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Post by Tobyjugs on Feb 12, 2021 20:43:36 GMT 1
I’m feeling pretty chuffed to get a pic of my first hybrid build on this epic build thread 😊 Keep it up Toby your getting there mate, you’ve solved a few problems since I got lost in my mancave build 👌 You’ve also caused a few too 🙈 Atb Matt Thanks Matt. Yes i seem to be building quite a collection of MK1 and MK2 parts. Ha Ha |
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Post by Yogi on Feb 12, 2021 20:45:35 GMT 1
I’m feeling pretty chuffed to get a pic of my first hybrid build on this epic build thread 😊 Keep it up Toby your getting there mate, you’ve solved a few problems since I got lost in my mancave build 👌 You’ve also caused a few too 🙈 Atb Matt Thanks Matt. Yes i seemed to be building a collection of MK1 and MK2 parts. Ha Ha You can never have to many parts 🥴 |
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Post by JonW on Feb 15, 2021 2:37:25 GMT 1
Love this build thread, pure class.
Interesting about the drain plug Toby and the levels are something Id not considered. Ive bought and used magnetic hex key plugs on some of my builds so you can drop the oil easier and also make use of magnetic swarf catchers. hmm...
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Post by Tobyjugs on Feb 28, 2021 13:23:54 GMT 1
In the previous pictures you might have noticed i was using a 4LO clutch cover. This was used as the kickstart hole was welded shut. Now that i have fitted the 8 friction plate clutch i need a YPVS cover as it has more room for the clutch. The YPVS casing i have modified for the water pump needs to have the hole for the kickstart closed. First i thought about a sight glass but it looks too high for that and i'm not very keen on welding it shut as it's one of my nicer side casings. In the end i decided to make a plug for the hole.  It bolted in from the back using a big washer and an allen bolt.  When i pushed it into the casing it went in very easy. Actually too easy, the hole is so sharp it cut the O-ring like it was a razor. After chamfering the leading edge of the hole it was a nice fit.  Here it is fitted and coloured in with a black paint pen.  |
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Post by JonW on Mar 1, 2021 0:15:14 GMT 1
nice!
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Post by Tobyjugs on Apr 7, 2021 19:24:30 GMT 1
Just thought i should update this thread a bit. After the last dyno setup there were a couple of things that needed to be improved. The engine was moving in the frame, the radiator was not working very efficiently and i had to use 6 heavy duty springs to stop the clutch slipping. I made these new engine mountings after Johnny C pointed out that the fittings being used were not big enough. The original fitting is on the left and the new improved version MK2 is on the right. Cheers pal always a fountain of knowledge and not to be ignored.  I was also starting to think that fitting 4 of the rubberised engine washers was also a mistake but after a bit of thought i think this was a good idea as i could use these to exert more gripping force on the engine. One other point was the fact i did the long engine fitting bolts up by hand thinking that i could feel the correct torque. When i fitted the MK2 engine fittings i used a torque wrench and i knew instantly that i did not tighten them up enough the first time. This is from someone who is constantly telling other people to use the torque wrench.  
Due to the fact i don't like gorilla grip style clutches i decided to make and fit an 8 friction plate clutch.  The radiator was a bit pants it worked but i could measure different temperatures in the core which made me think it can be better, below is MK2. When this was being fitted i was surprised at how little cooling fluid is in the system, approximately 3/4 of a litre.  Ok i trotted off to the dyno bank plopped the bike on the bank and warmed it up. Then the owner did his thing and made a few runs. Everything was going great. The clutch fitted with six standard springs was rock solid, the engine movement was very very small and an indicated 50 C on the temp guage. I was very happy thinking i had ironed out all the bugs. I just started to remove the bike and then asked Pieter the owner of the dynobank how much torque it made. To my dismay it was only pulling 49 foot/pounds and on the last dyno session it was making 59 foot/pounds. Bollocks, a quick check of the plugs showed it was too rich, after re-jetting the carbs the clutch began to slip. I came prepared for this as i was not too sure about using standard springs. I changed the springs for three heavy duty and three standard YPVS springs and the clutch was holding again. So at this moment in time i think an 8 friction plate clutch is only good for a tuned 350cc engine. If you go big i would recommend a 9 friction plate wet version or a dry clutch. Sometimes i spend hours trying to work things out using mathematics to try and prove something. The following time i will just leap before looking. That was the case with the 8 friction plate clutch. If you think about the standard 7 plate clutch is good for say 55 hp thats roughly 8 hp a plate it's fairly obvious an extra set of plates isn't going to be enough for a big bore engine. Ok there are extra plusses due to wider friction plates and bigger steels buuut? The temperature was a nice surprise and i am happy with the result. There was one thing that stuck out a bit and that was i measured approximately 55 degrees with a Raytech on the cylinders and 50 degrees after the engine. I will look into this and i'm kind off hoping that this is not the known problem where the cooling is hot around the exhaust ports and cooler over the cylinder head. I have been busy for a long time now making a dry clutch for this bike, i have been having problems trying to get a good set of primaries for it, when its sorted i will post some pictures. I hope that i can have much lighter clutch action using a dry clutch. Also i have been making jigs etc to make fabrication easier to make either a 9 plate wet clutch or a dry clutch. |
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Post by oldbritguy on Apr 8, 2021 21:21:04 GMT 1
The joys of building a special Tony.
Proper bit of problem solving going on there. Technical stuff beyond me.
Good to see this thread going again. 😉
John
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Post by JonW on Apr 9, 2021 1:12:31 GMT 1
Superb info and great progress mate!
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Post by Tobyjugs on Apr 9, 2021 10:39:44 GMT 1
The joys of building a special Tony. Proper bit of problem solving going on there. Technical stuff beyond me. Good to see this thread going again. 😉 John Thanks John it's never stopped but due to work circumstances it is slow. Plus two steps forward one step back. |
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Post by Tobyjugs on Apr 9, 2021 10:42:53 GMT 1
Superb info and great progress mate! Yes this project is a complete learning process and i hope people can make better choices through seeing what works and my mistakes and pitfalls. |
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Post by JonW on Apr 9, 2021 14:08:09 GMT 1
Superb info and great progress mate! Yes this project is a complete learning process and i hope people can make better choices through seeing what works and my mistakes and pitfalls. Totally agree. Thats why i wrote my website with mistakes and wins; warts and all. |
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Post by Mr Kipling on Apr 11, 2021 16:15:59 GMT 1
great to see u perservering with this, keep the pics an updates a flowing.....
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Post by Tobyjugs on Apr 11, 2021 19:34:20 GMT 1
Thanks Mr K. Another little job that i keep imming and amming over is whether to put in a de-aeration circuit or not. In the end i decided to at least make provision for it and at least use it for the first couple of times to check for leaks or problems. I sent a mate a drawing and aske him to make some fittings. I also asked him to make some aluminium threaded fittings so i could weld them to all my rads giving me the option to switch radiators around if needed. In the picture below you can see four fittings made to be welded into radiators if needed.  I decided to make all my radiator fittings M10X1, this proved to be not such a good choice as i couldn't find the correct type of fitting i wanted from Cheap Charly ebay with an M10x1 thread  . These were also made at the same time but with two variations of the same fitting. One fitting has a 4mm hole and the other has a 2mm hole. The 2mm hole fitting screws into the discharge side of the radiator. The small fitting is to keep the flow of the coolant down to a minimum whilst letting any gasses escape from the highest part of the engine. To be honest a 1mm hole would have also been better. below is the restricted fitting.  
After the fittings were fitted i realised the engine fitting was not ideal for the cooling water pipe path.  I might be getting two fussy about this and i have an idea to either make a 90 degree fitting up and fit it in the sensor hole or on the ringed block. Or just use it as it is now because it works and see how it goes if it goes well just plug it off all together.  The one thing i have a problem with is finding a place to put the expansion tank on the bike. I always find an excuse not to put it somewhere and can't think of a place where to put it. |
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Post by sucram33 on Apr 14, 2021 20:25:44 GMT 1
Lovely and unique bike, great job. Ive got a Bakker ypvs as well but a bit different, 1980 TZ 350 chassis wheels forks etc, and a ypvs engine, Ive had it 15 years but its needs completely restored and rebuilt. Interesting frame, tubular but rising rate suspension and quickly adjustable steering head angle, it will look very old compared to your Bakker
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Post by stusco on Apr 14, 2021 20:58:17 GMT 1
Lovely and unique bike, great job. Ive got a Bakker ypvs as well but a bit different, 1980 TZ 350 chassis wheels forks etc, and a ypvs engine, Ive had it 15 years but its needs completely restored and rebuilt. Interesting frame, tubular but rising rate suspension and quickly adjustable steering head angle, it will look very old compared to your Bakker Pictures its not true unless there’s pictures 😊 |
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Post by Tobyjugs on Apr 14, 2021 21:21:01 GMT 1
Lovely and unique bike, great job. Ive got a Bakker ypvs as well but a bit different, 1980 TZ 350 chassis wheels forks etc, and a ypvs engine, Ive had it 15 years but its needs completely restored and rebuilt. Interesting frame, tubular but rising rate suspension and quickly adjustable steering head angle, it will look very old compared to your Bakker Thank you for the compliment. I once went to buy set of rims and the neighbour next to the seller had a special Harris framed TZ in his front room and in the garage a Bakker TZ 350 with the same spec that you mentioned the adjustable head angle is like a flat square plate if I remember it correctly |
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Post by sucram33 on Apr 15, 2021 20:54:55 GMT 1
Not sure how to post pics,I have some pictures of the bike in bits at the but it still gives you a good idea what its like
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Post by Tobyjugs on Apr 15, 2021 21:28:11 GMT 1
Not sure how to post pics,I have some pictures of the bike in bits at the but it still gives you a good idea what its like Everyone would love to see it |
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Post by Tobyjugs on Apr 17, 2021 22:03:11 GMT 1
The tank is now back from the painter. Nothing fancy just plain white until i know what i want design wise. I decided to get it painted to help spur me on.   |
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phantom
Weekend rider
I ended up needing a new pair of underwear
Posts: 60
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Post by phantom on Apr 17, 2021 22:23:31 GMT 1
The tank is now back from the painter. Nothing fancy just plain white until i know what i want design wise. I decided to get it painted to help spur me on. such beautiful hybrid bike project. gonna love how stunning and lovely it is  |
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Post by Eyrey1 on Apr 18, 2021 5:22:17 GMT 1
nice hybrid is that mr jugs ! im going to put my 500 hybrid for sale soon ,the one with v-due engine in, its as new only been started for 1 minute . its bad as when you get to like 20k spent on it its going to be hard to let go of it and sell .
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Post by mouse on Apr 18, 2021 6:54:28 GMT 1
Looks really fantastic Tobyjugs, will this be a track only bike?
Mouse
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Post by Tobyjugs on Apr 18, 2021 7:35:30 GMT 1
nice hybrid is that mr jugs ! im going to put my 500 hybrid for sale soon ,the one with v-due engine in, its as new only been started for 1 minute . its bad as when you get to like 20k spent on it its going to be hard to let go of it and sell .
Yes that is a lot of money, but it is great looking bike and a V-twin 500cc two stroke. If i go to Plymouth to visit family i always go into GT Motorcycles and oggle their collection of Honda NSR's. I think the Honda V-twin 500's would be very expensive and make yours look like a bargain. |
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Post by Tobyjugs on Apr 18, 2021 7:36:52 GMT 1
Looks really fantastic Tobyjugs, will this be a track only bike? Mouse Hi Mouse track only, actually more front room ornament.  |
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Post by oldbritguy on Apr 18, 2021 7:45:53 GMT 1
I know you are still working away on this and have a few more things to iron out, but this is a top build! It will run very well on the track I am sure but would be a shame to end up a piece of front room furniture (I know it won't though  ) I have learned much from this one Mr T John |
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Post by abar121 on Apr 18, 2021 12:33:49 GMT 1
Wow, it's looking even more beautiful now! It'll be a shame to cover that beautiful frame with a fairing |
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Post by Eyrey1 on Apr 18, 2021 20:19:57 GMT 1
nice hybrid is that mr jugs ! im going to put my 500 hybrid for sale soon ,the one with v-due engine in, its as new only been started for 1 minute . its bad as when you get to like 20k spent on it its going to be hard to let go of it and sell .
Yes that is a lot of money, but it is great looking bike and a V-twin 500cc two stroke. If i go to Plymouth to visit family i always go into GT Motorcycles and oggle their collection of Honda NSR's. I think the Honda V-twin 500's would be very expensive and make yours look like a bargain. padgetts is only a few miles from me ! hey have the v twin honda in there ive sat on it , all the 2 stroke race bikes in there is dream tackle they are all over they are up in the roof downstairs and upstaors ,brand new 125s and 250s fresh out of the crate ! |
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Post by Tobyjugs on Apr 18, 2021 22:14:59 GMT 1
I know you are still working away on this and have a few more things to iron out, but this is a top build! It will run very well on the track I am sure but would be a shame to end up a piece of front room furniture (I know it won't though ) I have learned much from this one Mr T John Don't worry John my front room looks more like a garage it should fit in well when its not being used. |
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Post by Tobyjugs on Apr 18, 2021 22:16:02 GMT 1
Wow, it's looking even more beautiful now! It'll be a shame to cover that beautiful frame with a fairing It might end up scantily clad  |
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Post by Tobyjugs on Jul 19, 2021 23:23:54 GMT 1
Just a small update, I've finally been able to get some wheel spacers made for the front magnesium rim. It's not such a big thing but I'm glad I've been able to do it. One min point is i bought some discs more than a year ago and now i can't find them. When measuring the rim up for discs according to internet sources it seems to be a Honda PCD from an RC30 or a Fireblade from 94 to 96. I built everything for 300 mm discs and the Honda discs were 296 mm. I thought the easiest solution was to just chop 2mm off the outer side of the friction material on the pads but after listening to two mates i bit the bullet and bought 2 discs from ISR. ISR sell the normal size and a larger size which is 320 mm. I thought this would be overkill on this bike and after speaking to ISR they just made them 300 mm to suit my calipers. I've just got to find them. Bugger So here it is with two white wheels. 
 Another little job i have done is rubbed down and filled in the mould marks from when the seat was made. I'm not sure if i want to paint the fairing work or get it wrapped so that it is all the same colour. I'm looking for the cheapest option as i might still modify the fairing. I think i might have to do something about the front mudguard as it looks like it sits too high above the front wheel. I've never noticed this before until i fitted the white rimmed wheels. This year i've missed out on two chances to do some shake down tests and try it out on a track. This is also very frustrating. |
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. These were also made at the same time but with two variations of the same fitting. One fitting has a 4mm hole and the other has a 2mm hole. The 2mm hole fitting screws into the discharge side of the radiator. The small fitting is to keep the flow of the coolant down to a minimum whilst letting any gasses escape from the highest part of the engine. To be honest a 1mm hole would have also been better. below is the restricted fitting.
)
