ADVrider

Go Back   ADVrider > Bikes > Some Assembly Required
User Name
Password
Register Inmates Photos Site Rules Search Today's Posts Mark Forums Read

Reply
 
Thread Tools Search this Thread Display Modes
Old 04-05-2011, 09:44 PM   #31
sailah OP
Lampin' it
 
sailah's Avatar
 
Joined: Aug 2005
Location: Turning expensive metal into scrap
Oddometer: 5,259
Just a little prep work for when the suspension arrives. Got the carbs back together after the jet kit installation. Holy crap is drilling a tiny hole with a pin vise 8 times a nightmare. The Pod filters fit really well, pleased with how it turned out. Very nice kit







I also figured out the front end I think.

Since I have Yz450 triples laying around in multiples, and since they fit the KTM 950 forks, and since it just so happens that the FZ1 and YZ have the same diameter stem where it goes in the triple, and the stem is the same length, and that the bearings are completely incompatible....

I decided to take both triples to a shop tomorrow to have the stems pressed out and swapped. Well, only the FZ1 swapped to the YZ. That way I will retain the stock bearings and everything else will be YZ. I do have a couple small fitment issues but nothing that can't be overcome



I needed a spacer that covers the nuts that hold it together. The stock FZ1 triple has this spacer integrated into the triple, but it just so happened that robbing my buddies scrap bin I came up with AL tube of the exact ID. Love that. I tried welding it, but my TIG was just screaming on full throttle to melt that Pro Taper triple. Not happening, and not really needed either.






Working on the exhaust now. I have an R1 header which is supposed to tuck closer to the frame than the FZ. In trying to route the exhaust I have a couple options. On the right side, where the bags are going to be. Directly under the seat, which is where I am leaning. Doing this would require threading the tube down in the swingarm hole and tucked around the oil pan. I'm sure I can do it, just not sure it is worth the trouble, although it would look sweet and very tidy. I plan on running 8" Jesse bags so I'm trying to not add width, which this arrow can has plenty. I have already relocated the electronics under the seat to elsewhere so there's nothing under there anyways. I will have to figure out the rear lighting etc.
sailah is offline   Reply With Quote
Old 04-06-2011, 06:22 AM   #32
Damifino
Damn if I know
 
Damifino's Avatar
 
Joined: Mar 2006
Location: Maryland
Oddometer: 650
Man Pete, you don't fool around, I am amazed at your progress so far. How did the carbs look when you opened them up?

Cool as hell!
__________________
07 KTM 950 SE
99 KDX200
79 Yamaha RD400 76 BMW R76/6
06 Vespa Granturismo 200L
Green Marble Enduro Riders http://gmer.us
Damifino is offline   Reply With Quote
Old 04-06-2011, 06:40 AM   #33
sailah OP
Lampin' it
 
sailah's Avatar
 
Joined: Aug 2005
Location: Turning expensive metal into scrap
Oddometer: 5,259
Quote:
Originally Posted by Damifino View Post
Man Pete, you don't fool around, I am amazed at your progress so far. How did the carbs look when you opened them up?

Cool as hell!
Carbs looked great. I put the jet kit in and had to open the bowls. Little dirt but nothing bad. Thanks again for the bike
sailah is offline   Reply With Quote
Old 04-06-2011, 05:59 PM   #34
sailah OP
Lampin' it
 
sailah's Avatar
 
Joined: Aug 2005
Location: Turning expensive metal into scrap
Oddometer: 5,259
What are the odds???



Since the YZ triples uses a tapered roller bearing and the FZ1 uses ball bearings, a bearing conversion was going to be tough. I measured the stems where they go through the triples and they were both 32mm undersized.

Stopped by a garage on my way home and the guy said sure go for it, there's the press. I was a little nervous as I have never done this, but the FZ1 stem came right out. Same with YZ. The YZ is aluminum, FZ1 steel.

The big moment of truth would it actually press in. Oh yes!! It felt like winning the lottery, big problem solved and all it cost me was a case of Natty Light as the garage guy wouldn't take any money as I did it myself.



Got a nice package from Frank Wheelbarrow today. I have to jump on a conference call but will open after and give a full report.



Woodys let me know that the Excel is being anodized and should be to me next week.

Latest hurdle was matching up the 530 pitch chain on the FZ1 with the 525 950 setup. A 520 conversion is an easy solution, but I'm more concerned with durability than HP and weight savings. Sprocket specialists said they would make me a 530 rear sprocket from 7075 for the 950 so I can keep the 530 countershaft sprocket and 530 chain from the FZ1.

I'll wait until I get a little further along with my gearing calculations before I order. Anyone have a cool spreadsheet that will help me figure out a good gearing for this bike? At $70 the custom rear sprocket isn't crazy expensive, but certainly not something I want to do 5 times.
sailah is offline   Reply With Quote
Old 04-06-2011, 06:41 PM   #35
PABiker
Anywhere but here
 
Joined: Dec 2006
Location: Pittsburgh
Oddometer: 3,734
http://www.sprocketcalculator.com/


__________________
'12 Suzuki DR650SE
'10 Husaberg FE450 Plated
PABiker is offline   Reply With Quote
Old 04-06-2011, 08:38 PM   #36
trailtrick
goat trail rider
 
trailtrick's Avatar
 
Joined: May 2008
Location: socal
Oddometer: 3,306
Looking good , before you weld the shock mounth , take the spring out o the shock relese the nitrogen and cycle the swingarm with the shock bolt on to make sure everything works good .
__________________
"Vive tus sueños en vida, no la vida en sueños.

Kampale Moto Ranch
Bed and Breakfast
mototours/uruguay south america
trailtrick is offline   Reply With Quote
Old 04-06-2011, 09:02 PM   #37
sailah OP
Lampin' it
 
sailah's Avatar
 
Joined: Aug 2005
Location: Turning expensive metal into scrap
Oddometer: 5,259
Thanks, found this cool website: http://www.gearingcommander.com/

Here's what I came up with:

sailah is offline   Reply With Quote
Old 04-10-2011, 07:28 AM   #38
sailah OP
Lampin' it
 
sailah's Avatar
 
Joined: Aug 2005
Location: Turning expensive metal into scrap
Oddometer: 5,259
Quote:
Originally Posted by trailtrick View Post
Looking good , before you weld the shock mounth , take the spring out o the shock relese the nitrogen and cycle the swingarm with the shock bolt on to make sure everything works good .
Thanks for the call Javier!! I took your advice and installed the front end. Got the rake to about 28 degrees but not without some supreme shadetree machining.

I thought the triples were the same from KTM to YZ however the outer tubes on the KTM were 60mm and the YZ was 59.3ish.





I have a good day ahead of me today and hope to get a lot done. working on getting the dash figured out. I think I will lop off the stock attachment point on the stem and make my own. Only issue is that the VIN number is engraved right where I want to brace it up. I'll figure it out.

I made a dash plate for the gauges out of aluminum plate. The mount welded to the freame will be steel and the dash subframe I plan to do from Aluminum tubing. Get some good TIG practicing in.

I plan on running dual PIAA 540's for front headlights. Not sure how I will get around the highbeam issue. Maybe just make one low and one high? Can you run a dual filament bulb in a housing that wasn't designed for it? IE will a dual filament H series bulb have the ability to dip in the housing where it was only designed for an H4? If anyone else has suggestions, I'm all ears. The Buell setup is essentially what I am shooting for.






The exhaust is still a thinker. Def going to run a carbon Arrow under the seat, however the exhaust header comes out the right side under the oil pan. I have two options, one route it out the right, under the peg, over the swingarm and up under the seat. Sounds like a pain but it's actually easier than the other option which is to go around the shock and res, through the opening in the KTM swingarm, make a 90 degree turn and then into the header. Either way I'm into a custom exhaust. damn SS tubing is impossible to find in 2.375" and I basically need to use J bends or donuts to make the shapes I want. I think the shock route is cleaner looking and lestt heat on the right boot, but going to be tight in there and may involve some swearing

I had decided to make my own bags but Jesse had some overstocks for $300. I have been leaving him messages on his shop phone and emails asking him to send me a bill. I guess people don't want my money. So I am now back to making my own. will be aluminum, essentially a thin Jesse bag with custom permanent mounts.

I bought an entire side of black suede for my seat. I will most likely make the pan from aluminum plate and then rivet the cover to it. Enduro style, but no passenger footpegs at the moment.

I'll post some pics later today.
sailah is offline   Reply With Quote
Old 04-10-2011, 07:49 AM   #39
PhiSig1071
What's ******width?
 
PhiSig1071's Avatar
 
Joined: Apr 2008
Location: Tucson, AZ
Oddometer: 1,922
Cool project, can't wait to see the finished product.
__________________
Which one of you FF's was it?...FOUNDER!

Entia non sunt multiplicanda praeter necessitatem
PhiSig1071 is offline   Reply With Quote
Old 04-10-2011, 08:04 AM   #40
rideaholic
Gnarly Adventurer
 
Joined: Nov 2006
Location: Pittsburgh, PA
Oddometer: 229
Pete,

I may try to stop by your place today, while riding, to see how the project is going.
rideaholic is offline   Reply With Quote
Old 04-10-2011, 02:51 PM   #41
sailah OP
Lampin' it
 
sailah's Avatar
 
Joined: Aug 2005
Location: Turning expensive metal into scrap
Oddometer: 5,259
Quote:
Originally Posted by rideaholic View Post
Pete,

I may try to stop by your place today, while riding, to see how the project is going.
Yeah whatevah guy

Built the headstock for the light/instruments. This took awhile. I hated to MIG weld it, but didn't really have any choices.

The aluminum bracket bolts to the steel headstock.













Ordered the PIAA 540 lights from Summit so they should be here soon to finish the aluminum fabwork.

sailah screwed with this post 04-10-2011 at 03:19 PM
sailah is offline   Reply With Quote
Old 04-10-2011, 07:41 PM   #42
rideaholic
Gnarly Adventurer
 
Joined: Nov 2006
Location: Pittsburgh, PA
Oddometer: 229
I ended up riding all day.

Looks good though. I'll stop soon and give you some pointers.
rideaholic is offline   Reply With Quote
Old 04-10-2011, 09:43 PM   #43
tileman
Studly Adventurer
 
tileman's Avatar
 
Joined: Mar 2007
Location: Melbourne, OZ
Oddometer: 830
Quote:
Originally Posted by sailah View Post


Ordered the PIAA 540 lights from Summit so they should be here soon to finish the aluminum fabwork.
Well it aint gunna break!!!!
__________________
If ignorance is bliss, why aren´t more people happy?????
tileman is offline   Reply With Quote
Old 04-11-2011, 04:51 AM   #44
sailah OP
Lampin' it
 
sailah's Avatar
 
Joined: Aug 2005
Location: Turning expensive metal into scrap
Oddometer: 5,259
Wicked

Well I had the aluminum on hand and it weighs about half the steel thing I replaced. I'm new to tig welding so it's much easier to weld thicker material like that for me. Plus that strut will be supporting the 5" lights and a windscreen that will see some high speed runs.
sailah is offline   Reply With Quote
Old 04-11-2011, 10:11 PM   #45
sailah OP
Lampin' it
 
sailah's Avatar
 
Joined: Aug 2005
Location: Turning expensive metal into scrap
Oddometer: 5,259
Ran into my first dammit

The struts on the subframe don't allow the tank to sit against the frame. Also the petcock is pretty close to where I need to mount the upper shock point. I'm thinking about cutting and shaping the tank. I have never welded sheet metal that thin so a little nervous about that. Other option is to remove the struts and work the reinforcement in some other way. Lot of load in that area due to the shock so a little unsure. Plus the tank petcock has a special mounting place with tapped threads and the tank vent/drain comes out in the same place. I'd need to cut those out as is and move/weld them somewhere else then weld the tank, repaint it etc. I don't want to plow into the tank with out exhausting every other option first, that seems like a lot more work and I'm trying to move things along.





I did some more shadetree machining to make spacers for the top triple, it nows fits perfectly





I don't think the exhaust can route where the swingarm is due to clearance issues, so I will make my life easy and come up around the swingarm, under the seat to an center mounted exhaust. I bought some mandrel 2.375" SS bends to make the connection. Stuff is $$$$

I looked hard at my gauge cluster and thought it was too high last night. I was going to cut it off and tilt it forward to lower it. The more I look at it though, the more I like it as is. I held up some coffee cups to simulate the PIAAs and they will look good. Easy to mount too.

I'm ordering the aluminum tomorrow to make the bags for this bike. Once I get the bags done, I'll work on the mounting points.

I need to "machine" up the footpeg brackets as the stock ones are too high for endure riding. I have some heavy AL plate that I will work with.

The further I get along the more I realize what I have to do. Hoping to get this road ready for the Eastern Rendezvous in May, already sent my check in...

With Javiers advice, I set the rake to 28 degrees, now just need him to pipe up and help me with the rear shock mounting point and swingarm angle











Couple random shots with various crap thrown in place to give me an idea what I am looking at. The seat is a YZ450 endure seat and the tank isn't sitting down all the way. Also trying to find a place for the battery, I might need to get an AGM so I can mount it horizontal. Comments? Advice?











Bought an R1 exhaust supposed to tuck closer to the frame, but then I need to make new engine mounts. I may scrap that idea, I'll wait until it gets here.

Got my tires on the way so I can finally mount up the right rims and tires. Woody is supposed to have my front wheel done, had to buy an axle and spacers though.

Got a black Acerbis supermoto front fender, think it will look good.

sailah screwed with this post 04-11-2011 at 10:26 PM
sailah is offline   Reply With Quote
Reply

Share

Thread Tools Search this Thread
Search this Thread:

.
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is On

Forum Jump


Times are GMT -7.   It's 06:48 AM.


Powered by vBulletin® Version 3.8.5
Copyright ©2000 - 2014, Jelsoft Enterprises Ltd.
Copyright ADVrider 2011-2014