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Old 08-21-2012, 05:40 AM   #736
Joe Watson
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Latest night in the shed includes cleaning up and proper mounting of the main "forks" of the nav tower. Completed the headlight hangers, cleaned them up and mounted them too. Slowly making some headway.

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Old 08-21-2012, 07:47 AM   #737
drc42
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Quote:
Originally Posted by Joe Watson View Post
You guys blow me away with all your technical 3D drawings etc! All I have is a measuring tape, a square and a pencil!!

Here is the story of my backyard bodgyness:

The scary drilling holes part in the headstem:



The mounting block:



Which was all wrong so had to be cut off because the nylock nuts seized on the bolts!



Re-working:



The finished product:



Using a hole through the steering lock tab at the top where the lock parts won't hit:



From the inside:



Making the "Nav" tower now which will mount my lights, front fairing mounts, factory instrument cluster, switches, 12v outlets and GPS mount.
This is very similar to what I did on my DRZ for the Mexican 1000 Rally. With the curved headstock on the DRZ I had to use a 1/2 section of some DOM tube but otherwise pretty much just like what you did. I used 4 3/8" fine thread grade 8 bolts drilled through the headstock just like this and used red loctite instead of nylocks. I do have the advantage of since it is curved the bolts are at a bit of an angle so the load in them is partly in sheer, not just in tension. So far it is still rock solid and I have given the bike a fair bit of abuse.

Considering doing something similar on my new WR450 this winter.
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Old 08-21-2012, 01:43 PM   #738
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The Nordwest has a pair of 3cm long by 3cm dia cylinders welded to the headstock.
Dense rubber bushes and metal sleeve for the through bolts.

Easy to weld on to the headstock and gives the dash a little give.
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Old 08-21-2012, 07:37 PM   #739
michael1968
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Quote:
Originally Posted by Joe Watson View Post
Latest night in the shed includes cleaning up and proper mounting of the main "forks" of the nav tower. Completed the headlight hangers, cleaned them up and mounted them too. Slowly making some headway.

Looking good! Are they those generic 'Street Fighter' headlights? I was thinking about using them.
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Old 08-21-2012, 09:43 PM   #740
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Originally Posted by Mudguts View Post
Nope have not sold any thing yet as i don't know what i will need for next build
apart from $$$$$$$. my nav tower is staying the same might change out the lights to the BD squadron LED type as it will clear up some room be removing the ballasts from the 90mm HID Hella's.
Did you hear from the guys a Sud Africa? about the fairing?

Ballasts kinda annoy me too, I just went for a cbr250rr 4 inch headlight. The later models (i have now learn't this) use H4 bulbs, not the weird H6 I got.
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Old 08-21-2012, 10:03 PM   #741
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No they have not got back to me ( thats ok still waiting on tax return which is being held till oct ).

But I did get a new 690RR Fairing a really good copy gel coated with carbon kevlar reinforcements just needs a quick sand and paint. then its bling time
I'll get the Nav tower aniodised or power coated and re-do all the wiring using one of the fuse blocks shown on this thead . As it is a clutter of wires there .
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Old 08-21-2012, 11:34 PM   #742
Joe Watson
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Originally Posted by michael1968 View Post
Looking good! Are they those generic 'Street Fighter' headlights? I was thinking about using them.
Yup, that's them just "Dominator" or "Street fighter" twin headlights where are DOT approved and high/low beam and the wiring just plugs into my WRR!
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Old 08-22-2012, 02:47 AM   #743
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Quote:
Originally Posted by tileman View Post
Ballasts kinda annoy me too, I just went for a cbr250rr 4 inch headlight. The later models (i have now learn't this) use H4 bulbs, not the weird H6 I got.
I used a set of them on an old DR650rs, and I thought they put out the most pathetic light I have seen on a road going bike.

Looked good, but I would prefer to see good at night...

And I seem to do a bit of night riding.

After getting of my 640, I am amazed at how much light my wife's ZZR250 puts out, but I don't think it would like being run into rocks or having roost thrown at it...
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Old 08-31-2012, 08:48 AM   #744
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Originally Posted by tileman View Post
Earlier in this thread there was a discussion about using HDPE or equivalent to side plates or other parts of the structure. Have you thought of using this as it has a inherent amount of flex that alloy does not. I spoke to 2 different suppliers in regards to HDPE and both stated that UV (one of the issues) would effect the product but most likely not in the application like this.

Thoughts anyway
More out of curiosity then anything else, I figured what the heck.









Seems very rigid vertically and gives nicely side to side. Taking it for a ride this afternoon.
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Old 08-31-2012, 11:43 AM   #745
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More out of curiosity then anything else, I figured what the heck.





Seems very rigid vertically and gives nicely side to side. Taking it for a ride this afternoon.
Wow, that is cool!
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Old 08-31-2012, 12:07 PM   #746
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Originally Posted by cross-country View Post
Wow, that is cool!
+1 on the cool and a great way to use tis type of material! Definitely interested to hear ow it holds.

Can you load it with some more weight then just a gps while testing? Roadbook, icos and gps unit with plate do weigh a lot when combined.

...Now wondering of to find my hack saw and start comstruction too :)...
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Old 08-31-2012, 12:15 PM   #747
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That's indeed a very nice setup . Use of new materials is always nice ...

HDPE is third on the list for my setup at the moment but I will sure try it ...
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Old 08-31-2012, 12:52 PM   #748
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Originally Posted by theantipaul View Post
More out of curiosity then anything else, I figured what the heck.









Seems very rigid vertically and gives nicely side to side. Taking it for a ride this afternoon.
That is sooo friggin awesome! Good work Paul!
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Old 08-31-2012, 01:27 PM   #749
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Interesting.

Could you elaborate on why you switched from aluminum to HDPE?
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Old 08-31-2012, 02:52 PM   #750
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Interesting.

Could you elaborate on why you switched from aluminum to HDPE?
To try something new as I read it.
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