Project Full Circle:Ninja 650 gets a makeover

[LocuL]

nahh fantastic vvay is alot to say about this. I´m not fully satisfied vvith the outcome so far. But as a vvork in progress i hope to hone my skills and make it shovv on the bike. Regarding HP, vvell i like ´em.

[Motorfiets]

Originally Posted by LocuL

nahh fantastic vvay is alot to say about this. I´m not fully satisfied vvith the outcome so far. But as a vvork in progress i hope to hone my skills and make it shovv on the bike. Regarding HP, vvell i like ´em.

Don't mean to be a smart ass but.... did you loose your " w " key?

[LocuL]

Hovvvvvvvvvvvvvv did you guess. Thought lenovos vvere the bomb...hmm

[Motorfiets]

Originally Posted by LocuL

Hovvvvvvvvvvvvvv did you guess. Thought lenovos vvere the bomb...hmm

hahahaha!

[sailah]

Got my stuff back from the waterjet guy.

First the Dong is Done

Fits well, I knew I'd have to grind it where the welds from the tab attach to the frame. No biggie, and the bolts line up great. I'm going to punch some holes in it and hopefully find a good peg position when the new IMS pro pegs arrive. My waterjet guy looks at me when I walked in and said "WTF is that??"






He also made a plate that the fuel pump will bolt to. I had to open up the hole slightly to about 60 mm. I don't use my 4 jaw chuck often but tonight was one of those nights





Here it is bolted to the plate





And the 4" square tubing I'm basing the surge tank from



I need to find a sealant for the threads as they will be exposed to gas, didn't really think that through. Any suggestions? I bought some Loctite No 567 sealant as it was recommended for gasoline.

[bk brkr baker]

Halomar.Gas shouldn't affect it.

[sailah]

Originally Posted by bk brkr baker

Halomar.Gas shouldn't affect it.

Link? I couldn't find it on McMaster

[bk brkr baker]

What I have is made by Permatex, Hylomar universal blue racing formula.gasket dressing and flange sealant.
Says it's suitable on fuel injectors and pumps.
It comes in a tube like silicon but it's 2-3 times as expensive.You should be able to find it at a decent auto parts store.

[kellymac530]

These are the Permatex sealers that are recommended for fuel

http://www.permatex.com/products/pro...ategory&id=172

However I think your best bet would be to make some small cups and weld them over the end of the bolt holes now...that is a permanent and proper fix.

[mnd]

You're going to weld that plate to the square tube right?

Weld some caps over the bolt holes.

[sailah]

Yes going to weld the plate to the square.. Thinking I might just make a new one on the lathe out of thicker stock and tap with a bottoming tap and a stop on the drill press. Easier than welding cups I think. Plus ideally I would have "clocked" the pump 45 degrees so the pickup is in one of the corners as it hits the side of the tubing right now.

It's easy enough to make a new one and transfer punch the holes. I spent 2 hours carefully drawing that on CAD and they still are slightly off. Not enough to really matter though.

[sailah]

Remade the part using 3/8" plate. Bored the center hole on the lathe. transfer punched the holes, drilled 5mm holes close to the bottom using drill stop on the press. Tapped using a M6 but I need a bottoming tap to get all the way down. Have one on order.

The one I made came out nicer than the waterjet part. I spent hours laying those out in CAD, took 30 seconds with a transfer punch and the holes are more accurate.

You can see the stock donut gasket so I used some longer button head M6 bolts I had. I also clocked the fuel pump so that it will fit in the corner of the square tubing.

[sailah]

Someone suggested I make a groove for the O ring, so I did.

Didn't want to get any closer to the threads. O ring fits in there perfect and I did make it 80% depth of O ring









I have a new idea for an underseat tank. The stock plastic battery box doesn't fit anymore in the stock location due to the shock. This "box" was supposed to fit in there. I tried a sample piece and there's no way it's going to fit.

I moved it back and found some new real estate. My plan is to make a shallow tank probably 5-6" deep and fill in around the shock. Guessing I can get maybe a little less than a gallon?

[sailah]

Drew up the subtank in CAD and made a mockup from cardboard. Fits in there well, it's a little tight around the shock, esp since I needed to relocate the pump forward to get the draft necessary for sufficient fuel tankage. Might need to "massage" it with a tear drop mallet when I get around to building it.

I had to cut a corner off the fuel pump flange so that it wouldn't bind in the coils of the spring. Not a lot of extra real estate down there. Going to try for the battery just to the right under the shock.



I tried to get the cardboard exact but ended up changing it a few times. It's pretty close to the model. I ran the volume calcs and got 1.2 gallons which I was surprised about. I figured it would be 3/4 gallon.



The revision "cuts the corner" around the shock to gain a little more volume



My finger is where the fuel pump will be.



Trying to figure out the best way to cut the parts out in order to weld. My experience with making these previous is the less welding the better. I am going to try to bend as much as possible to minimize welding warpage.

[Salsa]

Here is a tip on sheet metal welding to minimize distortion.

Cut the metal .090-.120 inch or so long on each weld edge and bend it "out" 45 degrees. When you mate them together you get 2 edges to weld together. You might need rod to start it, but after you get started, try to not add weld. Just burn it down to the corner you want. You don't get much heat into the sheet of metal.

An alternative method is to round the corner "inward" about 1/4 - 1/2 inch from the weld to make a stiffened edge.

Charley Curnutt of Curnutt shock fame broke his collar bone in about 1970 and built a bike while he was recovering. A few months later I broke mine so I had to built a bike too. I built a sheet metal framed bike with the "tank" surrounding the engine including under the engine. I built a leading link front end.

Don