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Old 09-10-2013, 08:43 PM   #916
Katoom119
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Originally Posted by GrenDesb View Post
Ok then, I start saving right now.
Same here.
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Old 09-10-2013, 09:20 PM   #917
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Cool factor just jumped to universal levels...

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Originally Posted by CosentinoEngineering View Post
>>But is it replicable cool?

That's one of the reasons its taking so long! I originally planned on doing one, which can be done accurately in a quick and dirty manner, to doing 2, which makes a little investment into fixturing worthwhile. Then I had a couple of additional inquiries during the initial stages so thought putting a bunch more time into durable fixturing could be worthwhile. That added a lot more time but the plus is that it is now a 'process' and not just getting it all to fit.

Once we get Gregor and Tony's bike running I can get a handle on what the costs would be for additional conversions, hopefully in lots of 3 or so. The plan would be to send me a frame and forks and I send them back ready for reassembly. It would be a faster turnaround than these first 2 bikes (sorry guys!) since most of the legwork is already done.

As usual, keep checking on this thread for progress as the bike will be running this month.
And just when I thought my farkling list was completed... I better think again.
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Old 09-11-2013, 06:21 PM   #918
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Was hoping to get some work done in the shop tonight but Chris has family plans and I've put in a long exhausting day at the studio so it will have to wait. At dinner last night Chris claimed that the bike would be finished "next week" but I'm not sure if that was the extra beer Gino sent over or just optimism. Either way I'm hopeful and I think Chris is dying to get this done as well.

Woody's called to say my wheel is done and they sent me a shot of Zach truing it up.



I still need to get another hub for my dirt wheel but this will get me started. Alright Chris, it's up to you to do the next post and I'll be back to test ride it in three weeks...

Gregor
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Old 09-12-2013, 08:29 PM   #919
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more progress!

Now that the headstock welding is done we get into the interesting part. Will the gears mesh nicely? Is there enough room to shim? Is Chris about to start looking for a new KTM frame?

In short, yes, yes, no!

This is the bevel drive input gear cartridge. It has 2 bearings side by side on the gear end and one bearing on the opposite end inside the shaft seal. The seal on the shaft and o-ring on the threaded connection will keep the inside nice and dirt-free.



I was able to keep making progress and finish welding the transfer case mount and the bevel drive input mount. Nice, low heat welds kept everything from warping too much.



One thing I have to do is grind a bit of additional clearance on the inside of the headstock.



I designed in some overlap in this welded joint to make it less prone to blowing out during welding. I ended up having about .02-.03" too much protrusion which kept the gears from being in proper alignment.

Once this was done it was pretty simple to get the gears in proper mesh.



Each output gear is independently mounted to the headstock so it was only a matter of machining each mount until proper mesh was achieved for each gear.



I'll now turn up one piece steel replacements for each mount. The area adjacent to the gear is now the inner race for a needle roller bearing so the stock aluminum material is no longer suitable. These needle bearings are crucial to keeping the gears in alignment under various front wheel loading and are a result of using the existing KTM headstock.

The positioning of the transfer case is perfect. The clutch driveshaft spins freely with no binding. I am very happy to get very good results in this stage of fabrication.

Now that I have the all-important position of the transfer case final it is a perfect time to finalize the chain housing CAD and start machining.



Hopefully Gregor will be able to make it here tomorrow and rebuild his forks with the Christini gearbox lowers. That will take care of the entire drivetrain forward of the transfer case which is the meat of the project.

Looks like my drunken schedule musings may not be too far off!

Damn, Gregor takes some nice pictures! (Obviously not in this post)
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Old 09-12-2013, 10:05 PM   #920
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Gregor,

I'm working on a bicycle mount so I can ride down to Sisters for a MTB campout in late October. Seeing as you'll have your bike by then, maybe I should just make two?

So close. Can't wait to see it.
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Old 09-13-2013, 02:20 AM   #921
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Once installed, does this make changing the head bearings a bit of a mission with getting the meshings right again?
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Old 09-13-2013, 11:46 AM   #922
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>>Once installed, does this make changing the head bearings a bit of a mission with getting the meshings right again? Today 12:05 AM

Bearings are made with a precision in the .001" range so should be interchangeable without reshimming but I have not tested this out. The shims are 25mm ID and are available from McMaster in varying thicknesses. Also, the addition of the 2 large needle roller bearings will increase the life of the tapered bearings due to shared loading.
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CosentinoEngineering screwed with this post 09-13-2013 at 12:17 PM
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Old 09-13-2013, 07:12 PM   #923
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It's impossible for me to conceive tackling a project like this. You guys (Chris!!) are absolutely incredible. Great fun to follow along!

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Old 09-14-2013, 05:08 AM   #924
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Hack

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Originally Posted by Country Doc View Post
It's impossible for me to conceive tackling a project like this. You guys (Chris!!) are absolutely incredible. Great fun to follow along!

Instead of going two wheel drive on a 2 wheeled 950/990, how about tackling a 2 wheel drive 950 adventure hack project instead? ;)
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Old 09-14-2013, 03:16 PM   #925
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Johnny, I love you like a brother and so I'm going to pretend you didn't mention the S word here. Sidecar indeed.

So my work in NYC is very intensive and there's very little time to get out to the shop and squeak at Chris but he's got a pretty good head of steam on right now so I really wanted to just help keep the momentum. Therefore I finished my shoot early yesterday and hoofed out to the shop to put in a couple of hours before my flight home to Portlandia.

I had only one thing on my agenda, to swap the fork bottoms, and it was difficult work without my own collection of hand tools. Chris may have a full machine shop but I actually have a much better collection of hand tools - or at least better organized. I used to hate fork work but anymore I trust the logic of mechanical systems and so I just dove in sans manual.



First things first was I needed to hold the tube without crushing it. Obviously a vise would crush the aluminum upper so I used a hole saw to cut an opening in a 2x4 that I then split it on the band saw. This allows you to squeeze the bejeezus out the tube without damaging it. We didn't have a pin spanner (Chris, "how many of my bikes have forks? What do I need a pin spanner for? - Yes, very funny Mr. Funny Front End) so I rummaged around until I found a crescent wench with holes drilled in the tips - a makeshift pin spanner. Off came the fork caps.



Another hole was drilled in another board for the fork stanchions and they were sprayed down with brake cleaner to remove the fork oil that I spilled pretty much everywhere. Damn cartridge forks will drain until you think they're empty and then the next thing you know there's a puddle of oil on the floor.



No, you shouldn't light them on fire but this was the residual cleaner and oil being burned off by the propane torch. I like propane because Mapp gas can really over cook things if you're not careful. You want to heat this aluminum lower hot enough to melt the threadlocker that is holding it on - this is just about the temp where the oil left inside the tube starts to smoke.

It turns out that the best possible lever for the fork bottom is, of course, the axle which is sized perfectly. Once it's hot it just unscrews the conventional direction.



Chris and I decided that blue locktite would be fine for the new driven lowers and so I borrowed his blue chapstick threadlocker and screwed the unit home.



And that was all I had time for. My fork bushings looked a bit worn and so I left the forks apart and ordered a rebuild kit on my ipad on the way to the airport. I'd like to find a set of black upper stanchions as mine are scratched and faded so I'll look on ebay. If anyone has a set let me know - mine are a now a light lavender color that would be perfect for someone like Gino but I'd prefer something in black.

Gregor
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Old 09-14-2013, 03:47 PM   #926
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Nice work Gregor, you didn't happen to do our set as well

Hey Chris is it possible to get the upper stanchions re anodised?
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Old 09-14-2013, 05:13 PM   #927
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I am ADDICTED TO THIS THREAD
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Old 09-14-2013, 06:56 PM   #928
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Quote:
Originally Posted by DRjoe View Post
Nice work Gregor, you didn't happen to do our set as well

Hey Chris is it possible to get the upper stanchions re anodised?
Sorry, Joe, I barely had the time to do mine. You'll be happy to know that I did order a fork cap wrench so yours will be easy to take apart and put back together.

I know Chris has an anodizer he works with but I'm not sure if my forks are in decent enough condition to be redone. You really need a perfect surface to get a good result. Perhaps they could be chucked up in Peters big lathe and scotch brighted to a nice shiny finish that would give a good result. Mine have a couple of good digs from (ironically) fork protectors that rubbed on the upper. I'll let Chris weigh in on the anodizing - I'm game if the result it nice.

Gregor

______________________________________________

PS - Slideways, et al, I'm glad this is entertaining. To me this thread is like an "out of bike experience" where your bike has died and then you are floating above it, bike-less, watching mechanics furiously trying to rebuild it.

Well, like that crossed with the 6 Million Dollar Man (er, motorcycle)..."Rescued from the brink of salvage. Transformed by radical technology. Part motocycle, part weapon... Gentleman, we can rebuild it. We have the technology. We have the capability to make the worlds first bionic KTM. Gregor's KTM will be that bike: better, faster, stronger... Da da ta daaaa... da da da ta daaaa..."

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Old 09-14-2013, 07:18 PM   #929
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I'm sorry to burst your bubble Gregor but I think you'll find the one I'm building will be the best.
Yours can be its sidekick.
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Old 09-14-2013, 07:22 PM   #930
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Originally Posted by DRjoe View Post
Nice work Gregor, you didn't happen to do our set as well

Hey Chris is it possible to get the upper stanchions re anodised?
I asked a mob in melbourne about this and no problem.
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