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Post by yamark on Jul 12, 2024 14:13:43 GMT 1
Thanks urbantangleweed and JonW. I'll move onto the frame, I had a bit of luck as Dusty told me Alex (donkeychomp) had an aircooled frame with the headstock altered. It's a Daytona frame, with practically every bracket removed, but very rot free. So after managing to give Alex some money (he didn't want anything for the frame), I had a rust free frame, with a knackered headstock and a UK registered knackered frame that had a decent headstock, horizontal and vertical rails. So in true JonW tradition I cut the two frames to be fused together. The horizontal rails needed to be extended, so I cut new tubes in and sleeved them internally SDC12333 The top brace is at different angle on the C/D compared to the E/F/Daytona, so I'll sort that later. You can see the sleeves to locate the front downtubes in the next image. The front downtubes will be replaced as they have to curve outwards to clear the exhausts. (I have a stock RD400E to take measurements from) SDC12334 I then cut out the cross tubes, spread the frame 20mm, and fit new cross tubes (the 20mm gives me better chain clearance to the frame and rear tyre) SDC12335 I then bend the new front tubes, cut the right front tube out and laser level the swing arm spindle to the headstock SDC12336 I repeat for the other side after installing a new top rail (at the new angle), and making a frame jig to hold it all in place (The front weld is so poor as I had run out of gas!) SDC12339 And finally, jigged, tacked and assembled with internal sleeves ready for Glenn to weld SDC12340 I did make a rookie mistake and used galvanised tube for the front tubes, this is, as I now know, much harder to weld My welding is mediocre at best, so I never do any structural welding. Many thanks to Alex and Dusty Cheers, Mark
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Post by JonW on Jul 12, 2024 14:26:39 GMT 1
Love this update!
Thats the same kind of frame jig i will make for mine, I planned to also bolt it to the rad mounts on the LC, but of course you dont have those.
Superb work as ever Mark!
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Post by yamark on Jul 12, 2024 15:41:10 GMT 1
Love this update! Thats the same kind of frame jig i will make for mine, I planned to also bolt it to the rad mounts on the LC, but of course you dont have those. Superb work as ever Mark! Thanks Jon, you inspired me to do the headstock swap
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Post by donkeychomp on Jul 12, 2024 21:42:26 GMT 1
Nice work Mark! Do I spot an R1 poking it's nose in?
Alex
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Post by JonW on Jul 13, 2024 0:29:36 GMT 1
Love this update! Thats the same kind of frame jig i will make for mine, I planned to also bolt it to the rad mounts on the LC, but of course you dont have those. Superb work as ever Mark! Thanks Jon, you inspired me to do the headstock swap Haha, im not sure thats a good thing. But in this case I reckon it is ![:)](//storage.proboards.com/forum/images/smiley/smiley.png) Excited to see the progress on this, going to be a good build for sure.
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Post by urbantangleweed on Jul 13, 2024 6:12:40 GMT 1
Another epic build in process, this is going to be fabulous
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Post by lcmarky on Jul 13, 2024 7:08:52 GMT 1
Superb work.. Very generous folks on here too.. Team work makes the dream work!
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Post by dusty350 on Jul 13, 2024 7:41:57 GMT 1
Fantastic work as always mate ![:)](//storage.proboards.com/forum/images/smiley/smiley.png) I saw all these parts when you got them, and thought it would be a Titanic effort to build one of your superb specials from, but if any one can... ![;)](//storage.proboards.com/forum/images/smiley/wink.png) Popped and saw Glen yesterday. BWB are moving to Farnborough within the next week or two ![:'(](//storage.proboards.com/forum/images/smiley/cry.png) Glen is going with them, initially at least, but will still do welding (steel anyway) on a mobile basis. Shame, that engineering firm has been there 50 years. They are fitting a new Laser cutter in their new place though ![:)](//storage.proboards.com/forum/images/smiley/smiley.png) Awesome work Mark, look forward to the next instalment
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Post by mouse on Jul 14, 2024 7:19:21 GMT 1
This really is amazing work and all done in a fairly modest (no offence meant!) home garage!
Mouse
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Post by yamark on Jul 14, 2024 14:22:12 GMT 1
Nice work Mark! Do I spot an R1 poking it's nose in? Alex It is Alex, 2006 model on an 07 plate, under 3,000 miles! Embracingly, it's the bike I ride the most ![???](//storage.proboards.com/forum/images/smiley/huh.png) - it is a very quick bike
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Post by yamark on Jul 14, 2024 14:24:54 GMT 1
Superb work.. Very generous folks on here too.. Team work makes the dream work! Alex and Dusty have been pivotal and super generous in supplying parts for this build, a big thanks to them both
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Post by yamark on Jul 14, 2024 14:31:55 GMT 1
Thanks Urbantangleweed, Dusty and Mouse. Dusty- Glen lives 20 minutes from me and said I can drop any parts to be welded to him. Mouse- no offence taken, I also store tools and materials for my work in the garage, so it can get very full up at times. There's more room than it looks
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Post by Mr Kipling on Jul 14, 2024 19:28:52 GMT 1
Awesome work going on here, cant wait for more updates....A+++
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Post by arrdy350 on Jul 14, 2024 19:36:31 GMT 1
Great start to build Yamark👍 Keep the pics and updates coming 🙂
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Post by yamark on Jul 27, 2024 17:30:53 GMT 1
Thanks Mr Kipling and arrdy350 For the front and rear suspension, I'll be using forks and rear swing arm from a GSF400 Bandit. The forks are an easy swap, the rear not so straight forward. The 400 Bandit has a long swing arm, different spindle diameter and is mono shock, where I want to keep twin shocks. I have already spread the frame to the new width of the swing arm. So to get the wheelbase I'm after, I shorten the arm by 95mm, cut new chain adjuster slots, and cut out the front brace and move it forward to clear the wheel SDC12341 SDC12342 I then shorten the rear caliper arm by the same amount SDC12344 I then machine new sleeves for an interference fit, to give the correct spindle diameter SDC12345Press them in (I have 20 tonnes of pressure at my disposal ![8D](//storage.proboards.com/forum/images/smiley/insane.png) ) SDC12346 And assembled SDC12347As usual, structural welding will be done by Glenn. Engine mounts next time Cheers, Mark
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Post by urbantangleweed on Jul 27, 2024 17:34:16 GMT 1
That's coming along really nicely.
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Post by dusty350 on Jul 27, 2024 22:03:33 GMT 1
Awesome work, as always Mark ![:)](//storage.proboards.com/forum/images/smiley/smiley.png)
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Post by mouse on Jul 28, 2024 17:00:07 GMT 1
This looks great Mark, but in shortening the swingarm is that not going to make it a bit 'twitchy'?
Mouse
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Post by yamark on Jul 29, 2024 6:27:29 GMT 1
Thanks urbantangleweed and Dusty. Mouse, it took me a while to choose the front and rear ends. The standard swing arm on the A/C is 430mm (all approx measurements spindle to spindle) LC 450mm NC23 515mm NC29 510mm Bandit 600 515mm Bandit 400 570mm RGV 555mm 570- 95= 475 (bandit 400 subtract how much I shortened it by= new length) So the bike will be 45mm longer in wheelbase. Hope that makes sense Cheers, Mark
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Post by mouse on Jul 29, 2024 7:22:07 GMT 1
Thanks urbantangleweed and Dusty. Mouse, it took me a while to choose the front and rear ends. The standard swing arm on the A/C is 430mm (all approx measurements spindle to spindle) LC 450mm NC23 515mm NC29 510mm Bandit 600 515mm Bandit 400 570mm RGV 555mm 570- 95= 475 (bandit 400 subtract how much I shortened it by= new length) So the bike will be 45mm longer in wheelbase. Hope that makes sense Cheers, Mark It does sir! Somehow i knew you would have figured it out first!! It's a great project Mouse
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Post by yamark on Aug 12, 2024 13:40:21 GMT 1
The engine cases are machined ready for welding and have the 2 dummy shafts clamped in place by several crankcase bolts. So I can now do the engine mounts. On the A/C engines, the front mounts have a fixed bracket on the left, and a removable bracket on the right. The right removable bracket uses long bolts to pass through steel tubes welded to the frame tubes- these steel tubes pass through the frame tubes and this is how I'm going to fabricate both of the front mounts. I'll need a step in both of the removable brackets After welding the 4 steel tubes in place, I use plastic packers to line up the engine in the frame SDC12368 This shows the left removable bracket and how it all bolts together SDC12369 And the front right SDC12370 I then make the 2 parts of the removable upper right mount SDC12371 The lower right mount SDC12372 The lower left (sorry about being out of focus) SDC12373 And finally the upper left SDC12374 It can now all be welded in place Cheers, Mark
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Post by donkeychomp on Aug 12, 2024 21:22:01 GMT 1
Marvellous work Mark! I trust you are leaving the frame as is, with my pound shop rattle can spray job... ![:D](//storage.proboards.com/forum/images/smiley/grin.png) Alex
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Post by yamark on Aug 21, 2024 17:08:35 GMT 1
Marvellous work Mark! I trust you are leaving the frame as is, with my pound shop rattle can spray job... ![:D](//storage.proboards.com/forum/images/smiley/grin.png) Alex I'm afraid Alex, I might change it
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Post by donkeychomp on Aug 21, 2024 21:24:28 GMT 1
And ruin perfection?? ![:)](//storage.proboards.com/forum/images/smiley/smiley.png) Alex
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Post by JonW on Aug 22, 2024 1:38:35 GMT 1
Super work as ever Mark.
Lots of work there making those brackets.
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Post by chrisg on Aug 22, 2024 20:20:36 GMT 1
Loving the post. Good old fashioned engineering.
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Post by yamark on Aug 26, 2024 18:54:17 GMT 1
Thanks Alex, JonW and Chrisg The next stage is to get engine mounts, swingarm brace and crankcases welded, so I took everything to Glenn The next 3 pictures are of the cases welded together. In the first picture you can see where I milled the underside if the crankcase to fit a strengthening bracket later SDC12472 SDC12473 SDC12474 As the left engine cover will be cut in two, you end up having 3 fixing points for the front and 3 for the rear covers. The rear cover has the clutch actuator in it, so needs more fixing points added. There is an undrilled fixing point near the gearchange shaft, and I add another at the top of the cover. This fixing has to be set so it will miss the carburettor float bowl, which sits above it SDC12475 The swingarm brace welded to it's new forward position SDC12379 I plan to use LC footrest hangers (I'll modify the look of them later), so I make some brackets and tack them onto the frame SDC12376 SDC12377 SDC12378 I can now make the top and bottom shock mounts (the top mounts have been cut off the frame!) Getting close to a rolling chassis. Another huge thank you is needed. One of my non choke carbs was badly corroded internally- Reedpete to the rescue, he sent me a 1A3 carb body. Without the help from Forum members, this project would have not been possible. So thanks to Dusty, Alex and Reedpete Cheers, Mark
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Post by JonW on Aug 27, 2024 1:32:45 GMT 1
More great work. Its always nice to see how these engines are stitched together. I always like the maths and engineering that goes into making these work. The theory on how the crank is built, how the timing works and then making that work with the actual bits of alloy and steel etc. Without the help from Forum members, this project would have not been possible. Aint that the truth! Without our forum friends Im sure many of our projects would be dead in the water. Thanks also to everyone who has helped me along the way too. It's very very much appreciated! I considered doing that old street racing car thing of having the brands used at an angle on the side of the car, but with forum names on the bike. But, there would be so many on something like my decapitated LC that it would look a bit strange as it would be covered in names!
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Post by tout on Aug 27, 2024 2:06:52 GMT 1
Agree Jon,He`s a clever chap, some great engineering skills on show. true dedication
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Post by mouse on Aug 27, 2024 6:19:04 GMT 1
There is so much work involved in this. So much that people will not have any clue to when the bike is finished. Some outstanding welding too especially on the swingarm!
Mouse
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