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Post by Yogi on Jun 8, 2016 18:38:45 GMT 1
Hi Mark Just when I think you've slowed down a bit. Along you come with loads of pics again Showing good pace on this build considering the amount of work Love this thread ,Atb Matt
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Post by yamark on Jun 8, 2016 19:19:10 GMT 1
Mark, nice to see you are making progress with the many modifications that go into making a special. I seem to be making slow but steady progress with my build, and it will use the original engine, so can understand how much more effort goes into something like this. How weird to see you drill the flywheel off the boss, as I am planning this in future for a different reason. Will you get it balanced afterwards? Jon Thanks Jon, I'm following your build and marvel at your welding skills
There are two reasons why I'm reversing the flywheel. 1) If I keep the LC windings/flywheel, I would end up with 2 stators and a very wide generator cover. 2) The reversed flywheel can me machined close to the crankcase, 1 stator and the generator will be separate to the 3 ignition stator coils. I'll end up with a similar cover projection to standard. This is the same system Harry's triple has been using for 15 years.
Jon, why are you going to drill the flywheel off the boss? Yes it will be checked for balance.
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Post by yamark on Jun 8, 2016 19:41:38 GMT 1
Dusty, like your optimism- no way I'll be finished before you. I'm not even half way through my build list.
Matt, I'm a little bit ahead on the build, I've still got 3 lots of pics to post, but will drip feed them. I've learnt to ignore peoples estimates on work completed. So if I'm let down I can at least post up my reserve pics. My super reliable mate Dean is sorting nearly all the welding and he does a lot of my machining, media blasting as well. It nearly always comes back the next day! Delivered.
But Matt, I cant believe the speed that you have put your bike together- unreal.
Thanks chaps for the encouragement
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Post by jon on Jun 8, 2016 19:58:57 GMT 1
Mark, thanks for your appreciation of my build so far. I am not a professional welder (who would do a nicer job than me), but I am a time served engineer so lay my hands to most fabrication, and am in the most part pleased with my efforts.
In answer to your question of why I am drilling the boss off, I have been collecting not only parts to build a fair few YPVS engines, but also a couple of special Lambretta engines. There is no time scale on these, but I have measured, then pondered, then collected parts to mount a YPVS barrel to a Lambretta crank case. The flywheel will be a modified YPVS unit, but it needs the boss mounted internally rather than externally to give more clearance to the stator plate.
Maybe a build thread in a few years if people are interested.
Jon
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gsexr
Thrash Merchant
Posts: 352
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Post by gsexr on Jun 8, 2016 20:16:09 GMT 1
Great to see more action on this build. Luv the engineering going on
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Post by fatfastroger on Jun 11, 2016 9:08:51 GMT 1
Though I can't add any advice on your build, have to say you're doing a fantastic job and its a great thread to read. You'll have to share a video when its done so we can hear it running.
Roger
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Post by unrealedd on Jun 12, 2016 11:39:06 GMT 1
Though I can't add any advice on your build, have to say you're doing a fantastic job and its a great thread to read. You'll have to share a video when its done so we can hear it running. Roger Hear hear I will second that.
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Post by yamark on Jun 12, 2016 22:32:32 GMT 1
Thanks gsexr (paul)
Thanks Roger and Edd, nice comments, I will post up a video when it's running- never uploaded a video but I've got a while to work it out.
Next instalment- the flywheel and left engine covers. I say covers as 3 covers are used. An LC rear section (done already) An aircooled E/F front genny section An LC outer genny cover to cover the stator plate.
Muttsnutts kindly supplied an aircooled cover, which I cut up (sorry Dave)
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I then had to remove webs and raised sections with a Dremel as the rear of the cover will be seen
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As I used the LC genny cover disc on the clutch cover I needed a LC damaged cover (if they are damaged I feel a lot better about taking a grinder to them) And Marsbar came to the rescue. The cover looks good, but has a knackered fixing and a crack in the unwanted section
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The flywheel back from machining (my mate Dean ). The CBR flywheel was bored out and a shoulder left on. The LC centre boss was turned down to fit. This is an interference fit at the moment as the final position has to be measured later and only then will it be welded. Also the outside of the boss was reduced so the CBR generator windings can be installed.
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Post by yamark on Jun 19, 2016 16:56:05 GMT 1
Using 10mm thick ali plate and an aircooled outer cover as a guide, I start to shape the new stator plate. (The drill bits held the 2 parts in alignment)
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Sorry for the out of focus picture, checking the plate against the inner cover
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Another one out of focus, the inner cover counter bored ready for dowels,
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Then the ali plate counter bored
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Next, the LC outer cover comes in for some angle grinder action
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Then ground flat
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Dowels fitted in the inner cover
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Final shaping of the stator plate using the LC cover and the end result
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Phew!
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Post by Yogi on Jun 19, 2016 17:11:18 GMT 1
I'm knackered just watching Plenty of work gone into that small spacer Still think your finish before me Atb Matt
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Post by unrealedd on Jun 19, 2016 17:31:03 GMT 1
Bloody awesome I'm so loving your fabrication work.
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Post by plumma on Jun 20, 2016 5:26:00 GMT 1
Yes true inspiration
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Post by yamark on Jun 21, 2016 20:09:18 GMT 1
Thanks lads Really appreciated.
The frame has been blasted, and the jig made with the frame now in the jig. I'll try to get some pics up at the weekend of this.
There are 10 alterations to the frame, 3 major, 3 intermediate and 4 minor alterations. I'll list them as they unfold, but the major ones are to be done first.
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Post by jon on Jun 21, 2016 20:24:05 GMT 1
Mark, will one of the major frame modifications be spreading the swingarm width?
I seem to remember in a different thread you were going to use an RGV arm?
I've been looking at my latest LC tonight, and can decide whether to scollop the frame, or spread it? Sorry if I'm off topic on this.
Looking at your latest post I'd be interested to see how you intend to disguise the stator plate wiring coming out of the magneto cover if you are?
I for one appreciate the amount of work goes into something like this, as just about everything needs modifying, I have for years liked a bike where on the face of it the amount of engineering/modification is not noticed on first glance, but reveals itself the more you look.
Jon
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Post by dusty350 on Jun 21, 2016 21:08:36 GMT 1
You are right Jon, the amount of work that goes into a build like this is just unbelievable . I've seen Mark's bike up close and it's amazing how much thought and work has gone into it so far. And not a cheap bike to build either, so you need to be mad keen to do it which Mark obviously is. So many small parts to alter or fabricate as well as the more obvious components, and a lot of time taken to do them right. Mark did describe the ignition system to me and just that gave me nightmares !! It's an overused word but this will be truly...awesome Dusty
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Post by yamark on Jun 21, 2016 21:28:43 GMT 1
Mark, will one of the major frame modifications be spreading the swingarm width? I seem to remember in a different thread you were going to use an RGV arm? I've been looking at my latest LC tonight, and can decide whether to scollop the frame, or spread it? Sorry if I'm off topic on this. Looking at your latest post I'd be interested to see how you intend to disguise the stator plate wiring coming out of the magneto cover if you are? I for one appreciate the amount of work goes into something like this, as just about everything needs modifying, I have for years liked a bike where on the face of it the amount of engineering/modification is not noticed on first glance, but reveals itself the more you look. Jon Jon, yes the spreading of the frame is one of the "major surgery mods." Your right, an RGV braced arm is going in. Spreading the frame is done to increase the chain clearance. Also to minimise spacing the exhaust hangers out. It's achieved by cutting out the centre stand mount tube, 2 cuts are then made in the frame below the cross brace (the tube that has the rear engine mounts). The frame is then "jacked apart" by 20mm, the frame sides re-connected and a new wider stronger brace welded to replace the centre stand section. I'll post up detailed images as the work is done.
The other major parts are the front frame tubes- new curved sections being fitted(to miss the two outer exhausts) and the new front engine mounts that have to be fabricated. For your build, I know you will make the right choice as you have the skills to perform either, and your not off topic at all
All will become clear on the wiring, it will exit the genny cover in the normal way behind the left cylinder.
Your vision is the same as mine. The bike will look like a fairly "standard" hybrid but with 3 exhausts. I want to keep the standard rad cover, but it will be a third wider, as will the radiator. Only when you look closely will you see the degree of modification of the majority of the bike. I hope it turns out as I picture it in my head. 1 year to plan, 18 months to dry build (estimate) plus then the time to dismantle and re-finish. Most of the engine decisions were set in stone a year ago, including one piece head, tie bar arrangement, engine mount locations, clutch actuation (I could have had a PV clutch mechanism) outrigger and side cover options.
The major frame mods should be finished in 2 to 3 weeks Good luck mate with your new project
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Post by yamark on Jun 21, 2016 21:35:02 GMT 1
You are right Jon, the amount of work that goes into a build like this is just unbelievable . I've seen Mark's bike up close and it's amazing how much thought and work has gone into it so far. And not a cheap bike to build either, so you need to be mad keen to do it which Mark obviously is. So many small parts to alter or fabricate as well as the more obvious components, and a lot of time taken to do them right. Mark did describe the ignition system to me and just that gave me nightmares !! It's an overused word but this will be truly...awesome Dusty Dusty, you are one of the people that inspired me, with your fabulous builds and attention to detail. (Yogi as well) Your help so far has been invaluable.
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Post by Yogi on Jun 21, 2016 22:02:16 GMT 1
I just love watching this top build Loads of quality pics and explainations as to what and why No comments ever ignored,good or otherwise Mark,his builds and attitude are a real credit to this forum Keep it up mate your gonna end up with a real Top quality Hybrid Atb Matt
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Post by yamark on Jun 21, 2016 22:41:40 GMT 1
I just love watching this top build Loads of quality pics and explainations as to what and why No comments ever ignored,good or otherwise Mark,his builds and attitude are a real credit to this forum Keep it up mate your gonna end up with a real Top quality Hybrid Atb Matt Truly humbled mate.
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Post by yamark on Jun 26, 2016 18:15:48 GMT 1
First image is the reversed flywheel in position. The generator coils will be mounted on the rear of the new stator plate and the ignition on the outside of the plate.
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Next; the stator is checked and drilled to find the centre, as there is more machining to do on the ignition side
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The frame has been blasted. A jig has been made, as when the frame is cut it can spring out of alignment (so I've been told). The work is being carried out by a retired engineer and this is his last job . I was really impressed with his workshop and attitude- nothing fazed him. He used to make frames for sidecars, and showed me pictures of him racing in the TT on outfits that he built. Brilliant. So he said he quickly knocked up a jig!
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Looked pretty solid to me!
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However I did have a bit of a setback. Here in the south, Thursday over a months rain fell in 45mins. The garage, workshop, and new mancave were flooded. Luckily no damage to bikes. No one in the area can remember water at this level, but I took a picture before it went dark but it went up about another inch after the photo
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Frame to come back in 3 weeks, just enough time for me to dry out everything
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Post by leaky on Jun 26, 2016 18:42:54 GMT 1
Sorry to see the flooding Mark but glad it hasn't fazed you.. Cracking work, stay on it!
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Post by dusty350 on Jun 26, 2016 21:01:27 GMT 1
Hi Mark Frame's looking good mate - ready to go under the knife !! Sounds like you found the frame guy just at the right time Looking forward to seeing the mods to the frame. And that's a pain regards the flooding. I've got a Vax if you need to sort the carpet tiles in the manshed. You are welcome to borrow it if you want. There seems no end to this awful weather - it's turning into a good year for building a bike rather than riding one !! Catch up soon bud Dusty
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Post by yamark on Jun 27, 2016 19:06:16 GMT 1
Sorry to see the flooding Mark but glad it hasn't fazed you.. Cracking work, stay on it! Thanks mate, the flooding wasn't too bad. About an inch through the garage and workshop, they are connected and have the same floor level. My boys and I sorted all the parts in the soaked cardboard boxes and got it nearly all done Friday and a bit of Saturday. The floor had to come out of the new mancave but it's all drying well.
I feel so sorry for anyone who has their house flooded.
My damage was minimal with little cost. Probably 3 days to sort.
Dusty- thanks for the kind offer, but the floor is click together vinyl. The ply and insulation below it took a battering. .
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Post by Yogi on Jun 27, 2016 19:33:35 GMT 1
There's no slowing you down Mark I thought we would have to start a (save the cave) fund for a minute Looking good Atb Matt
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Post by cinder on Jun 30, 2016 19:02:59 GMT 1
Keep up the good work mark, can't wait to see it finished.called in on Harry last night so you may be getting a suprise soon.all the jobs your getting through bring back memories of my own build.just keep ticking off things on your still to do list lol
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Post by yamark on Jun 30, 2016 19:42:29 GMT 1
Keep up the good work mark, can't wait to see it finished.called in on Harry last night so you may be getting a suprise soon.all the jobs your getting through bring back memories of my own build.just keep ticking off things on your still to do list lol Thanks Graham - I like surprises
My list is reducing, but also getting more detailed. So "do radiator work" turns into - extend rad cover, extend radiator, move rad top hose connection position, make new mount brackets, get brackets welded.
Thanks for your encouragement mate. Hope the mods on your exhausts have gone well.
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Post by jon on Jun 30, 2016 20:19:42 GMT 1
Mark, I was thinking about my build at the weekend that whoever ends up with it in the (distant) future is going to have a job replacing parts that have been adapted to fit.
Your build is totally bespoke, so pity the person that eventually ends up with it.
In the mean time, enjoy.
Jon
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Post by dusty350 on Jun 30, 2016 21:40:05 GMT 1
Don't think Mark will ever sell this one It will live in the man cave forever !! Pm sent Mark. Dusty
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Post by Slabsideian on Jun 30, 2016 22:45:47 GMT 1
Yah agreed there. This will be a keeper!!
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Post by yamark on Jun 30, 2016 22:48:15 GMT 1
Don't think Mark will ever sell this one It will live in the man cave forever !! Pm sent Mark. Dusty Correct Dusty and slabsideian, one of my three boys will own it one day. This is assuming the bike goes to plan and works!
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