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Old 11-29-2012, 09:35 PM   #16
digger440 OP
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I know I said exhaust but here are the Rearsets

What cafe bike is complete without rearsets?

I love the rearsets Boxermetal (be sure to like on facebook) puts out but they were not the look I wanted, much too clean and too nice. I like the look of rubber and steel pegs which say "when you drag me you will be in huge trouble" so I set about to build my own.

I unbolted the stock peg and stared at them I looked at where rearsets normally mount and had an idea-rrrrrr, if I take the stock pegs and mount them where rearsets usually bolt up......

...so I got to work

Left peg first as it has the shifter I cut the support and set it to the side







I thn mocked it up to the upper hole in the rear peg support



Then I had to make a shouldered boss for the shifter to ride so I used a bolt (that was hard as Hades BTW) and put it in the lathe. I turned thread on both ends ad machined a section fo te shift lever to ride
















After I machined it it threaded into the peg on one side and nutted to the frame on the other and the shift lever pivots in the middle








On the passenger side I had to cut the squiggly piece out between the peg and the mount hole to get the correct height then weld it back together













now I have to find a way to support them and since they are mounted near the old passnger pegs that seems like a good idea. So I cut up the old passenger pegs to join with the new rearsets.













I love molten metal







The finished product





bolted up and looking like I wanted











Got linkage (even if temporary)





Das Boot








The next chapter is the brake pedal and linkage (I have had too many libations to type much more






BTW I promised exhaust and it is coming


To be continued......
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Old 11-30-2012, 09:45 PM   #17
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The brake pedal

Yeah rear brakes since I built the rearsets I needed to move the rear brake controls so they are reachable. You can see how far away from the new location the stock lever is







So I removed the arm and cut off the portion of the lever that actuates the master just below the pivot bolt





Then I drilled and tapped what was left of the brake lever in order to bolt a "bellcrank" to that will be actuated by the pedal






I then found a "splined piece" (I dont dare say what it was) that captures the head of the pivot bolt and formed a bellcrank that would bolt to the stock lever that is drilled and tapped.






Ok do you remember the support I cut from the left footpeg behind the shift lever and the squiggly piece I cut from the right footpeg? Well in the interest of recycling and reusing I saw the shape of what I wanted in these two "leftovers". So I did what any self respecting tinkerer would do and I welded them together and bored out the end that attached to the "splined piece", pressed in a 17mm hex and welded that into the arm.











I welded the Bellcrank to the "splined piece" and checked to make sure that when the two pieces were put together ther was enough bite on the splines so that it wouldn't round out or break under heavy stomping.





I drilled a small hole in the head of the pivot bolt and tapped it with a bottom tap to retain the lever. Seems safe enough as there is no lateral moment with the bolt tightened.






The last part I needed a actual pedal piece, so I cut off the factory foot-trap and drill it and tapped the lever so it would bolt on. And Viola, brake pedal with a stock brake light switch and actuating arm.








Next is exhaust , really , no joke




digger440 screwed with this post 12-05-2012 at 12:15 AM
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Old 12-01-2012, 03:17 AM   #18
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Enjoying this.
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Old 12-01-2012, 07:54 AM   #19
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Thumb

Hey thanks guys for the word of encuorgement and interest! Any questions, suggestions, comments or criticizims yall might have are always welcomed.

And let me add a disclaimer: I post at night after work and since I am on the comfort of my couch I usually post after a few libations. So, grammar and punctuation will always be my victim of abuse and neglect
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Old 12-05-2012, 12:12 AM   #20
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Exhaust V1.1

I have been putting off posting this because, well, I still have to change some pieces I am not happy with the right side tube and it needs to be raised about an inch where it snakes around the left side tube. But you get my fails along with my successes so here it is.


I was getting to the point in his project where I needed to drop some cash (that I did not have BTW) because I started pricing DOM tubing and just could not pry it out of my wallet.

I saw these in the far back reaches of my shop and they had been taking up room forever. I tried to Craigslist them for 50.00 each but there was not even one response, Both were 1 5/8 tubes 1 set was new for small block chevy truck and the other set was used but still in excellent shape for a 2nd gen 455 Pontiac F-body. All those sexy mandrel bends....





All those seck-say mandrel bends in a pile I could pick from







I cut off the factory pipes 2 inches in front of the nuts and started on the left side first. I routed it to the right side and left room to get the oil filter out.





I then took the right side pipe and curled it around the left ( here is the spot I am not happy with)









At this point the pipes are within 1/2 inch of each other 26.5 and 27 inches




Now I start adding on, raising the level as I plan to go under the transmission














Now that I am at the "bend in the road" so to speak I get input from my supervisor who confirms my doubts about the right side pipe being too low and not looking just right. However in the spirit of creative influence he says to continue and I can fix the pipe later







Now I have to go under the trans and the ultimate goal is to exit under the tail with no mufflers. Would you believe me if I said "loud pipe save lives", I thought not. I cannot even believe I typed that lame ass screaming eagle horse shit. I dont want mufflers because it will efff with the look and flow of the bike. I will lose some ( a lot) of low end but I am not building this for the Iron-Butt or Paris to Dakar.


Not only do I have to make a 90 degree bend but I have to megre 2 into 1 to balance the system but I also want to have the look of dual pipes. So I start by building a 2 into 2 "X" pipe with a small choked area about 2 1/8 inches ID

gotta have a merge collector and I had four laying about I cut from the headers. So I put them in the band saw







I got 2 90's and expanded the ends so I could use band clamps to seal them and tacked them into the merge I also used a piece of 2 inch stainless as a form so the outlet would be round







The finished product looking very merge-y







It goes under the transmission or it gets the hose again












now it has to go up the other side under the linkage I built to exit under the tail to be continued.....
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Old 12-05-2012, 02:45 AM   #21
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Gearbox oil change will mean pipes out of the way, but I guess you know that.
That'd be the time to change the oil filter too!
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Old 12-05-2012, 07:09 AM   #22
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Wow, you're getting busy. Looking great. Nice work
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Old 12-05-2012, 09:00 AM   #23
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Quote:
Originally Posted by boxerboy81 View Post
Gearbox oil change will mean pipes out of the way, but I guess you know that.
That'd be the time to change the oil filter too!

You can not really tell from the photos I took that the merge collector is just to the rear of the trans drain plug. I can take pictures in the same way a chimp with a hammer can pound a nail; It gets done but it lacks finesse.

The whole exhaust system will be built with slip joints sealed with stainless band clamps. In all my years of wrenching I hated nothing more than having to cut apart something or completely build from scratch something someone did not have the foresight to see would be a problem or in the way of serviceability.
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Old 12-05-2012, 09:26 AM   #24
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This is a great thread! Your sharing of the pics and build/modification process are much appreciated.

Keep up the good work.
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Old 12-05-2012, 09:16 PM   #25
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Now it is time to make the exhaust come out from under the trans and up the other side under the seat. So I have to make a ( kinda sorta) mirror image of the merge clloector i just built.

I selected two 90s from the pile and spaced them apart just a little so i could expand them and slip a ban clamp between them.








The flat plate my ground clamp is on, is tacked to both pipes to prevent movement i will cut it out when i am done building the merge





Here is that same piece of stainless pipe I am using as a form to keep the inlet round





Once i finished this half i welded both halves together to make this monstrosity







And here it is in place the shift linkage clears it although I mish put a heat shield on the trans side and one on the leg side (something with lightening holes I think)








Right now this is where I am at with the project I will continue to update as I build stuff.
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Old 12-15-2012, 10:38 PM   #26
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I had to mount the seat, I have been putting this off. It has just been sitting on the subframe and I want to build the rest of the exhaust.


so I added some pads to the rear with nutserts in the ends of the tubes and straps to bolt the seat to






I used the nutserts with bolts to use to locate the tail left to right, drilled holes in the straps and made floating hold-down that I will capture with tabs so the hold-down will "float " in order to allow adjustment front to rear and left to right.









Tail is solid as a porn star's behind
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Old 12-18-2012, 12:08 PM   #27
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Did you try full rear shocks compression ? Seeing the pics, it looks like the shocks tanks should hit the bracket when rotating under compression. It might be just visual, but that seems a really really tight fit...
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Old 12-18-2012, 01:37 PM   #28
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Quote:
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Did you try full rear shocks compression ? Seeing the pics, it looks like the shocks tanks should hit the bracket when rotating under compression. It might be just visual, but that seems a really really tight fit...

It looks that way in the photos but with the springs removed the shock have plenty of clearance in the mounts under full compression. Actually because of the angle of the shocks the arc of travel is very small.
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Old 12-18-2012, 01:49 PM   #29
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Quote:
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Adjusting the free play in your clutch is going to be near impossible .. But I have to admit ... it's very cool.

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Old 12-18-2012, 06:06 PM   #30
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Adjusting the free play in your clutch is going to be near impossible .. But I have to admit ... it's very cool.

That is one of the reasons I built that piece with slip joints, I wanted it to have a nice clean look that flanges do not provide and I wanted to be able to take it off easily in case I had to fix someting. I really am trying to put as much forethought into making the pieces that I do so that in the future they will either not get in the way, be easy to take off if they are in the way, and/or easy to replace.

The battery is the next trickey item that is ugly and needs to be hidden I am shooting for under the tank in the area the stock coils took up but we will see how that plays out
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