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Old 04-21-2011, 06:07 AM   #76
OhioPT
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Pete, take the spring off the shock so you can easily move the swingarm through its full range of travel. Pull up on the swingarm/rear wheel and when the whole bike starts to move, stop and measure the eye-to-eye length of the shock and also the distance from the center of the rear axle to a marked reference point on the rear subframe. Then let the swingarm fully extend and again measure the axle-to-subframe length and the eye-to-eye length of the shock. Now you can calculate the average wheel-to-shock leverage ratio. You should compare your ratio to that of a 950 Adventure- hopefully it is real close. Javier should have that data for you.

When you are taking the swingarm through it's range of travel, observe the clearance of the chain and swingarm to check for any potential issues.

If you haven't already, you should also go ahead and remove the springs from the forks so you can easily move the tubes through their full stroke and check for clearance issues. You might end up needing to place a spacer in the forks to limit the compression travel (to keep the front wheel off the frame or whatever else it may hit there). If so, you'll have to find someone to make you one out of elastomer of the correct height. I believe some Ohlins forks used elastomer bumpers as a compression stop, so it can be done.

I'd like to stop by sometime to check your bike out. The weather forcast sucks so anytime in the next week would be good if it works for you.
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Old 04-21-2011, 06:40 AM   #77
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Mark,

I need to get a compressor to take the spring off. I'm gone through monday unless you want to come today. If not, any time after 6. Do you have my address cell?
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Old 04-24-2011, 04:50 PM   #78
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Quick update, busy over the Easter weekend with things other than the bike but got a few things done.

Finished the light bracket. I'll round off the light tabs and then that will be done. I did just buy a Garmin 60csx so I need to figure out where I'll mount that. I don't like stuff on the bars so I might need to add to the bracket.





Burned in the rear shock mount. I need to clearance it in a few spots where the top of the shock might rub. Got 3-4" clearance between exhaust and ride hight seems good. I might leave that section of the frame unpowdercoated in case I need to make adjustments. Or I might ride done to the rally with no powdercoat and then decide when I get back.

You can also see where I finalized the battery placement. Course you need to remove the shock to remove the battery, but I don't anticipate that being a huge deal.



Got the rear exhaust tab in. I may cut the exhaust and reweld it slightly. It's just ever so tweaked and it's pissing me off. Not enough to have done something yet, but I can tell it will need to be reworked.

The hoop is the rear bag mount. Still working on that.



Potential bag placement. I need to get the tank and seat done before I can do a final mounting to ensure proper leg clearance.



Next big items to get done are the tank, seat, new center & side stands. Then the small projects like rearsets, high fender kit, rewire, skidplate etc.

I have a new 48T custom rear sprocket from Sprocket Specialists. When I get that in I can measure for links for the 530 chain. I am running the 15T countershaft sprocket.

I may make my own brake lines. Any reason to not do this? I already have a stock KTM one. Maybe cheaper to just order another for the high fender kit? The supermoto fender looks good and I'll be able to get good clearance from the front wheel to radiator. I do plan on making a custom rad guard from the killer aluminum mesh my buddy gave me.



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Old 04-24-2011, 09:15 PM   #79
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Got a few more things done tonight.

finished the radiator guard. I might make crash guards that are welded to the frame, I might not. This will def help with the rocks etc. Love that this stuff was free.



About a finger of clearance. I can shim the fender away and it's only being held on with one bolt at the moment. Glad that was easy.



Build a longer center stand. Haven't welded on the feet yet. Side stand I sleeved with 7/8" tube, welded up the top and then drill and welded plug welds at the end of the original.



Cut the tank to clear the frame spars. Still needs a lot of finessing, but good enough for one night.



Glory shot of the front end.



I've sat on the bike now without a seat and everything feels really good. I need to drop the shifter/rear brake controls but I'm going to build the seat first. Need to get the tank all set before I go ahead with seat plans. I'm still thinking aluminum seat pan with some kickass heat shield tape on the underside.
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Old 04-25-2011, 03:39 AM   #80
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Making good progress Looks like you are on track for the unveil date.
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Old 04-25-2011, 05:04 AM   #81
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Quote:
Originally Posted by OhioPT View Post
Making good progress Looks like you are on track for the unveil date.
I've been really trying to crank on it, burning up a lot of 1 am nights.

I think I am on target for the rally with some spare time for testing. But I've worked on enough projects to know that last 10% takes way longer than expected.

I'd love to bring it to QS&L for a bike night if I can get it rideable in the next few weeks before I go down.
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Old 04-25-2011, 04:45 PM   #82
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Great build, I've been watching.

Im waiting on funds for a TIG, bring on the bird poo!
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Old 04-26-2011, 09:58 PM   #83
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started work on the tank. This isn't going to be as bad as I thought, just tedious. I got most of the patches in, just can't run a cutoff wheel with my wife asleep. Fits along the lines of the frame as before and I don't need to relocate the petcock.









Also started on the seat pan. Not sure if it will look like this or not. I have plenty of aluminum.....





Aluminum welding is getting easier. The thick stuff is fun now, the thin sheet metal is a total mindscrew,



Bringing the bike to a friends house tomorrow to have the spacer machined. Then its off to the races to get this thing wrapped up and the final details done. Still a ways off, but making good progress.
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Old 04-27-2011, 12:56 AM   #84
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keep it coming , this thing is going to be Nastier than a pit bull with it nuts wired to the mains

cant wait to see the finished item and the frazzled look of your mind after riding it
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Old 04-27-2011, 04:51 AM   #85
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this thing is going to be Nastier than a pit bull with it nuts wired to the mains
That put a picture in my mind that I hope I never have to see live

Thanks it should be a total blast. Kickoff is in 3 weeks!!!! Either that or I'm riding my Trail 90 down to North Caroline
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Old 04-27-2011, 07:53 PM   #86
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brought the spare frame and swingarm over to a friends for the spacer.







After watching how easy it is to make stuff with a lathe. I want one. REAL bad

Bought 3 kinds of foam today, will get the seat hammered out in the next few days along with the tank. Then it's suspension out to trail tricks and finish up the remaining items.
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Old 04-27-2011, 08:27 PM   #87
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Love the size of that lathe chuck. I've a vintage Atlas 618 that is fun to play around with.

Note: Have you played with the bias on your polarity to reduce the etched zone on your aluminum welds? You can reduce the frosting although your welding machine might not have that function.

Looks like a great project. Interested in seeing the final result!
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Old 04-28-2011, 04:39 AM   #88
sailah OP
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Love the size of that lathe chuck. I've a vintage Atlas 618 that is fun to play around with.

Note: Have you played with the bias on your polarity to reduce the etched zone on your aluminum welds? You can reduce the frosting although your welding machine might not have that function.

Looks like a great project. Interested in seeing the final result!
Yeah it was really fun to watch the lathe do it's thing.

I do have a polarity adjust, I just set it once and forget it. I was under the impression that the frosting indicated good cleaning and as long as the tungsten didn't get too hot, that it was okay? I'll look where it's set, I'm guessing 25% EN/EP.

Final result needs some really concentrated effort on my part. I've been trying to work in the garage until midnight or 1 most nights but with a newborn and a 3 yo, it's hard to justify all the time. My shooting season is over which takes up saturdays and the Penguins lost last night so no TV excuses. I should be fine for my kickoff date assuming no major problems.
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Old 04-28-2011, 06:16 PM   #89
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Lookin' good man. I'm also following this on the FZ1OA site and think you're doing the FZ1 crowd PROUD!!!!
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Old 04-29-2011, 12:43 AM   #90
Houseoffubar
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Quote:
Originally Posted by SimpleSimon View Post
Love the size of that lathe chuck. I've a vintage Atlas 618 that is fun to play around with.

Note: Have you played with the bias on your polarity to reduce the etched zone on your aluminum welds? You can reduce the frosting although your welding machine might not have that function.

Looks like a great project. Interested in seeing the final result!
Agreed, I would turn The arc balance way up toward the penetration end. Your tungsten will thank you, and you will get more definition in the weld bead.
I'm an aerospace welder, and never turn the AC balance to less than 7 out of 10, and usually 8-9.
I must admit, I am impressed by your aluminum welding. It took me years to make my aluminum look as good as yours!
How much gas do you run, it looks like too much on aluminum, and too little on the steel? Hope you don't mind a slight critique. I usually run about 25cfh on steel, and 5-10cfh on aluminum (5 for gas lens, 10 if not)
Keep up the good work, your gonna have one mean machine there!
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