The biginning of the heap of crap

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Re: The biginning of the heap of crap

Postby touchwoodsden » Fri May 19, 2017 7:49 am

the grinch wrote:I have started filling up the gaps in the tank it is going well so far just need to make a paper template cut 2 pieces check fit get it as close as posible and thats it. This is the first time I have used the plywood form like this. The last time I made a tank for my son’s bike I just made a form for both sides and filled in the middle. But this is a far better approach so far. I hope to get it all done by the end of the month. I have to make the tunnel and work out the mountings. I have a sender unit and will be putting some fittings for banjo bolts for the fuel lines. I will be welding it up with MIG using 0.6mm wire as this seems to be better for tanks. I have an old Cebora 130 for this special occasion. I prefer this for tanks as it gets into all the tight spots.:D


I am WELL impressed with the tank build. This is a LOT of work. Well done.
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Re: The biginning of the heap of crap

Postby Diesel Dave » Fri May 19, 2017 12:48 pm

I like MIG brazing for the same reason - easier to use and you get more certainty of filling all the gaps so it won't leak.

Mind you I've only used it on Sluggy's old tank to patch the rather colander like bottom - worked a treat 'till the other side fell out of it and it cracked in half. :roll:
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Re: The biginning of the heap of crap

Postby the grinch » Sat May 20, 2017 6:56 am

Getting there.
I have almost done the outside of the tank it is tacked up and I have started the underneath I may have to scrap the sender idea and put a clear pipe on the outside. I expect to start welding on Tuesday if I can finish of the fabrication in time. :D
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Re: The biginning of the heap of crap

Postby the grinch » Fri Jun 02, 2017 10:37 am

The tank is done now not the best welding but it is completely leak free all pressure tested hence the rust. I just used some washing up liquid and water mix and a coolant pressure tester attachment with a car tyre valve bodged on to the end. I use between 4 and 8 psi of air( much more and as I found out the the hard way on the first tank I ever built the tunnel will try to turn inside out :lol: ). The tank mounts are made and tacked to the frame. I need to find some banjo fittings but that is not the end of the world I have made the points for the level hose. Although it is not the best welding I like the way it looks. The plan was that I would give the whole thing a skim of filler to smooth it out but I’m going for rough and ready so I think I will just clean it and leave it as it is give it a coat of rust converter and red lead it for now. I think I need to look at the foot rests and controls next shouldn’t be that difficult. I think that I will be near making a list of jobs to do soon all the big jobs are getting done. :D
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Re: The biginning of the heap of crap

Postby the grinch » Sun Jul 23, 2017 12:14 pm

Gears
It been a while since my last update I have not worked on the bike now for a month now. I have been really busy at work and to top it off I now have to go away for 3 months. But I did make a bit of progress before the work got in the way. I have done my gear selector I had 3 attempts to get it sorted but I got pissed off ended up getting some inspiration from the horse’s stable of all places. A simple door bolt. Took 30 minutes to make a selector from a bit of scrap box and some 16mm round bar I made 2 pivots I have not finished them yet but even with the extra play I have got good gears. Foot rests I have made a start just a simple bit of tubing I had lying around and I made a couple of braces to go from the frame to the engine.
But that will be it for a while as I’m off to Suffield Canada for a few months at really short notice. Now my deadline is blown I won’t be here but I will hopefully have a bit of extra cash when I get back I may be able to make a bit more progress. I will have to get it ready for the RBLR 1000 perhaps or something similar.
some of the pictures are a bit crap :(
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Re: The biginning of the heap of crap

Postby the grinch » Tue Oct 10, 2017 1:08 am

Back soon few more weeks to push and I will be getting back on track with the build. I will have to get the other piece of crap going when I get home as I have got to have something to ride. I am hoping to be back on the build by the middle of November it will be a year then but I would hope that I can get it mocked up properly before the end of January. Ready for the side car build. :D
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Re: The biginning of the heap of crap

Postby the grinch » Mon Nov 13, 2017 8:18 am

Back again :D :D

Not done much but i have had a good think about things. I have re-profiled the seat as it was a bit hard around the edge when putting my feet down. I have started thinking about the clutch. I have managed to find Vauxhall clutch flexi hose with the quick connector on one end and threaded on the other so it can use an old Lucas master cylinder and being able to use the thread means I can just make up a bit of brake pipe and it will give me more flexibility for master cylinder location i am not sure how it is all going to go yet i think that a foot clutch would be good for a outfit but if i do ride without the sidecar then its not so practicle. So i am still thinking about it i have got the brake servo from the car but it is quite a big lump maybe i can get a hand clutch working somehow.
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Re: The biginning of the heap of crap

Postby the grinch » Sun Dec 17, 2017 4:11 pm

Foot controls
Ok I’m making slow progress unfortunately I have had to put the bike on the back burner due to having to start a new job earlier than anticipated. However I have found a couple of spare hours to bodge up some master cylinder mounts and some pedals. Not pretty but will do the job I still want to get the thing done before the summer i have to get some clivis forks but but they will be easy enough to find. I’m going to make some footrests next as the pipe was just for a rough idea of where I had to put them. I have found some spare box section I have left over from another job I will use that and some flat bar or something else I have laying around. :D
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Re: The biginning of the heap of crap

Postby the grinch » Tue Dec 19, 2017 7:48 am

Bugger

It turns out that the quick release union on the Zafira hose is not the correct dimensions. :( It was too long and has a slightly bigger diameter it is also different where the chamfer is. I spent about an hour with a half round file taking the bloody thing down to size hopefully it will work or it will be Plan B not sure what that is yet. I made some new rods and put some metric clevis forks on for the master cylinders. I hope to get the clutch working today so I can see what is required to operate it as I want to see if I can make it work from the handlebars too. I will make a pipe later and bleed it up.
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Re: The biginning of the heap of crap

Postby the grinch » Fri Dec 22, 2017 9:58 am

Hand controls
I need a front brake and a throttle to start with I am too tight to get some handle bars made from the correct stuff so the bars I have will do. I used 1” Gas pipe which is just over 26.5mm O.D and I managed to get some that’s 27mm I.D for the grips. I bought 2m of it as I thought I was bound to f%$k it up before I got it to work. I will have to make a throttle as it will be too much work to try to get something else to fit. I have been looking up internal throttle and I have decided to have a play around. My first attempt worked but it needs a lot of refinement. I have about 1.5” of pull on the cable but the slot needs to be a lot cleaner I have a new blade somewhere for my mitre saw I will try this next. I used a M6 Allen screw for the slider I think it will work but I will have to use some Loctite on the threads to prevent it coming loose.
For the brake I had a cheap copy of a CB400 master cylinder and I thought I would see if I could get it to fit. A ran a tap down the threads to make sure that I had plenty in the housing for the bolts as I would need to grind away near the bolt holes. I think it can be done but I will need to make another bracket to clamp around the bars. :D
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Re: The biginning of the heap of crap

Postby the grinch » Fri Dec 22, 2017 7:59 pm

Hand controls part 2
Front brake master cylinder is now mounted to the bars I used an offcut from the throttle tube and a piece of 5/8” square bar a bit of drilling and filing and its sorted. I did have to file the bars where the bolts pass to allow them to screw in correctly as the diameter of the bars was slightly too big to allow them to pass without binding. I will fill the void in the casting with some epoxy putty and clamp it to the bars to get a perfect fit to prevent any rocking later when the brake is operated it is not moving now but there are a few gaps.
I have started on the throttle I used the mitre saw but I had to make an adjustable fence as I needed more than 45 degrees for the slope 45 degrees would only allowed 25mm of movement. I still have to make the slot in the bars yet and I need a few more bits.
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Re: The biginning of the heap of crap

Postby the grinch » Sun Dec 31, 2017 5:03 pm

Bit more progress :lol:
Been fiddling around have made a stand as I have got to have a stand for MSVA and because I am having a sidecar it would need to be a centre stand. Bloody hell its fucking heavy I had to get it off the pallets on my own, well I managed to do it without dropping it on the floor but it was a bit sketchy. I have made a stand I needed a long lever to get the thing off the floor but it works. I broke my tack welds on the handle bars. This gave me a reason to make some new risers I used some box section and some threaded bar nuts. I made a mudguard bracket and I have started on the exhaust. I found a fire extinguisher in the skip and I am going to use it for all the electrics. It is getting there slowly now I just want to get all the parts made up then I can finish off all the edges before the final build. I have got another right angle gearbox coming as the PTO will be awkward to get done. I have got an Audi TT transfer box on its way along with a drive shaft. But I need to get everything else done before I can tackle that. It would be nice to get all the fabrication done before March I think I can get it done. I have started thinking about cooling I am trying to find a cheap radiator I am looking on eBay I found a couple new less than a tenner but are too big for my fitment. I am looking at VW Polo as it is about the size I am after. I have fabricated a header tank as it hat to fit in under the tank above the fuel pump. My phone will not upload so no photos today.
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Re: The biginning of the heap of crap

Postby gilburton » Mon Jan 01, 2018 9:13 am

Good luck on the MSVA. I've never attempted one as I've always gone for a frame/bike with a v5 log book.
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Re: The biginning of the heap of crap

Postby the grinch » Sat Jan 27, 2018 8:13 am

Well I have been getting things sorted out. I have done a few of the big problem jobs and I think I am well on the way to get the mock up done by end of March. I need to get a few more bits done. I think I will be getting to the wiring before long and It will be nice to get it running in the frame and sort out the cooling and bits. I have done the rear wheel drive flange I used the tractor PTO in the end as the Audi part is not fully connected at the flanges also it was quite a bit bigger than I thought it was. The drive shaft what a result I cut down the PTO adaptor and shortened the splined part on the CV joint it could not have been any better I don’t need to cut the shaft. I have started on the headlights I want to use 2 lamps. I have decided to stack them vertically. I didn’t like the look of them horizontal. :P
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Re: The biginning of the heap of crap

Postby Tetronator » Mon Jan 29, 2018 9:13 am

What a beast. :shock:
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Re: The biginning of the heap of crap

Postby the grinch » Mon Feb 19, 2018 8:04 am

A bit more progress.
Just been fiddling around and done a few small jobs have started getting more of the jobs that don’t matter so much done. The fuel pump and filter are fitted I have still got to plumb everything in. I am working on a clutch hand control just in case it will operate the master cylinder. I have put the pivot behind the bar instead of in front. This has given me about 35mm of cable movement. This will allow me to ride the thing without the sidecar a bit safer. Mudguards are on rear light and a rack on the back. I am trying to get the jobs done I have made a headlight cowling I used a very technical approach as I have never used fiberglass I did some research I decided I would make a flimsy steel framework then I stretched a polyester fleece blanket around it all. I mixed up the resin and started to put it on well I should have read the instructions as I was about ¾ done and I put the resin down to get something and the result of that was the paint brush was firmly embedded in the resin as it was going off. The next day I made some more resin it turned out ok I have to finish off inside. But the blanket worked well. :D :D
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Re: The biginning of the heap of crap

Postby the grinch » Thu May 17, 2018 7:03 am

:evil: Bugger. :evil:
Today’s lesson don’t please don’t leave ECU without power for too long. Well I have been sorting out a few bits made wiring harness and it was time to fire the beast up. It has been about 18 months since I had the engine running. I spent hours making the loom and checking and sorting everything out. Well needless to say it didn’t all go to plan. I had everything I needed but the dreaded pump would not come to life. Money is tight so I have spent hours and hours re checking and trying to sort it out but not a chance. So I decided when I first wanted to do it I wanted an old school fuel pump I had several options.
1 Could I put a different pump on it probably but how much was it going to cost.
2 Could I get ECU flashed probably but how much and it could also be the pump.
3 Look on Ebay find another engine for the right price.
So I am now the proud owner of a 1.8 non turbo Endura DE with mechanical pump now I Just have to make everything fit again. I have a lot of things on at home now and a lot to do now but hopefully I can get back on track. :D :D :D
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