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Post by arrdy350 on Aug 12, 2020 8:38:17 GMT 1
I would love to build a hybrid at some point I have got a PV and I am in keep thinking should I take it back to stock or not? 🤔
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Post by philmill on Aug 12, 2020 9:01:00 GMT 1
Going to be another thing of beauty, exactly what Ive come to expect from anything you do Dusty....
Phil
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Post by dusty350 on Aug 12, 2020 19:42:28 GMT 1
Cheers Phil Today was engine fit day. This felt like a major milestone has been reached, and another Rd has been born !! Plenty of pipe lagging to protect the powdercoat finish; 20200812_091523 by dusty miller, on Flickr Then I stripped off the carbs and stator cover, and even removed the plugs as they can catch on the frame above the engine; 20200812_092241 by dusty miller, on Flickr It's a weighty engine, a fair bit heavier than an Lc or Pv I reckon, but I had my porridge for breakfast, so not too bad !! 20200812_121146 by dusty miller, on Flickr I trimmed the HT leads and fitted the new plug caps, and refitted the carbs. It's a bit cramped in my garage for a decent pic, so I wheeled her out in the sunshine; 20200812_142334 by dusty miller, on Flickr 20200812_143627 by dusty miller, on Flickr 20200812_142108 by dusty miller, on Flickr Colour scheme-wise, the 400 is very much like the Café Racer. I love the Tz inspired white/red combo; 20200812_142536 by dusty miller, on Flickr Next job is rearsets, and I'm going to offer up the Allspeeds from my 430 so I can work out how they are going to fit. Dusty
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Post by sidney81 on Aug 12, 2020 21:24:40 GMT 1
Looking lovley dusty 😎
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Post by donkeychomp on Aug 12, 2020 22:08:14 GMT 1
Blimey.
Alex
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2taol
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Post by 2taol on Aug 13, 2020 12:21:16 GMT 1
oh yea, looking good.
im not too far behind you dusty with my build.
how does everyone weigh their bike?
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Post by dusty350 on Sept 11, 2020 14:51:17 GMT 1
The 430e was collected today, and gone to a new home in Essex. I now have the funds and the room to progress this build. I've ordered a set of chrome, small can Allspeeds from Tony at Gibsons, and current estimate is 6 weeks wait. Once I have them I can do the rearset plates, as I hope to mount the pipes using the hole the footpeg mounts through, to keep things neat. I wanted Yss twin piggybacks from the start of this build, and they arrived this week, Once I had the room in the garage, I removed the old Xjr shocks I had fitted for mock up, and bolted on the YSS shocks; 20200911_115435 by dusty miller, on Flickr 20200911_115426 by dusty miller, on Flickr Really nice quality as usual, and adjustable for length, preload, rebound and damping. I also bought 2 new Ramair filters as the old ones were a bit worn out. Ramair were brilliant to deal with directly - £30 posted next day, for the pair; 20200911_115524 by dusty miller, on Flickr There is a new kickstart fitted as the engine didn't come with one, and I've also got a new Yam tacho cable to fit. I also ordered a new CDI unit from Rex's Speed shop, as again, I never had one originally. I could have used a spare Lc Cdi I have but thought it worth buying a new, upgraded box to save on any electrical issues a 40 year old CDI might throw up. Need to work out where to mount it as this is a D frame, and doesn't have a CDI mounting point. I have an idea for it's placement - possibly on a plate mounted under the battery box. Next job is to look at chain run and offset sprocket size. Dusty
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Post by sidney81 on Sept 11, 2020 15:01:35 GMT 1
I've been waiting for your next update dusty , looking lovley !! In regards to the new CDI ,I might be in the same boat ! Do they plug straight in ? And they expensive ? Thanks Chris
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Post by dusty350 on Sept 11, 2020 15:30:57 GMT 1
Hi Chris Rex's Cdi can be supplied either with a 6 way plug or a 6 separate pin loom. Its just over 94 quid posted. As said, you can use an Lc Cdi, but they are all getting on for 40 years old so I thought a new one would be sensible. Same size as the original unit for fitting purposes too. Should receive it next week😉
Dusty🙂
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Post by flames on Sept 11, 2020 16:52:47 GMT 1
Looking good as usual Dusty. Hope new owner of 430e joins up so we still get to see and hear how the ol girl is getting on.
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Post by dusty350 on Sept 11, 2020 18:38:36 GMT 1
Hi mate Not sure he does forums ? He has a collection of 50 bikes - no Lc's or Pv's and 1 other 400. He has Bridgestones, a rare 125Lc Laverda, loads of Ts Suzuki's - all sorts of strokers, plus diesels. I don't think he will be adding too many miles to the odometer ! Dusty
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Post by flames on Sept 11, 2020 19:03:47 GMT 1
Same.....I would ride the spuds off it if it were mine. The bike deserves it.😁
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Post by mouse on Sept 11, 2020 21:13:18 GMT 1
Shocks were well worth waiting for, they look awesome!
Mouse
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Post by donkeychomp on Sept 11, 2020 22:07:40 GMT 1
It's great to see you back on this Dusty. Those shocks look really good. Can't tell from the pics but what tyres are you using on this build?
Alex
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Post by sidney81 on Sept 11, 2020 22:26:47 GMT 1
Hi Chris Rex's Cdi can be supplied either with a 6 way plug or a 6 separate pin loom. Its just over 94 quid posted. As said, you can use an Lc Cdi, but they are all getting on for 40 years old so I thought a new one would be sensible. Same size as the original unit for fitting purposes too. Should receive it next week😉 Dusty🙂 thanks dusty it's giving me another option nice one
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2taol
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Post by 2taol on Sept 12, 2020 7:37:25 GMT 1
ah that looks really good, high level of finish on "everything" with no compromises.
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Post by dusty350 on Sept 12, 2020 8:13:44 GMT 1
The shocks are lovely - beautifully well made and super adjustable. I could have bought some cheap Chinese shocks for a fifth of the price, but I wanted something that actually worked, as well as looked good, and the length adjustability is a good thing to have on a hybrid build. Been really happy with all the YSS monoshocks I've had before, so I'm sure these will be good too. Alex, tyres are Bridgestone Bt 090r - front 110/70/17, rear 150/60/17. Dusty
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Post by JonW on Sept 12, 2020 14:05:53 GMT 1
Loving the shocks. I nearly got the piggybacks for my XT500, but instead went for the cleaner/simpler looking non piggys. Defo not a cheap set of shocks and yours were more im sure, but lovely quality as you say.
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Post by dusty350 on Sept 19, 2020 13:24:43 GMT 1
Computer has been playing up all week so haven't been able to load up any pics till now. I bought a CDI unit from Rex's Speed shop, and it arrived quickly, and well packed. This is an earlier frame so didn't have provision for mounting a CDI unit like the later bikes so I needed to find somewhere to locate it. I made a mounting plate that sits below the battery box and bolted it in there. Battery will be an AGM type, so no risk of acid spills finding their way onto the CDI box, and the connector will be in the same place it would be for the E loom; 20200915_190112 by dusty miller, on Flickr 20200915_192108 by dusty miller, on Flickr The next job is chain run. It's out by a fair bit on this build, so I bought a 9mm offset front from Talon - again, great service and quick delivery, and I have bought a Talon 39 tooth Rgv rear sprocket that is being counter bored on it's inside edge by 2mm to draw the sprocket nearer to the wheel. I'm also having a new spacer made for behind the front sprocket that is 16.5mm, so 2mm wider than an a/c spacer but 2.5 mm less than a Pv spacer, which is hardened and cant be machined down unfortunately. I want to avoid machining the Rgv sprocket hub as they can be fragile, and I think this set up will line up ok, and allow the locking tab washer to still sit under the lock nut at the front and work as it should. I've ordered the DID chain so should have the chain fitted and sorted by next week hopefully Dusty
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Post by dusty350 on Sept 25, 2020 9:38:26 GMT 1
Sorted the chain run this week. I was originally looking at a fairly large offset. The 400e front sprocket spacer is the same as an Lc, at a smidge over 14mm deep. A Pv spacer is just over 19mm, so gives you 5mm gain before you fit a sprocket, but wont allow the fitment of the sprocket tab washer as the output shaft is underflush with the surface of the sprocket You cant machine down the Pv spacer as it's hardened. You could pack the 400 spacer with a 2mm washer just behind the sprocket - this allows the fitment of the tab locking washer (just"), so a 16.5m spacer was decided upon. Sorting chain run is a juggling act, and other issues affect it such as tyre width, frame tubes etc, so I was looking for the happy medium where I missed the tyre, frame, and didn't have such a massive offset that it stressed the output shaft bearing, or contacted the clutch actuator against the front sprocket ! So I was looking to gain width at the front and lose some at the back. My engineering guys are hit and miss at the mo - not a lot of work about so they are often closed, but my welding guy put me onto another local engineer who could sort the jobs needed. He is a biker too, and another top bloke who understood the issue. First, he made a new front spacer at 16.5mm. It's between the large Pv spacer and smaller 400 spacer; 20200923_115011 by dusty miller, on Flickr 20200923_115037 by dusty miller, on Flickr With that fitted, I added the Talon 9mm offset sprocket, and can just locate the tab washer on the output shaft; 20200923_193950 by dusty miller, on Flickr 20200923_194023 by dusty miller, on Flickr 20200923_194113 by dusty miller, on Flickr So I have effectively offset the front by 11mm. At the rear, I originally fitted a Renthal sprocket. I didn't want to have the carrier milled as the Rgv sprocket hubs are known to be a bit fragile, so another way of bringing the sprocket in nearer the wheel is to counter bore the sprocket itself. I bought a Talon rear sprocket as it has less decorative/weight saving holes drilled in it, so I thought it would be a better sprocket to machine. A 520 sprocket is 6mm wide, so 2mm was machined off, leaving the teeth at the original 6mm for the chain to run on; 20200923_114802 by dusty miller, on Flickr Cost was £40 for the new front spacer and the sprocket machining. I bought a new DID chain, and yesterday I offered it up. I always buy overlong chains so I have some leeway regards wheel position - I just cut off the links I don't need. I deliberately set the wheel quite far back, and once a chain starts to stretch through use, will just cut a link out again - easy with a split link chain. I didn't fit the Talon rear sprocket at first, so just went with the offset front. There is some leeway with the chain running slightly out of a perfect line - I've not measured it but a good 2mm I think is acceptable. Too much and you will wear the sprocket teeth on one side, create stress and noise and a chain that doesn't run smoothly. With the links cut out, and the chain fitted, I adjusted the wheel position and spun the wheel. Thankfully, the chain runs smoothly, and appears to sit evenly on the sprocket teeth and not pitching to one side or the other. So I didn't need to fit the Talon sprocket after all ! If I did fit it, the 11m at the front, the 2mm at the rear and the 2mm deviation would make for a perfect line, but I think leaving the rear sprocket standard will work ok. I now have clearance with the frame tubes (scalloped previously, just in case !) and there is about 3-4 mm clearance with the edge of the tyre; 20200925_093043 by dusty miller, on Flickr 20200924_143404 by dusty miller, on Flickr Dusty
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Post by sidney81 on Sept 25, 2020 10:22:15 GMT 1
That looks a treat dusty ,is the new spacer stainless ?? ,I will be having the same task soon 🙂
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Post by arrdy350 on Sept 25, 2020 11:14:57 GMT 1
That look's great Dusty. I am enjoying reading about the build. Do you use Metmachex swingarms for all your build's?
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Post by 2taol on Sept 25, 2020 12:49:09 GMT 1
per my ow build I know the issues with offset sprockets, yours has worked very well indeed.
hopefully I'm not too far behing ya 🤟
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Post by dusty350 on Sept 25, 2020 14:08:15 GMT 1
Hi Yep, the new spacer is in stainless. I gave Steve, the engineer, the pv spacer for dimensions id and od, and he made it to 16.5mm. I try to use Metmachex arms on all my builds now. Allows the use of different rear wheels whilst keeping the wheelbase stock, plus I just love the look of them. Wanted a Metmachex arm on a bike for many, many years and now I've had 5 or 6 ! They are great guys to deal with now too, and make one off parts too😉 2taol- I posted some extra info in case it helps you. The chain deviation may help you keep the offset respectable ! When I first "straight edged" my sprockets, the offset gave me a sleepless night !!😲
Dusty🙂
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Post by midlifecrisisrd on Sept 25, 2020 18:25:48 GMT 1
Nice progress Dusty 👍
If you are still slightly out I'd try the cut rear
Remember 2mm at the rear will be under 1mm at the tyre
When I got my 3hm1 it had a 3xc rear wheel and it was out by 4mm
I know that's a lot but I was still surprised how much it had eaten out the edge of the front sprocket
The arm does look awesome by the way. Are you going to fit a chain guard? Got that dilemma myself on the TR
Steve
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Post by 2taol on Sept 25, 2020 19:40:54 GMT 1
yea the arm (and everything surrounding) looks great.
(thanks for the info dusty)
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Post by dusty350 on Sept 26, 2020 8:31:03 GMT 1
Hi Steve Gonna see how it runs with the current offset. Certainly seems smooth enough on the paddock stand, but will see if anything changes when on it's wheels and running. I have the option of the Talon sprocket, and plenty of clearance with the tyre should I fit it. Regards chain guard - I go without them on the Met arms. I did specify one on my first arm I bought from Dean, but it never looked quite right in my opinion, so I haven't bothered since. If you could design something smaller, it could look quite trick though 2taol - you are welcome - I'm sure you'll sort it but there are always compromises when building hybrids !! Another item ticked off the list is a pattern loom. There are a couple of options for looms on ebay for these bikes. This one was £170 odd - the other is £100 more ? 20200924_143351 by dusty miller, on Flickr Seems really well made, with all original connectors and correct wiring colours as far as I can see. The Allspeeds have been made - paid for them now and they are off to Chrome next week, so all being well, end of October may see them done. Once I have them the footrest plates will get sorted and I can fit the foot controls, pipes and rear brake components, which I still need to source. The list of new parts is now longer than the list of used parts !! Dusty Dusty
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Post by sidney81 on Sept 26, 2020 12:26:03 GMT 1
loom looks good dusty !how nice to fit that and just plug it all in etc all nice and new !!
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2taol
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Post by 2taol on Sept 26, 2020 20:15:24 GMT 1
loom looks good dusty !how nice to fit that and just plug it all in etc all nice and new !! and reduces headaches! nice loom dusty
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Post by dusty350 on Oct 14, 2020 19:38:46 GMT 1
Not had much time to do any work on the 400 recently, but have been collecting a few parts. I've bought a couple of rearset controls in readiness for when I can sort the mounting plates - can only do that once the pipes arrive and are offered up so I can work out exactly where to fix them; 20201014_165554 by dusty miller, on Flickr One job I did find time for today was the cut out for the rear light. On the last 400 I built 11 years ago, I recessed the rear light into the cowl, and had a special bracket made to mount it properly; rear light bracket 006 by dusty miller, on Flickr rear light 001 by dusty miller, on Flickr rear light 002 by dusty miller, on Flickr When I did this originally, tail cowls were plentiful and cheap - not so anymore unfortunately, so I was extra careful cutting this one !! 20201014_143716 by dusty miller, on Flickr Luckily, no mishaps. I kept the CAD template from all those years ago, so I will pop down to my engineering guys next week to see if they can make another plate. I plan on templating a second plate that will act as a number plate bracket too 20201014_165525 by dusty miller, on Flickr Dusty
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