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Old 02-01-2013, 12:33 PM   #106
toplessFC3Sman OP
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Thanks for all your kind words! What started out as a "hmm... it wouldnt be that hard to..." joking discussion with some friends over a couple beers has kinda taken on a life of its own.

Got some more time to stew over it last night & mock up where the fuel pump, filter, FPR, & fittings on the fuel tank will go. The best place for the pump seems to be laying flat on the back of the transmission, right next to the mount to the frame's spine so I can use that bolt for mounting. This also puts it as the lowest point, so it should have no problem priming/re-priming when I inevitably try to start the bike with the fuel valve off.



Speaking of the fuel valve, it will be in the same location as that picture, but I need to cut off the stock fitting since it's very stripped, and weld on a new NPT bung. The FPR can barely be seen in this next picture - it is way up under the tank (removed in the pic) near the top of the head, so that a continuous uphill run from the injector rails can be made. The little brass fitting in the middle, about 1/3 from the top is the inlet port from the fuel pump, and the high-pressure outlet to the rails is pointing backwards (out of view). The low-pressure outlet to the tank is pointing backwards too, a little higher up.



That position for the FPR should work out, and can be easily mounted to the two center studs at the back of the head holding the cam cover on. Since I'm welding on the tank already, I'll be adding another bung for the fuel return. Im considering putting it on the other side of the tank, but that would force all the fuel that gets returned to flow through the cross-over hose, which may be a restriction when the tank gets low. Plus, I couldn't get a tube inside up to the top of the tank, so it may have to go further forward, requiring tubing to be run forwards over the top of the head & next to the plug wires & coils. I'll need to puzzle on it a bit more before coming to a solution.


All tucked in for the night!
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Old 02-05-2013, 06:32 AM   #107
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Got a little bit of welding done at i3Detroit last night - still needs a bit of finishing, and man am I rusty with the torch, especially on the thin walls of the tank! Anyhow, now for a couple pictures...


"custom" M10x1.0 to 1/4" tube compression fittings for the ends of the fuel pump


plugged the ends of the fuel rail with phillips-head screws, with most of the screw ground off


This will become the fuel return tube - basically its a section of tube inserted through a hole drilled in the tank so that it ends as close to the top of the tank as possible to keep the return pressure constant as the tank's fuel level decreases. I still need to cut off and grind down this side of it so that I can weld an NPT bung over it to thread the return elbow fitting into for ease of maintenance later on. Except...


Thats where the other end of the tube ended up. Right underneath the cap, which means that if the fuel pump is on when the cap is open or loose, you're getting a nice spray of gasoline IN THE FACE. In theory, this shouldn't happen if you shut off the bike, turn off the fuel feed to the pump, and wait 30 sec or so before opening the tank, but you can't guarantee that always happens, plus it really tests the seal of the tank lid, and the tank "breather" is in the lid, so you may end up flooding that and getting a leak anyway. Basically... I didn't plan this as well as I should have, so I'll be drilling out and grinding off this tube, bending the top around at least 135 deg so it points down into the tank, and re-welding it to remove this potential for disaster.

Anyway, a big thanks to my co-worker who introduced me to i3Detroit so I can get this stuff done and showed me the place last night!
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Old 02-15-2013, 12:00 PM   #108
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I had a chance to go back to i3Detroit on weds night, and hopefully have the tank finished now! Still need to check for leaks (with water first - i've made that mistake before), and then re-seal the inside, but both fittings as well as a new return tube are welded on.

Return tube welded in & ground flat


Visible, but pointed towards the back of the tank where the pick-up is - much better than before


I thought this bit, welding a nice thick NPT bung onto the thin sheet steel with that much of a gap was going to be a big pain, but it actually went very smoothly


All done with that one! Right around the seam and cross-over tube was a little tricky to get the torch into, but it got done


And the other bung for the return, over the hole where the tube was welded into. I didn't remove the paint in a large enough space around this one, and it caught fire when I was welding. Took me a little bit by surprise, at which point I burned a hole in the tank which had to be filled, explaining that blob to the lower left of the bung.

So, the only welding that I can think of left is for the O2 sensor bungs in the exhaust, and possibly for a fuel pump/filter bracket
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Old 03-03-2013, 07:48 PM   #109
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Got a little bit done this weekend - received the O2 bungs to weld onto the exhaust, got the new handlebars wired, connected & bolted on, and started putting things back together a little. Notably, the Megasquirt engine controller is installed & I got the firmware loaded onto it and began setting up the inputs. The battery I had for the bike was completely dead & wouldn't hold a charge, so I couldn't crank it over with the starter. However, kicking it over with the MS on and datalogging, it was reading about 600 RPM - this seems a little high for kick-starting, but at the very least I am getting signal from the cam position sensor. Picked up a new battery earlier today which I'll be charging to try again with the starter, and hopefully I'll have more of the sensors wired up to conduct a more thorough test.

At this point, the biggest mechanical tasks to be done are fixing a couple of tiny leaks around the new fittings on the tank that will need another weld bead drawn over them, re-sealing the tank, a little touch-up on the throttle cable mounts, and the O2 sensor bungs to be welded to the exhaust, plus a tiny bit of wiring and wrapping up the harness.

Electrically there's a bit more testing thats involved, and then of course the tuning, but for that to start, the bike needs to make its way out of hibernation in the basement

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Old 03-03-2013, 09:45 PM   #110
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Don't stop now, this thing is looking fly!!
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Old 03-11-2013, 02:54 PM   #111
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This weekend I was test-assembling things to make sure all the fuel tubing runs could be made and all the various connectors & wires were where they needed to be & providing signal. There was a small snag - without the injector connectors on, the throttle bodies fit fine, but the connectors hit the middle spine of the frame, keeping the whole throttle body from sitting on the mount correctly. Twisting the TB's around helped a little on one side, but the other would run into interference with the battery box or the TPS sensor. After disassembling & looking at the TBs closely, I realized that I could just rotate the injector so that the connector exited between the fuel rail and TB instead of on the far side of the TB.
to...

Now they could sit the way I had intended so any bubbles in the fuel could get bled out just through buoyancy. An added benefit is that the throttle cable doesn't need to bend as sharply around the engine to connect to each TB, making the routing a bit easier.


The downside to this is that the holes in the injector aren't pointing in the same orientation as stock, so I may be getting more wall-wetting than normal, but we'll see if that seems to be an issue once it fires up.

I also stole the battery from the project car, charged it a bit, and was using it to drive the starter so that I could get a much more consistent engine position/speed signal than kicking it could hope to provide. Anyhow, after adjusting the VR pickup in the cam end cover where the points used to be so that it was slightly closer to the toothed wheel, and fixing a couple settings in the code, the Megasquirt had no problems syncing up to the engine, showing a cranking speed of 250 - 300 RPM, as well as reading the coolant head temperature, air pressure, and throttle position.


Things are getting done slowly, but they are moving in the right direction!
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Old 03-11-2013, 04:57 PM   #112
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Awesome. I'm still pumped.
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Old 03-18-2013, 06:40 PM   #113
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Got a little bit of welding done on the exhaust and throttle cable mounts for the throttle bodies. I haven't had a chance to go back to i3Detroit, so this was done with a friend's flux-core mig-style welder; sure, its a Harbor Freight special, but it worked well enough. Not exactly pretty, but oh well



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Old 03-19-2013, 06:25 AM   #114
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Oh, I forgot to ask, is there a source that anyone recommends for replacement or up-rated cam chain tensioner sprockets? Before assembling everything and filling up the area behind the engine & over the transmission, I'd like to take care of it. I've seen plastic ones pop up on ebay occasionally (although none seem to be there now), but was curious about what else was out there, especially if I could buy one from a site sponsor. Thanks!
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Old 03-19-2013, 06:49 AM   #115
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Hey, you should talk to toplessFC3Sman over at hondatwins.net

He's doing a very similar project!
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Old 03-19-2013, 07:05 AM   #116
Kt-88
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Quote:
Originally Posted by gravityisnotmyfriend View Post
Hey, you should talk to toplessFC3Sman over at hondatwins.net

He's doing a very similar project!
I'm so hoping this is a joke.
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Old 03-20-2013, 05:49 PM   #117
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It's no joke. Seriously, check it out:

http://www.hondatwins.net/forum/view...=2951&start=60
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Old 03-20-2013, 06:33 PM   #118
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Quote:
Originally Posted by gravityisnotmyfriend View Post
It's no joke. Seriously, check it out:

http://www.hondatwins.net/forum/view...=2951&start=60
Dude... the OP of this thread is the same person.
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Old 03-20-2013, 09:18 PM   #119
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No one could write this stuff

Quote:
Originally Posted by 'Flagger View Post
Dude... the OP of this thread is the same person.

But maybe the persona over there has info this one doesn't have.....
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Old 03-20-2013, 10:47 PM   #120
'Flagger
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Originally Posted by pennswoodsed View Post
But maybe the persona over there has info this one doesn't have.....
I'm not sure why I volunteered to argue with idjits... but..... the creator of the thread you are reading right now is the same damn person as that who created the thread over on HondaTwins. Unless two different people choose the same odd screenname... which isn't likely.
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