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Project bodge-it

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andym
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PostPosted: 16:45 - 27 Oct 2017    Post subject: Project bodge-it Reply with quote

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 Evil or Very Mad :
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 Very Happy

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 Evil or Very Mad
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DRZ4Hunned
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PostPosted: 17:01 - 27 Oct 2017    Post subject: Reply with quote

Looks like a right heap, good luck with it Laughing
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andym
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PostPosted: 15:27 - 29 Oct 2017    Post subject: Reply with quote

DRZ4Hunned wrote:
Looks like a right heap, good luck with it Laughing

Running heap thank you very much. (extremely shaky video, maybe filming in portrait mode would have helped)

Had a quick tinker with it today, both M/C's are shot. As you can see from the video it did piss fuel, but that seemed to stop after it had been run for a couple of minutes.

Clutch lever is really stiff with the biting point almost off the lever, impossible to find neutral when it's running.

It moves fine in gear (because of the lack of brakes I could only move it slowly though), and seemed to find 2nd easily enough.

Finally I managed to get the important wires connected up again and now the engine switches off with the key.... the kill switch seems to work a lot slower though
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andym
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PostPosted: 13:51 - 02 Nov 2017    Post subject: Reply with quote

I had a little mess around with this pile of scrap today.... it now starts, runs, moves, stops.... still a bit of work needed with some of these though as I managed to get up to 2nd gear and was shitting myself.

One of the jobs I done today was messing around with the carbs again and changing the float height (having never done this before), that's going to take a fair bit of tweaking I think, there's around .5mm adjustment between pissing and no fuel.

On the plus side, from cold it started on the first kick
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winz
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PostPosted: 14:59 - 02 Nov 2017    Post subject: Reply with quote

andym wrote:
I had a little mess around with this pile of scrap today.... it now starts, runs, moves, stops.... still a bit of work needed with some of these though as I managed to get up to 2nd gear and was shitting myself.

One of the jobs I done today was messing around with the carbs again and changing the float height (having never done this before), that's going to take a fair bit of tweaking I think, there's around .5mm adjustment between pissing and no fuel.

On the plus side, from cold it started on the first kick


Good work Andy! Was expecting to say it's fucked and you've burnt it with moonshine!
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haroman666
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PostPosted: 16:43 - 02 Nov 2017    Post subject: Reply with quote

Currently sober me, is saying: "Fuck that, it's a death trap."

2018 BBQ, 6pm on the Saturday me is likely to say "Hold my beer, i'm wheelying this bastard to the end of the field!"

Good luck man!
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andym
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PostPosted: 15:29 - 03 Nov 2017    Post subject: Reply with quote

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 Laughing

Since I have a fair bit of foam left, I might pad out the sides a bit
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Moto Roma Wasp, Intruder 125, XJ600 Diversion, GPz 750r, zxr 750 H1, vfr750, CBR600f, ZX9R
I'm not an alcoholic, I'm a drunk..... alcoholics go to meetings
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Howling Terror
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PostPosted: 15:55 - 03 Nov 2017    Post subject: Reply with quote

Bring BCFBBQ I will ride. Wub
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nowhere.elysium
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PostPosted: 20:38 - 03 Nov 2017    Post subject: Reply with quote

I'm not gonna lie, that's about the most andym bike I can possibly imagine.

10/10.
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pepperami
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PostPosted: 20:46 - 03 Nov 2017    Post subject: Reply with quote

Quality Thumbs Up 10-out of-10 Thumbs Up . More pic and more detail Thumbs Up
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Howling Terror
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PostPosted: 21:12 - 03 Nov 2017    Post subject: Reply with quote

Paint it and I'll fookin' kill ya.
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andym
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PostPosted: 01:38 - 04 Nov 2017    Post subject: Reply with quote

Howling Terror wrote:
Paint it and I'll fookin' kill ya.


Not even the non rusty parts? Laughing
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andym
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PostPosted: 16:14 - 04 Nov 2017    Post subject: Reply with quote

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 Embarassed

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 Embarassed

https://youtu.be/MH8RtLjnWM0
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andym
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PostPosted: 14:50 - 11 Nov 2017    Post subject: Reply with quote

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 Evil or Very Mad )

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 Thumbs Up

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 Evil or Very Mad
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Rob Fzs
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PostPosted: 17:06 - 11 Nov 2017    Post subject: Reply with quote

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 Evil or Very Mad )

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 Thumbs Up

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 Evil or Very Mad


you're running a shitty k&n air filter on it, thats why, you need to rejet
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andym
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PostPosted: 20:25 - 16 Nov 2017    Post subject: Reply with quote

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 Rolling Eyes
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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