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buzzer1955 |
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buzzer1955 Nitrous Nuisance
Joined: 12 Jan 2019 Karma :
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Posted: 15:23 - 05 Aug 2021 Post subject: |
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the speedo/ rev counter I am going to use has a plastic case... which does not look good. I tried to get some tube the right diameter but it was too big or too small, so I cut 12mm out of some bigger stuff and seam welded it back up, using a piston ring clamp to pull it together to weld it. I knew it wouldn't look right with a flat bottom so I made a conical one by spinning it in the lathe. The alloy needs to be soft for this so I annealed it by heating it up to temperature, and letting it cool. A neat trick to know when its the right temperature is to use a Sharpie pen, and when its burn off and has disappeared, its the right temperature! a bearing on the end of a bar makes it easy! here is a short video...
https://jtccc.files.wordpress.com/2021/08/51359638684_d869d74bf1_o-copy.jpg
https://www.youtube.com/watch?v=EzapW5hnO3I |
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buzzer1955 |
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buzzer1955 Nitrous Nuisance
Joined: 12 Jan 2019 Karma :
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Posted: 21:19 - 08 Aug 2021 Post subject: |
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The seat base is finished, added the rivinuts to hold it on, and made a bracket so it only bolts on at the rear so it comes off easily. The last build is a pain to remove the seat. just need to add the foam and sand it to shape. I am happy with the mock-up but cant decide if the front mudguard needs to go central or biased to the front, but that can wait a while. the exhaust is all but finished apart from polishing and adding the hoops for the springs.
https://jtccc.files.wordpress.com/2021/08/seat-base.jpg
https://jtccc.files.wordpress.com/2021/08/mockup-1-copy.jpg |
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buzzer1955 |
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buzzer1955 Nitrous Nuisance
Joined: 12 Jan 2019 Karma :
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Posted: 19:22 - 14 Aug 2021 Post subject: |
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many (many!) years ago I modified the frame on a Bultaco for a race seat. I put a complete back end on, much like what I have done here. I made very careful measurements using various fixings as datums, and welded it all up. soon as it was finished, and the seat on, it was evident that it didn’t sit straight on the bike. I was gutted as I had painted the frame. No one else noticed, but it bugged the hell out of me for years! I learned from this, these days, here is how I do it… I get the bike dead upright to a spirit level on the wheel, and then make sure the seat is level. seems to work!
I have also made a new purchase... an auto darkening welding mask... why the hell I didn't buy one years ago I just don't know! its so much easier!
https://jtccc.files.wordpress.com/2021/08/is-it-straight-copy.jpg
https://jtccc.files.wordpress.com/2021/08/frame-hoop-copy-2.jpg |
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Shaft |
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Shaft World Chat Champion
Joined: 27 Dec 2010 Karma :
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buzzer1955 |
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buzzer1955 Nitrous Nuisance
Joined: 12 Jan 2019 Karma :
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Posted: 10:09 - 19 Aug 2021 Post subject: |
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With the new seat the rear foot pegs were too far back, and uncomfortable for her legs, so important to get this right! I have made some new hangers out of 10 and 12mm steel tube. I made a jig first so all the angles and bolt holes were correct, and it wouldn't move as I brazed it. this is my first time TIG brazing and I was worried about strength, so I did a test piece first and tried to break the joint... the parent metal broke before the joint so all is well there!
https://jtccc.files.wordpress.com/2021/08/rear-footrest.jpg |
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buzzer1955 |
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buzzer1955 Nitrous Nuisance
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buzzer1955 |
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buzzer1955 Nitrous Nuisance
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buzzer1955 |
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buzzer1955 Nitrous Nuisance
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pepperami |
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pepperami Super Spammer
Joined: 17 Jan 2010 Karma :
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Posted: 09:46 - 03 Oct 2021 Post subject: |
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Impressive ____________________ I am the sum total of my own existence, what went before makes me who I am now! |
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buzzer1955 |
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buzzer1955 Nitrous Nuisance
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Posted: 16:05 - 04 Oct 2021 Post subject: |
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My engine cases are back from the vapour blasters… another superb job from SP Vapour Blasting who are meticulous and I completely trust to do a good job! When I get them back, the first thing I do is clean them of any media that is left from the cleaning process. They were VERY clear of media, but I like to be sure! I then inspect all the threads. No point in building the engine up to find you have suspect threads, as at this stage its easy to rectify any that are poor. As it happens the only two that needed attention were the ones that hold the stand bracket on. This is a common failure point and I have seen a few cases cracked in this area due to lose bolts. I drilled the hole out and used a M10 x 1.5 helicoil. As these are a couple of really stressed bolts I use a double depth helicoil inserts (see picture for comparison) , just to make a good job of it.
https://jtccc.files.wordpress.com/2021/10/helicoil-3-copy.jpg
https://jtccc.files.wordpress.com/2021/10/helicoil-5.jpg |
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buzzer1955 |
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buzzer1955 Nitrous Nuisance
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buzzer1955 |
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buzzer1955 Nitrous Nuisance
Joined: 12 Jan 2019 Karma :
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Posted: 11:32 - 08 Oct 2021 Post subject: |
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when people say to me Ducati bikes are expensive to service I ask them if they have ever done the valve clearances ! on this engine there are 8 clearances to set, on the 4V there are 16! at £12 a shim and with the time involved no wonder its expensive!
https://jtccc.files.wordpress.com/2021/10/valve-clearances-copy.jpg |
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buzzer1955 |
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buzzer1955 Nitrous Nuisance
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A100man |
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A100man World Chat Champion
Joined: 19 Aug 2013 Karma :
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buzzer1955 |
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buzzer1955 Nitrous Nuisance
Joined: 12 Jan 2019 Karma :
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Posted: 15:10 - 12 Oct 2021 Post subject: |
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for £50 he can have it
There is something satisfying about doing the hydraulics. I pulled everything apart and gave it all a good clean, bead blasted everything and put it all back together with a smear of rubber brake grease and brake fluid. I didn’t replace any of the rubbers on this build, all seems to be in nice condition, so they just got a quick wash in methylated spirits.
Last update for a few days... I will be 66 tomorrow... a Pensioner! Another milestone reached! My wife is treating me to a few days away and we have family things planned!
https://jtccc.files.wordpress.com/2021/10/brake-rebuild-copy.jpg
https://jtccc.files.wordpress.com/2021/10/brake-rebuild-2-copy.jpg
Last edited by buzzer1955 on 15:52 - 12 Oct 2021; edited 1 time in total |
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Fat Angry Scotsman |
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Fat Angry Scotsman World Chat Champion
Joined: 12 Jan 2021 Karma :
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Posted: 15:36 - 12 Oct 2021 Post subject: |
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First time I have ever checked this thread and I am not disappointed. Those brake components all shiny gave me a bit of a chubby ____________________ PRESENT: 2018 BMW S1000XR SE Sport.
PAST: 2009 Kawasaki ER-6F. 2021 Zontes ZT-125U. |
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buzzer1955 |
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buzzer1955 Nitrous Nuisance
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Posted: 10:46 - 17 Oct 2021 Post subject: |
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I took a good look at the forks, and while the sliders were perfect, the anodizing on the legs was past its best. I popped them in the lathe and used some 240 paper to remove the anodising, then followed it up with some 800, and then a polish. they came up a treat! I did consider re-anodizing them but there is so much to polish anyway! I fitted a couple of new seals, and some new oil. all in all not a difficult job!
https://jtccc.files.wordpress.com/2021/10/forks-4.jpg |
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Easy-X |
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Easy-X Super Spammer
Joined: 08 Mar 2019 Karma :
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Posted: 12:56 - 17 Oct 2021 Post subject: |
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buzzer1955 wrote: | I took a good look at the forks, and while the sliders were perfect, the anodizing on the legs was past its best. I popped them in the lathe and used some 240 paper to remove the anodising, then followed it up with some 800, and then a polish. they came up a treat! I did consider re-anodizing them but there is so much to polish anyway! I fitted a couple of new seals, and some new oil. all in all not a difficult job!
https://jtccc.files.wordpress.com/2021/10/forks-4.jpg |
Lacquer to preserve the finish? ____________________ Husqvarna Vitpilen 401, Yamaha XSR700, Honda Rebel, Yamaha DT175, Suzuki SV650 (loan) Fazer 600, Keeway Superlight 125, 50cc turd scooter |
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buzzer1955 |
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buzzer1955 Nitrous Nuisance
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buzzer1955 |
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buzzer1955 Nitrous Nuisance
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Easy-X |
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Easy-X Super Spammer
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buzzer1955 |
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buzzer1955 Nitrous Nuisance
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buzzer1955 |
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buzzer1955 Nitrous Nuisance
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buzzer1955 |
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buzzer1955 Nitrous Nuisance
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Old Thread Alert!
The last post was made 2 years, 182 days ago. Instead of replying here, would creating a new thread be more useful? |
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