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Post by oldbritguy on Aug 3, 2020 21:13:41 GMT 1
Great work Mark. A lot of skill and detail going into something as innocuous as the air filter box, will probably be lost on the finished article. But it is all of these things like getting the oil pump right, the air box and the million other little one off fabrication jobs which all together will make this bike a true special. Top job mate. John
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Post by JonW on Aug 4, 2020 1:28:42 GMT 1
Stunning solutioning and engineering as ever Mark. Loving your work!
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Post by yamark on Aug 5, 2020 14:58:39 GMT 1
Great work Mark. A lot of skill and detail going into something as innocuous as the air filter box, will probably be lost on the finished article. But it is all of these things like getting the oil pump right, the air box and the million other little one off fabrication jobs which all together will make this bike a true special. Top job mate. John Thanks John, it's the bit I enjoy the most- fabricating and problem solving. When people look at the triple, first you get a chin rub, followed by a head scratch and then the full autopsy as they start to work out what has been modified. I always enjoy answering questions and talking them through the parts they don't understand fully, it gives me a buzz and has motivated a few people to "have a go" themselves.
Thanks for your kind words John, and Jonw.
Cheers, Mark
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Post by yamark on Aug 6, 2020 15:43:25 GMT 1
Airbox Part 6
I'm posting early as I'm out of the UK very early tomorrow.
I cable tie and duct tape the air box together to check it clears the frame, shock, oil tank and battery box. It does, but I decided to alter the front section as it virtually touches the frame tubes, and I moved the rear mounts a little.
SDC11906
And the view from the rear
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I used the welder that Dusty knows. In fact Dusty was very instrumental in getting my parts welded, so a big thank you mate
The main 2 sections welded together
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The front mount welded
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Underside rear mounts
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The join at the 2 sections
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And finally, a view of the end section.
SDC11937 I'm really pleased with the welding, no distortion at all.
So next time, the filter holes will be cut and the holes for the air ducts cut. If I make a mistake, close to 20 hours of work will be wasted - no pressure then!
Cheers, Mark
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Post by veg on Aug 6, 2020 18:09:48 GMT 1
Thatβs an absolute work of art. Very few can weld alloy even fewer do it well. Lovely.
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Post by dusty350 on Aug 6, 2020 19:54:54 GMT 1
This airbox really is an incredible piece of home engineering ! I doubt you could have had it made anywhere, by any expert metal worker better than what you have achieved. It would have been so easy to fit 4 foam pods on the back of the carbs, but instead you chose the better, but much harder route, with a bespoke airbox made to fit perfectly ! It's details like this that make these multicylinder builds of yours so amazing. And Glenn, the welder is very, very good. Been doing it over 30 years, and has a great portfolio of work he has done in the past - much of it for Tv and film at Shepperton studios, so he is very used to doing some challenging welding. He was pretty impressed with the work that had gone into this Dusty
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Post by donkeychomp on Aug 6, 2020 21:48:01 GMT 1
Welding porn. Yes that guy does some seriously good work.
Alex
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Post by yamark on Aug 9, 2020 19:46:08 GMT 1
This airbox really is an incredible piece of home engineering ! I doubt you could have had it made anywhere, by any expert metal worker better than what you have achieved. It would have been so easy to fit 4 foam pods on the back of the carbs, but instead you chose the better, but much harder route, with a bespoke airbox made to fit perfectly ! It's details like this that make these multicylinder builds of yours so amazing. And Glenn, the welder is very, very good. Been doing it over 30 years, and has a great portfolio of work he has done in the past - much of it for Tv and film at Shepperton studios, so he is very used to doing some challenging welding. He was pretty impressed with the work that had gone into this Dusty Dusty, once again, Iβm humbled by your kind words. Glenn is a truely talented welder and thanks mate for sorting it all mate. For me, the look of the bike is everything, followed by performance. I try to achieve the look Iβm after, no matter how hard or time consuming.
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Post by sidney81 on Aug 9, 2020 22:41:24 GMT 1
That air box is a great bespoke item I can really appreciate how much work you have put into that ! Awesome ,I'm a fabricator / coded welder so I appreciate it even more πππ
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Post by yamark on Aug 16, 2020 16:27:32 GMT 1
Hi all, still out of the UK for a few more days. I just thought Iβd bring you up to date with progress. The air box is just about finished, I have cut the 2 air filter holes out, and I then carefully marked out the holes for the carb air rubbers to go. I set up a pair of outer cylinders with reed blocks, inlet rubbers and carbs. After centralising the air box, marked the height of the holes, and centres. I drilled a series of small holes and then Dremelled the remainder to form circles. This was much safer than using a hole saw. It all aligns up . Iβll post the pictures later in the week. Cheers, Mark
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RD700LC
Aug 16, 2020 16:29:44 GMT 1
Post by dusty350 on Aug 16, 2020 16:29:44 GMT 1
Hey mate How's the beer ? Nice and cold I hope
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Post by yamark on Aug 17, 2020 8:20:09 GMT 1
Hey mate How's the beer ? Nice and cold I hope Hi mate, the beer is how most men like their women- tasty and cheap
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Post by yamark on Aug 17, 2020 8:20:26 GMT 1
Hey mate How's the beer ? Nice and cold I hope Hi mate, the beer is how most men like their women- tasty and cheap
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Post by yamark on Aug 17, 2020 15:25:05 GMT 1
Managed to find a computer I can use, so here's air box images The air filter holes cut out SDC11940 The air inlet ducts marked out SDC11941 One side checked SDC11942 And the other side SDC11943 I also cut out the middle holes for cylinders 2 and 3. Cheers, Mark
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2taol
Thrash Merchant
Posts: 378
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Post by 2taol on Aug 17, 2020 19:22:31 GMT 1
absolutely briliant!
a well worked plan !
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Post by flames on Aug 17, 2020 19:53:44 GMT 1
Unbelievable. Watching this is awesome. π
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Post by yamark on Aug 23, 2020 18:11:41 GMT 1
Cheers 2taol and Flames .
I continued to shape and rub down the airbox, so this is pretty much the finished item
SDC11947
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Next stage is the coil mount bracket, that will also double up as the front support for the airbox. 4 coils will be mounted to the bracket. I made a template first, then cut sheet steel to size. Then cut slots and marked the fold lines.
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I then cut out the sections where the coils will sit, and filed it all so it was symmetrical
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I then used a small diamond disc to score the fold lines
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Cheers, Mark
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Post by tony2stroke on Aug 23, 2020 18:21:45 GMT 1
That's some impressive fabrication there.
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Post by sidney81 on Aug 23, 2020 22:45:24 GMT 1
Brilliant ,love that airbox πππ
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Post by yamark on Aug 30, 2020 20:59:06 GMT 1
Cheers lads,
Continuing with the coil mount bracket I next drilled all the holes, ground out more of the fold lines and cut the base of the support braces
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Then folded the support braces
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Next, the vertical supports bent into their position
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And finally, the bracket bolted into position to check my clearances (I only fitted 2 coils at this stage)
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The supports and nuts to mount the coils have to be welded, as well as a nut under the bracket to mount my airbox at the front.
I'll show the welding next time
Cheers, Mark
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Post by donkeychomp on Aug 30, 2020 21:12:17 GMT 1
Amazing work Mark, amazing.
Alex
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2taol
Thrash Merchant
Posts: 378
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Post by 2taol on Aug 31, 2020 19:44:58 GMT 1
further fine fab fabricating . . .
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Post by oldbritguy on Sept 1, 2020 10:04:55 GMT 1
Top work as usual Mark. Moving along nicely too. I thought you would have gone with two twin output coils rather than 4 singles given your ignition is operating from two pick ups. Might have saved a bit of space, a bit of fabrication time and also a bit of cash. 4 coils will look neat though John
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RD700LC
Sept 6, 2020 13:55:27 GMT 1
Post by yamark on Sept 6, 2020 13:55:27 GMT 1
Top work as usual Mark. Moving along nicely too. I thought you would have gone with two twin output coils rather than 4 singles given your ignition is operating from two pick ups. Might have saved a bit of space, a bit of fabrication time and also a bit of cash. 4 coils will look neat though John Hi John, I toyed with the idea of two twin output coils, but height is the problem in the area at the front of the tank. So the standard LC type coils would have been a squeeze two in a line, HT leads bending sharply to miss the rear coil. The Banshee coils are very small, and the HT lead route was better as I angled the front coils. Also, I love a bit of fabrication and the Banshee coils are cheap as chips.
Great question and nice comment mate , cheers, Mark
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RD700LC
Sept 6, 2020 15:15:02 GMT 1
Post by jon on Sept 6, 2020 15:15:02 GMT 1
yamark, Have you considered rivnuts for the threads? They would suit this application very well. Jon
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RD700LC
Sept 6, 2020 19:13:01 GMT 1
Post by yamark on Sept 6, 2020 19:13:01 GMT 1
yamark , Have you considered rivnuts for the threads? They would suit this application very well. Jon Jon, you'll probably be surprised, but I've never used rivnuts. I always have nuts welded on to brackets and fabricated parts, just habbit. I really should look into rivnuts, I assume they are easy to install.
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Post by yamark on Sept 6, 2020 19:50:13 GMT 1
Cheers, Alex, 2taol and oldbritguy
I had all the welding done at the same time. This is the coil bracket, the front airbox bracket and the rear right engine mounting plate welded.
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The coil bracket in position
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The inside of the clutch cover, disc from a generator cover welded
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The side stand needed a stop so it didn't foul the left exhaust
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Finally, the generator cover, the mock up and the cover to be used. I started to cut out the section where the second pick up will sit
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And the cover welded, ready for cleaning up
SDC11925
Cheers, Mark
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Post by flames on Sept 6, 2020 20:07:08 GMT 1
This is very special. I love the thought and detail that is going into every bit of this build. Its incredible.
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Post by yamark on Sept 13, 2020 20:22:08 GMT 1
Cheers Flames, and everyone following.
I had some time to clean up both engine covers and work on my wiring loom.
This is the modded clutch cover, that will now clear a lock up clutch. To remind you, the 3 standard star disc lugs have been removed, and a generator cover disc cut and welded in place
SDC11948
The generator cover weld cleaned up, for the second pick up housing
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I also finished restoring the standard LC loom. I removed all the terminals out of the blocks, soaked the terminals in white wine vinegar and salt, neutralised them in bicarb of soda and re assembled
Terminal removed
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Cleaned
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The upper 3 done- very mind numbing, but worth it
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Lastly, I repaired all the bullet connectors, and replaced any damaged block connectors
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SDC11922
Cheers, Mark
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RD700LC
Sept 13, 2020 20:34:02 GMT 1
via mobile
yamark likes this
Post by flames on Sept 13, 2020 20:34:02 GMT 1
Wow, the connectors have cleaned up really well.
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