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Old 04-21-2013, 04:41 PM   #61
DisTech OP
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Custom tubing bender mandrel cutting jig!


Tubing bender in action, start with unbent tube.


Finish with bent tube!


Yup.


Perfect circle!
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Old 04-21-2013, 04:53 PM   #62
chasbo
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Fak! Brilliant idea to bend the tubing!
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Old 04-21-2013, 11:22 PM   #63
Te Hopo
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Excellent work, I'm enjoying watching your ingenuity.
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Old 04-22-2013, 07:36 AM   #64
Greg Bender
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Quote:
Originally Posted by DisTech View Post
I'm 99% certain I have the correct replacement male terminals you'll need. If you want some, ping me off list, we'll verify, and I'll get you hooked up.

Regards,

Gregory Bender
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Old 04-22-2013, 09:58 AM   #65
Mikey Boy
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Subscribed. This is such a great build.
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Old 04-23-2013, 06:16 PM   #66
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Thanks guys. Thanks for the offer Greg. I have the correct connectors it's just the temporary splice where I used the crimp-on spades. When I know the actual length the pigtail needs to be they will be removed.

Oh how I lust for a mill. Sawed/filed half slots on the edge and then welded these tabs together.


Welded the circle together and looking at how the slotted tabs will connect.
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Old 04-26-2013, 05:48 PM   #67
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After some welding & grinding, welding & grinding, welding & grinding and more grinding the headlight frame is the shape I want it to be.


Side shot to see how the proportions work out, hard to tell yet.


Took the headlight frame to Seattle Power Coating today, get it back in a week.
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Old 04-26-2013, 06:43 PM   #68
Boojum
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Cool build Distech.......That bike is gonna be kick ass!


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Old 04-29-2013, 01:32 PM   #69
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Shit, hurry up will ya...waiting is painfull

Great build and fabricating skilllz man.
It will be my turn next winter but in the mean time keeping an eye on these 790 builds. So far they seem kats ass...
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Old 04-29-2013, 08:07 PM   #70
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Yea, figuring out what the top bracket is slow business.

But, hey! Seattle Powder Coating surprised me today when they called and said the headlight frame was done!


Gloss black, looks good!
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Old 04-29-2013, 08:36 PM   #71
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Quote:
Originally Posted by DisTech View Post
Given the lack of tools I have for bending metal,
I'm pretty happy with how symmetrical the brackets turned out.
Me too.

Ya know that once ya put pics on the internet, a photo pirate mite post 'em some where else, right?
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Old 04-29-2013, 09:07 PM   #72
Rainier_runner
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How's the Renazco racing seat? I'm currently running the seat concepts, but am strongly considering the upgrade.

And the project is looking awesome. Can't wait to here your opinions on the 790!
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Old 04-30-2013, 04:55 AM   #73
deathu
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Hi,

Thumbs up for the rebuild, I only hope I'll be able to do a similar project someday.

Can you please explain how does your tube bender actually work? It seems very simple but I can't figure out how that model actually bends the tube, the principle...
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Old 05-01-2013, 03:30 PM   #74
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How's the Renazco racing seat? I'm currently running the seat concepts, but am strongly considering the upgrade.
I have a Sargent seat on my R11GS that is pretty nice, probably equal to Seat Concepts and put a Guts Racing tall foam and cover on the DR455 that is pretty good for the money, but the Renazco on the DR790 is the best seat I've got. Not sure how practical a choice black suede was, but I love it! Chris is in Ravensdale so I just drive my seat pans out there.

Quote:
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Can you please explain how does your tube bender actually work? It seems very simple but I can't figure out how that model actually bends the tube, the principle...
Sure, what's probably confusing is the 2x4 attached to the side. It's only there to counter the leverage being applied to the vise while bending the tube. The tube was only 1/2" EMT, so really I am the tubing bender. I clamped the mandrel in the vise, stuck the tube between the bottom of the mandrel and jaw beam, wrapped the tube up around the mandrel with one hand and held the 2x4 with the other hand to keep the vise from tearing off my work bench.
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Old 05-02-2013, 07:32 PM   #75
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Hrrmm... a hand brake would sure be nice.
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