Saturday, 21 February 2015

Rewind 12 months

It's actually more than 12 months ago now that work began on this new bike project. This time last year all i had was this headstock tube and a bottom yoke.

It doesn't feel like much progress has been made recently but I've spent a lot of hours working on it, there's just not a lot visually to show for it.
I have now patched up the bodyshell after cutting it into 3 pieces, and the seat is a lot better- i can at last sit on it, sort of comfortably!

The front fairing was a bit of a gamble as i wasn't sure i could make it fit and look right, but it seems to sit ok on the bike and doesn't foul the steering, or suspension etc. The next nice day i get I'll finish the last batch of brazing jobs, all the small brackets, footpeg mounts, chainguard stays etc. They're all made and ready, just need fixing on.

Tuesday, 3 February 2015

Very offsetting

Got another step closer this weekend with the arrival of an billet offset front sprocket, and a blank rear sprocket.  The front needs a bigger offset and a shorter nose than my current one, as the back wheel is wider necessitating the chain being further out to one side. The rear sprocket is also larger than the one i use at the moment to make up for the increase in tyre diameter from 26" to 28".
Same as the last time i bought a blank sprocket as it's a lot cheaper than having one machined to suit, and it only takes a bit of working out and an hour or so on the mill to do myself. And besides the mill needs to start earning it's keep!
A fuel tank is next on my list of things to make, I've been experimenting with large bore fuel taps and made up a 4 way splitter to feed the carbs. It'll need 2 taps altogether, one for the nitrous side and one for the carbs. It's not as nice as a pingel tap but probably flows the same and cost 10x less.

Sunday, 25 January 2015

Body work

The bodyshell i bought has gone through a slight - cut it into pieces stage, mostly because it didn't fit right good! The seat rails on the frame are so low the seat of the shell was miles off, it was also too long by a few inches oh and my ass was too fat to actually fit in the gap where the seat was.
So, the seat hump had been chopped out and the tank separated to allow things to sit better.
The front fairing is not a drag race item, i just liked the look of it and now trying to make it fit. Today i made the front subframe to hold it and added the mounts for the electronics which will live up there too. Small side panels are yet to be added to the front fairing and lots of the body shell is still to be cut round the engine and frame rails.

Sunday, 11 January 2015

Problem solved

Quick recap.....
The last race of 2014 - the extreme bike weekend, we qualified first but after the last round of qualifying i found a problem with the clutch and decided not to run it in eliminations in case it got worse and damaged something.
3 months later and after a lot of head scratching, it seems i have found the problem. At first it seemed the clutch primary gear was bent, I'd measured the runout of the gear by setting it up on an input shaft in a set of cases and using a dial gauge, and by laying it on a flat surface, and it did seem to be simply bent.
Then i decided, to be more accurate i'd put a bit of large diameter bar in the lathe and machine a shoulder into it and butt the gear up against that and bolt it to it, guaranteeing a true surface. This corroborated the theory that it was bent as it had nearly 0.5mm of runout. 
However, in my attempt to mark it up with a view to straightening it i turned the gear around and bolted it down again. Suddenly, the gear isn't bent anymore - no wobble!
I'd never even imagined the thrust surface of the gear wouldn't be straight... after all why wouldn't it? I still don't know. But anyway it was miles off, as you can see in one of the pictures where I've started to cut it flat again.
The surface was tough but with a carbide cutter and light cuts it turned up just great, and i finished it by lapping on a flat plate till it looked consistent.
Total runout now is less than 0.1mm. So i made up some new rivets to hold the basket and gear back together and used a large glamp to hold it all whilst i welded the ends of the rivets to the backing plate.

Tuesday, 6 January 2015

What's 2015 got in store?

Lots of small things happening in the background at the minute. I've been tidying and rearranging things in the cellar, making new shelves to store some of the rubbish i keep collecting, and generally trying to make it a nicer place to work. Plus i've been freeing up some space by selling quite a few surplus GSX bits on eBay, Barrels and pistons, and a few smaller bits. Cylinder heads might be next. I have 9 of them!

With the proceeds of the eBay purge I've managed to save up enough to upgrade my DC arc welder with scratch tig torch to a proper TIG set with High frequency start gas flow control and Pulse welding mode. Disappointingly it hasn't improved my TIG skills, i still need some practice.
Also managed to find a 30 ton hydraulic ram at a good price on that site, it arrived today. It's massive,  and a decent frame to mount it on is on the agenda now too. It'll also need a hand pump and some significant steel slabs to finish it off, but it's a useful thing to have is a small press - steering stems, gearbox parts, cranks etc.
Bodywork is due to arrive via courier tomorrow. The courier is bound to have something to say about the size, but at least it won't be heavy. Once i have it i can make a start on mounting it, getting the seat position right, and related parts like footpegs. Plus I'll have my first job for the new welder - making a stainless fuel tank.

Sunday, 21 December 2014

Sprocket support

I've not been able to make much progress with the bike recently, largely because i'm waiting on a few parts before i can move on.
Bodywork is next on the agenda, and i've long since abandoned making my own, it's just too much work. Instead I've had one made from a mould, it's ready and just needs collecting.

One of the parts i have done is a sprocket support plate, it's been designed, waterjet cut, test fitted and machined for the bearing holder and crank seal.
The design was too 'curvy' to do on the mill, so it went to K-cut, where John was as helpful as ever, firstly fixing my troublesome CAD file, then cutting me a wooden one to test fit first, and finally cutting ally one.

Found time to do some footpegs too!

Tuesday, 2 December 2014

Aluminium cake

I've had numerous cake shaped pieces of aluminium delivered before, most get turned largely into swarf  and this one was no exception. This one was destined to become offset sprocket bearing holder. It took a lot of hacksawing to cut it in half partway through.

This was preceded by top yoke manufacture.....