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Old 11-13-2012, 07:43 AM   #106
Pugsley/Hobbfather
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^Forgive ignorance here...

...but any reason to use the hole saw in the handheld drill? It looks like the pilot was created with a drill press.


Otherwise:

HOLY COW THIS IS AWESOME!
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Old 11-13-2012, 09:04 AM   #107
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Looking great. I hope I get to come up there one of these weekend's to break stuff...I mean, help out the build too!
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Old 11-13-2012, 09:09 AM   #108
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Originally Posted by oregoncoast View Post
Looking great. I hope I get to come up there one of these weekend's to break stuff...I mean, help out the build too!
I was just asking Luke yesterday if we might see you, he said that between working overtime and building your MK1 Rally Suby, you were swamped. Hope we get to see you sometime soon, would hate to have you miss all the fun.
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Old 11-13-2012, 09:38 AM   #109
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...
Small tool, big job. But it worked.
...
Sooner, or later, this is bound to wind up being a caption for different picture.
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Old 11-13-2012, 09:53 AM   #110
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Originally Posted by MortimerSickle View Post
Sooner, or later, this is bound to wind up being a caption for different picture.
This may be evidence of Luke's very dry wit....
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Old 11-13-2012, 01:36 PM   #111
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Quote:
Originally Posted by Pugsley/Hobbfather View Post
...but any reason to use the hole saw in the handheld drill? It looks like the pilot was created with a drill press.


Otherwise:

HOLY COW THIS IS AWESOME!

The cordless drill can turn much slower than the drill press, which is good for the hole saw bit. Here's the post: http://advrider.com/forums/showpost....postcount=1695

Jdrocks wasn't kidding about the binding either, I've got a tender spot on my ribs where the drill's battery pack smacked me a few times.
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Old 11-16-2012, 12:48 PM   #112
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^Luke^

Ahhh...added to my vast knowledge base...
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Old 11-19-2012, 09:24 AM   #113
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Swing Arm

Luke came over Saturday and started fabricating the swing arm, as you can tell from the photos, he made pretty good progress. I'll post the pics and let Luke weigh in later with the commentary.

Swing arm pics;









And Luke's new toy;





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Old 11-19-2012, 12:47 PM   #114
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Why are you making the swingarm out of multiple pieces of box tubing? Doesn't look like it would be and harder to drill offset holes for the swingarm pivot that would give you the angle/clearance you need? Luke, if you want to send me some dimensions I can help you figure that out?
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Old 11-19-2012, 03:04 PM   #115
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A straight tube won't work because the shock mounts are going to be under the center of the swingarm. Here's the cross section of the parts to be avoided at the centerline of the swingarm.

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Old 11-28-2012, 12:45 AM   #116
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Very nice TIG torch Luke! Is the little knob towards the upper end of the torch handle a shielding gas control valve?The swingarm is coming along nice as well.

Only problem is we need more updates! I'm sure I'm not the only one having CBZR-650 withdrawals...
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Old 11-28-2012, 11:19 PM   #117
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Yeah, I'm having withdrawal too. I got a little work in last week but have been busy since then.


From last week, a little more swingarm work:

Start with making a tube to simulate the hub with extra spacers.


This'll be a lot faster when I get the parting tool working.







Then tack some parts together.




More stick welding. I like.



The welds turned out as flat as the tube stock.



It turned out pretty well, with the axle and swingarm legs clamped together they were within 1/2mm at the swingarm pivot tube.

Cutting the cross brace.


The legs needed a bevel cut into them, and that was the last thing to do. These cuts were tricky, and I had to learn a few things about chop saws and metal tube. Chop saws need pressure to cut. Long flat cuts don't work. Metal tube has internal stress. Slit it long ways and it will spring out. Not the end of the world, but that'll be something to fix next time.

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Old 11-29-2012, 12:11 AM   #118
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Understand what you're doing with that swingarm now. Thanks for clarifying. For any precision cuts, you might want to try scribing lines on all four sides and then using a 4-4.5" angle grinder with a cutoff wheel. It's almost impossible to hit perfect angles on a chopsaw.
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Old 11-29-2012, 01:17 AM   #119
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precision ... angle grinder

You must have a much steadier hand than I do. I always do way better with the chop saw. Start with a decent one and take the time to square it up. It's a moot point anyway because the accuracy of the swingarm doesn't depend on the accuracy of the cuts. It just makes the fit better for welding.


The half mm was the difference in width between each end of the swingarm with the axle end bolted up and the pivot end free. A 0.05 degree error.
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Old 11-29-2012, 01:59 AM   #120
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Like your build up so far ..Thanks Have a question on the front end .. which tripple trees did you use for the forks ? did you have to modify the neck bearings to fit ?
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