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Old 03-05-2013, 08:04 PM   #781
Katoom119
Mmmm....Orange Kool-aid
 
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Looking good. Get that bike done and come to Alaska in July. I'd like to see an AWD 990.

Beers on me.
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Old 03-05-2013, 09:28 PM   #782
sakurama OP
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Quote:
Originally Posted by Katoom119 View Post
Looking good. Get that bike done and come to Alaska in July. I'd like to see an AWD 990.

Beers on me.
I was actually thinking Alaska in August. Maybe you'll still be there? I'll need that beer. For sure the KTM rally.

Gregor
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Old 03-06-2013, 11:26 AM   #783
Katoom119
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Quote:
Originally Posted by sakurama View Post
I was actually thinking Alaska in August. Maybe you'll still be there? I'll need that beer. For sure the KTM rally.

Gregor
Nah, much as I'd like I've got to be back beginning in August to get everything squared away for fall semester. Padre and I are leaving Anchorage about July 20 to head back home. I might be headed down towards the Lost Coast so I can meet KatoomWife and one of her friends in California so I may just start heading down Highway 1 at the Canadian border. If so, beers are still on me.
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Old 03-07-2013, 09:03 PM   #784
CosentinoEngineering
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I hate taking the bandsaw to nice billet parts.


1,2,3,4,5,6,7,8,9,10 fingers, check!


But then cleaning it up in the mill makes me feel better.



More coming soon....
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Old 03-12-2013, 05:31 PM   #785
mookymoo
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Quote:
Originally Posted by CosentinoEngineering View Post
>>that was a little anticlimactic

Yes, we were just a little bummed out.

>>f you open-up the throttle slowly after cranking on choke....

Didn't do that but will check next time I try.

>>You guys have it all opened up and are playing with the fuses, pop that headlight fuse out and save a little battery life while cranking.

Yes, we were a bit tunnel visioned at that point.

The initial tyest was with an 85 starter jet, the same size as in the FCR-MX on my ktm 450. We also tried with no jet installed and definitely was getting fuel through the choke passage. Gregor how's that eye? Still burning? I'll try a 65 when I get a chance.


Chris
Any further work planned on the choke? Or is it shelved for the moment?
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Old 03-16-2013, 01:33 PM   #786
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Any further work planned on the choke? Or is it shelved for the moment?
I think it's on hold for the moment. Chris is deep into the 2wd conversion and since we can't run it until that's complete now it's going to be on hold. I'm going to be pushing for that though as I think it's the final part of the FCR puzzle but at the moment I'm neck deep in house remodeling so it's not on my radar right now either. We will pick it up again and hopefully get it figured.

Gregor
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Old 03-16-2013, 06:23 PM   #787
mookymoo
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Originally Posted by sakurama View Post
I think it's on hold for the moment. Chris is deep into the 2wd conversion and since we can't run it until that's complete now it's going to be on hold. I'm going to be pushing for that though as I think it's the final part of the FCR puzzle but at the moment I'm neck deep in house remodeling so it's not on my radar right now either. We will pick it up again and hopefully get it figured.

Gregor
Righto. Sounds like nothing going to happen for a while then
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Old 03-17-2013, 06:56 AM   #788
Pete640
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Arrrggghhhhh.. I want some 39s and Id really like chokes.....
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Old 03-19-2013, 08:18 AM   #789
wiseblood
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Old 03-25-2013, 12:49 PM   #790
CosentinoEngineering
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While I'm still waiting on some output sprocket parts from Christini focus was changed to the headstock gearbox assembly. Since I don't want to weld on the replacement headstock we need to accurately measure the new bearing spacing so that the bevel drive input gear is properly located.

After some careful measuring and machining of the existing parts I was able to fit the standard KTM head bearings and seals. This setup is merely to allow for alignment checks and smooth operation and all of the internal headstock parts will be remade without shims and spacers.



Now I can fit the new triple clamp assembly into the headstock to verify locations and alignment.


and


Now knowing that it all actually fits together I need to determine the location of the input shaft relative to the steering bearing seat. This is crucial because the frame needs to be drilled and a bearing support installed and if done in the wrong location would mean a noisy gearbox at best and at worst a non-functioning gearbox.

To do this i needed to make a test headstock where I could machine the input shaft in its likely position and then shim the steering bearings until I got a proper gear mesh. Once done shimming I know exactly where everything needs to be. All of the relevant surfaces were machined so getting accurate measurements should be easy.

I started with a block of aluminum held in a vice in the 4 axis mill.


In several operations I machined the input and headstock bearing bores and a couple of inspection windows to allow for direct backlash measurement.


and

and


With the assembly test fixture done its time for a test assembly.

and

and


With a few thousandths of shimming I was able to get excellent gear mesh.


Now that I have all the many components done I need to make a drilling/welding fixture for the actual frame modifications.

It will look something like this and allow me to drill out the access hole, machine a bearing support for a tight fit into the hole, and then hold it in proper alignment for welding. Getting as snug a fit in the drilled hole as possible will eliminate any distortion due to gaps in the fitup.



I should get the sprocket parts this week which will allow me to finalize the idler gear shaft centers and start to draw up some chain support and housing parts.

Once that is done it will be time to start molesting the frame in earnest.
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Old 03-25-2013, 12:54 PM   #791
CosentinoEngineering
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>>Arrrggghhhhh.. I want some 39s and Id really like chokes.....

Once the bike is together enough to start I'll try to do some more work on the chokes. At this point the only option is jet size so once the bike is together a little more testing will be a definitive yes or no. I only hope the weather is still cold enough to test cold starting.
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Old 03-25-2013, 07:22 PM   #792
sakurama OP
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I am at once thrilled and slightly disappointed that all this work will be almost completely invisible when this is done. Great work Chris.

Gregor
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Old 03-26-2013, 03:15 AM   #793
kamanya
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I love your work!

Would this not help you?

Cad drawing of LC8 frame

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Old 03-26-2013, 10:14 AM   #794
CosentinoEngineering
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>>Would this not help you?
Thanks for the link, it will definitely be a help.

Someone spent a lot of time scanning and modelling! Its the right color too.
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Old 03-27-2013, 07:43 PM   #795
Pete640
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Quote:
Originally Posted by kamanya View Post
I love your work!

Would this not help you?

Cad drawing of LC8 frame

That is a beautiful frame. Its a pity its covered by the tanks and fairings mostly isnt it??? Love the digital scanning thats available now.

No rush on the FCR's - I'll prolly be shipping them with a frame when you get it worked out.
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