym |
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andym World Chat Champion
Joined: 16 Nov 2010 Karma :
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andym |
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andym World Chat Champion
Joined: 16 Nov 2010 Karma :
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winz |
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winz World Chat Champion
Joined: 05 Feb 2015 Karma :
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haroman666 |
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haroman666 World Chat Champion
Joined: 17 Sep 2008 Karma :
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andym |
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andym World Chat Champion
Joined: 16 Nov 2010 Karma :
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Posted: 16:29 - 03 Nov 2017 Post subject: |
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Today I got fed up trying to find a seat that was within budget (and one that I knew would fit), sooo..... I decided to make one at a cost of £2 (2 £1 rolls of duct tape).
Cut a bit of plywood, which I quickly realised wouldn't work:
https://imgur.com/VXEM29K.jpg
A quick cut later (also put an extra bit of plywood at the front to secure it better, also put a couple of holes in there to bolt it to the frame):
https://imgur.com/Tk4YJFJ.jpg
My sofa bed will never be the same again, but lots of lovely foam:
https://i.imgur.com/zr9D9eG.jpg
Add 1 1/2 rolls of duct tape and some creative cutting here and there:
https://i.imgur.com/brUWhKv.jpg
Also has enough of a gap for my side stand bodge:
https://i.imgur.com/CMNDM7a.jpg
Total spent on repairs so far: £17
Since I have a fair bit of foam left, I might pad out the sides a bit |
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Howling Terror |
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Howling Terror Super Spammer
Joined: 05 Dec 2008 Karma :
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nowhere.elysium |
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nowhere.elysium The Pork Lord
Joined: 02 Mar 2009 Karma :
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pepperami |
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pepperami Super Spammer
Joined: 17 Jan 2010 Karma :
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Posted: 21:46 - 03 Nov 2017 Post subject: |
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Quality 10-out of-10 . More pic and more detail ____________________ I am the sum total of my own existence, what went before makes me who I am now! |
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Howling Terror |
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Howling Terror Super Spammer
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andym |
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andym World Chat Champion
Joined: 16 Nov 2010 Karma :
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andym |
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andym World Chat Champion
Joined: 16 Nov 2010 Karma :
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Posted: 17:14 - 04 Nov 2017 Post subject: |
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Today's tinkering....
It turns out I'm a complete idiot (no surprise there I know), but after mucking about for a couple of days with the mixture etc it turns out I had the choke on full
This was just after getting it started and running (with an audience), and I managed to f**k it up at the end of the video
https://youtu.be/MH8RtLjnWM0 |
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andym |
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andym World Chat Champion
Joined: 16 Nov 2010 Karma :
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Posted: 15:50 - 11 Nov 2017 Post subject: |
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Quick update to this thread...
Total spent on parts now up to £40 (most expensive being the mud guard at £13, but also need to take £8 from that as the ebay seller said there was a problem with the batch of rear master cylinders )
The mud guard looks too new and shiny, so I'll need to do something about that:
https://i.imgur.com/v3RyVE8.jpg
Also had a go at removing the snapped exhaust stud.... not sure why people complain about it tbh, quick squirt of GT85, an extremely large set of mole grips and it came out in seconds:
https://i.imgur.com/sqrWklR.jpg
https://i.imgur.com/Q5AIed4.jpg
It was also introduced to it's first bit of proper paint to see how it took (I know it's all over the rim too, but I have checked and an old scourer takes it off nicely) :
https://i.imgur.com/2FO5xAk.jpg
Other little jobs I've done recently, sorted the oil spraying out the engine, I'm guessing that was down to a split hose, but just to make sure a quick tap with a hammer to the starter to make sure it was secured properly and a few millimeters snipped of the engine breather pipe (not sure if that's the right name for it), and the engine is nice and dry again
I still have some work to do on getting it running properly as it's bogging down at full throttle, not sure if that's still the mixture (2 1/2 turns out) or the lack of half the exhaust.... which I had a go at welding today.... turns out that's impossible off the bike as the 2 parts move around too much |
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Rob Fzs |
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Rob Fzs World Chat Champion
Joined: 07 Oct 2015 Karma :
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Posted: 18:06 - 11 Nov 2017 Post subject: |
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andym wrote: | Quick update to this thread...
Total spent on parts now up to £40 (most expensive being the mud guard at £13, but also need to take £8 from that as the ebay seller said there was a problem with the batch of rear master cylinders )
The mud guard looks too new and shiny, so I'll need to do something about that:
https://i.imgur.com/v3RyVE8.jpg
Also had a go at removing the snapped exhaust stud.... not sure why people complain about it tbh, quick squirt of GT85, an extremely large set of mole grips and it came out in seconds:
https://i.imgur.com/sqrWklR.jpg
https://i.imgur.com/Q5AIed4.jpg
It was also introduced to it's first bit of proper paint to see how it took (I know it's all over the rim too, but I have checked and an old scourer takes it off nicely) :
https://i.imgur.com/2FO5xAk.jpg
Other little jobs I've done recently, sorted the oil spraying out the engine, I'm guessing that was down to a split hose, but just to make sure a quick tap with a hammer to the starter to make sure it was secured properly and a few millimeters snipped of the engine breather pipe (not sure if that's the right name for it), and the engine is nice and dry again
I still have some work to do on getting it running properly as it's bogging down at full throttle, not sure if that's still the mixture (2 1/2 turns out) or the lack of half the exhaust.... which I had a go at welding today.... turns out that's impossible off the bike as the 2 parts move around too much |
you're running a shitty k&n air filter on it, thats why, you need to rejet ____________________ '00 Aprilia RS50 > '92 Honda CG > '99 Yamaha Fazer > '91 Yamaha RXS > '79 Suzuki X5 > 01' Honda Cg > 07' Honda Cg > 82' Kawasaki Z200 > suzuki gsxr 400 gk73a > honda vfr 400 NC30> Yamaha RD350 YPVS F2 > Kawasaki ZZR 600 D1 > Yamaha TZR 250 2MA >Suzuki TL1000R > Yamaha TDR250 > Honda 929 blade > Suzuki SV1000 > Honda H100
Mod 2 Passed 09/06/2011 |
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andym |
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andym World Chat Champion
Joined: 16 Nov 2010 Karma :
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Posted: 21:25 - 16 Nov 2017 Post subject: |
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Since I've had so much free time this last couple of weeks I decided to get some more work done to the rolling scrap heap.
A few days ago I decided to sort the exhaust, the only problem was I had to take it to my parents to do.... so I had to shed as much weight from the bike as I could so I could lift it into the car myself, (interestingly none of the nuts or bolts caused me any problems when removing them*):
https://i.imgur.com/1TYN6QN.jpg
It turns out the silencer was made of tinfoil, every time I went near it with a rod a hole appeared or it just melted away instantly, since the main pipe seemed solid enough I just built up the weld on that then let it fall on to the silencer.... which ended up with a really shitty looking weld that was impossible to grind back.... still it adds to the look of the bike:
https://i.imgur.com/CcKxOoX.jpg
And the only really shiny part:
https://i.imgur.com/BGnbBGM.jpg
How ol' Rusty looked before getting thrown back into the lockup (literally):
https://i.imgur.com/rOKsiAt.jpg
I managed to sort the leaking carb, and I don't know if it's that it now has a full exhaust, but there is definitely more power now... and even with only an extra 1/4 turn of the mixture screw it bogs down much higher up the rev range... it may even pull a wheelie, but I'll find that out tomorrow.
*The headstock bearings did explode when putting the front end back on though, but from the condition of the parts I removed... it looked like a previous owner just grabbed the pile of bits and mashed them into a copper grease snowball and crammed them back in place
Turns out it was an awkward size to get hold of too, of all the bearing sellers.... only pyramid parts had the correct sized one for £9.99 (next cheapest was about £24). |
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Old Thread Alert!
The last post was made 6 years, 160 days ago. Instead of replying here, would creating a new thread be more useful? |
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