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Post by vtrfighter on Oct 31, 2009 22:38:31 GMT 10
Pics pics pics pics pics pics ! WE WANT PICS
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cheekybugger
True Stormer
98' Black - Needs a Wash . . . Sold. 2014 899 Panigale.
Posts: 1,156
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Post by cheekybugger on Nov 1, 2009 15:52:27 GMT 10
Your wish is my command . . . :-) Here is how it was as I got it back from the welders - they did what I asked for and no more so I didn't get a nasty surprise with the bill. Then I took at it with a Rasp, the Angle Grinder, and the some flap disks etc to get it looking a bit tidier. Pretty happy with the job and have worked out what bits I need to order from the Exhaust place to do that myself. THe design is such that I should be able to keep it to 44 mm pipe the whole way which should breath nice. Haven't decided completely how I will treat the swingarm, but edging towards powder-coating the same colour and time as the wheels. Also have some Paddock Stand Spools to put on it too. I have also done some more work on the top cowl/cover hinge and latch, but nothing worthy of a pic yet.
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Post by sideshow on Nov 1, 2009 23:34:03 GMT 10
That came up nice, when I saw the first pic I was worried but nice job, cant wait to see the finish.
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bristunt
Senior Member
2000 SP1
Posts: 298
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Post by bristunt on Nov 2, 2009 14:24:10 GMT 10
Dunno if anyone has mentioned/suggested this, but that's a lot of heat in proximity of the shock. You are likely to get some shock fade as a result.
Probably a good idea to heat wrap the pipes.
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cheekybugger
True Stormer
98' Black - Needs a Wash . . . Sold. 2014 899 Panigale.
Posts: 1,156
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Post by cheekybugger on Nov 2, 2009 14:53:55 GMT 10
That is exactly what I will be doing - Have some ceramic wrap that will run from the swingarm right up to the cans. Not only will it keep heat away from the shock, but my legs too! Also have heat shield for the sides of the new subframe . . .
Ordered the exhaust bits today too. Should be here this week.
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Post by vtrfighter on Nov 2, 2009 18:55:06 GMT 10
That came up nice, when I saw the first pic I was worried but nice job, cant wait to see the finish. +1 Looking good Cheeky, and a nice job done finishing off the welds!!
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cheekybugger
True Stormer
98' Black - Needs a Wash . . . Sold. 2014 899 Panigale.
Posts: 1,156
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Post by cheekybugger on Nov 6, 2009 12:29:24 GMT 10
I love Christmas. Presents. So when my little parcel arrived today I was very excited. Curious? It was my new exhaust . . . Kinda like Lego, but a bit harder . . . . :-)
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Post by Fozzy Bear on Nov 7, 2009 17:54:48 GMT 10
The big doughnut thingy has me stumped....
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cheekybugger
True Stormer
98' Black - Needs a Wash . . . Sold. 2014 899 Panigale.
Posts: 1,156
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Post by cheekybugger on Nov 7, 2009 18:09:06 GMT 10
It's for my hemorrhoids . . . . :-)
Actually it is the only way to get really tight angled bends in an exhaust. Will give me 4 (only need 3) 90 degree bends that are tight, works out only about $10 more than buying 3 x 90 degree mandrels and will mean what I need to do will actually fit. Difference in Radius (at centre of pipe) is 33%.
Spent a bit of time this arvo looking at the bits and pieces (including some not above) to make sure it is going to work. Next step is off to a different exhaust place to get some swaging done (expanding the ends of the pipe) and then to mock up stage.
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cheekybugger
True Stormer
98' Black - Needs a Wash . . . Sold. 2014 899 Panigale.
Posts: 1,156
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Post by cheekybugger on Nov 10, 2009 12:21:49 GMT 10
Turns out the donut is 2" not 1 3/4" so I've sent it back and await the correct one. Got the swaging done and scavenged some gaskets, so am nearly sorted . . . .
Won't be able to work on it for the next week or so though :-(
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Post by vtrfighter on Nov 11, 2009 8:41:27 GMT 10
Keep your chin up mate, i think it was Shayne that said to me once "dont rush things" i cant really do much to mine at the moment due to stupid car breaking down..GRRRRRRR didnt leave much moolah for the bike this month
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shayne
Omnipresent
1998 Blueprint
Posts: 8,639
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Post by shayne on Nov 11, 2009 14:38:06 GMT 10
Keep your chin up mate, i think it was Shayne that said to me once "dont rush things" i cant really do much to mine at the moment due to stupid car breaking down..GRRRRRRR didnt leave much moolah for the bike this month Yep, it was me. Patience is your friend when doing projects. It is easy to get fired up and work too quickly, only to be disappointed when the job is done. When I found myself doing this I closed the shed up and did something else for the rest of the day.
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Post by vtrfighter on Nov 16, 2009 11:23:24 GMT 10
Keep your chin up mate, i think it was Shayne that said to me once "dont rush things" i cant really do much to mine at the moment due to stupid car breaking down..GRRRRRRR didnt leave much moolah for the bike this month Yep, it was me. Patience is your friend when doing projects. It is easy to get fired up and work too quickly, only to be disappointed when the job is done. When I found myself doing this I closed the shed up and did something else for the rest of the day. Great advice there cheeky, i was bending fins on my new radiator (cause i needed PAIR plates fitted first) so i waited and fitted in no time at all.
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cheekybugger
True Stormer
98' Black - Needs a Wash . . . Sold. 2014 899 Panigale.
Posts: 1,156
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Post by cheekybugger on Nov 21, 2009 19:21:49 GMT 10
Been doing some more thinking. And a little research. As result I am gonna give the final welding on the exhaust a go. I got some 1.6mm Welding Rods (apparently they're hard to come by), and will do a lot of practice to make sure I know what I'm doing. My welder will only go down to 40 Amps and I probably need 30 ideally, but with a stitch pattern and a healthy dose of patience I reckon it's worth a shot.
Anyway if it works I'll save some $$$ and be able to say I did it all myself, and if it doesn't, well at least I tried.
Have also had a chance to look at a couple of minor things that weren't 100% and find solutions . . . . taking the time to sit back and be objective has been great so I will also thank Shayne for his wisdom :-)
More coming soon . . . including pics for those who need them :-P
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cheekybugger
True Stormer
98' Black - Needs a Wash . . . Sold. 2014 899 Panigale.
Posts: 1,156
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Post by cheekybugger on Nov 22, 2009 17:23:05 GMT 10
Had time for a brief play today. First thing I did was cut out a couple bits of the frame to make space for the wiring loom - the original space allowed was too small. Filled the holes with some 30mm RHS and some shitty welding. Should look alright once it is ground back and painted - couldn't do much grinding today cause of the heat and wind. Then I tacked a couple of 'stiffening' plates over the indicator tabs - will need to tidy up the welding there. The most exciting thing though was my first attempt at welding 1.6mm wall pipe. Struck a little bit of trouble with the thickness of the rod. It has no inherent strength so would flex all over the place, and that made it splatter a bit more than I would like. Am considering cutting them short to prevent this, but not down with the waste :-( Penetration was good and with a basic grind (final product will get more attention) looks okay. Certainly won't need any bog . . . Anyone who has experience welding light stuff with a stick? Tips would be appreciated.
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Post by vtrfighter on Nov 22, 2009 17:30:17 GMT 10
Well done mate, i hope my painting skills are going to be as successful as your welding attempts. keep up the good work
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Post by strez on Nov 22, 2009 17:41:25 GMT 10
Had time for a brief play today. First thing I did was cut out a couple bits of the frame to make space for the wiring loom - the original space allowed was too small. Filled the holes with some 30mm RHS and some shitty welding. Should look alright once it is ground back and painted - couldn't do much grinding today cause of the heat and wind. Then I tacked a couple of 'stiffening' plates over the indicator tabs - will need to tidy up the welding there. The most exciting thing though was my first attempt at welding 1.6mm wall pipe. Struck a little bit of trouble with the thickness of the rod. It has no inherent strength so would flex all over the place, and that made it splatter a bit more than I would like. Am considering cutting them short to prevent this, but not down with the waste :-( Penetration was good and with a basic grind (final product will get more attention) looks okay. Certainly won't need any bog . . . Anyone who has experience welding light stuff with a stick? Tips would be appreciated. welding that with a stick is insane get yourself a mig , make life a lot easier
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cheekybugger
True Stormer
98' Black - Needs a Wash . . . Sold. 2014 899 Panigale.
Posts: 1,156
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Post by cheekybugger on Nov 22, 2009 17:54:25 GMT 10
You're right - a MIG would be great. But a Gasless MIG (a misnomer in itself) is $400 + and not suitable for small stuff anyway. A normal MIG is out of my budget ATM :-( Oh and I don't have a certificate for sanity . . . . make of that what you will
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Post by vtrfighter on Nov 22, 2009 19:46:58 GMT 10
I don't have a certificate for sanity . . . . make of that what you will I got mine free in a box of cornflakes
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shayne
Omnipresent
1998 Blueprint
Posts: 8,639
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Post by shayne on Nov 23, 2009 17:06:19 GMT 10
I have used a stick welder a few times over the years, but for a total of about 5 minutes.
I have a MIG, and find that with small wire you can do just about anything. Pity you can't afford one. Once you have one, you will find many uses for it I am sure.
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cheekybugger
True Stormer
98' Black - Needs a Wash . . . Sold. 2014 899 Panigale.
Posts: 1,156
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Post by cheekybugger on Nov 28, 2009 18:29:48 GMT 10
Not achieved a lot in the past few days . . . . But I did get to make the sides for the subframe. Cardboard model first - cut once etc. The material is fiberglass that has been baked under pressure in an autoclave. Really strong, really light not brittle and won't conduct any heat either. Is only 1 mm thick. Oh and it was FREE - rep from a plastics company gave it to me years ago and it was one of the few things I didn't through out when we moved. This week I hope to have time to strip the bike down and get the proposed subframe mods done.
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Post by vtrfighter on Nov 28, 2009 22:40:06 GMT 10
Any progress no matter how small is progress....
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cheekybugger
True Stormer
98' Black - Needs a Wash . . . Sold. 2014 899 Panigale.
Posts: 1,156
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Post by cheekybugger on Nov 30, 2009 17:00:23 GMT 10
Made a little progress today. One of the challenges this build has faced is the severe reduction in space. The rear coil pack had to be relocated as it wasn't going to fit in the back without major rewiring problems. So this arvo when I stripped the bike to look at the subframe design, the relocation of the coil pack was a consideration. Anyway after some thinking and looking and a lot of measuring this is what I made. It is a combined 3mm SHock Spacer and Coil Pack mount. The hole for the smaller bolt is threaded so no nut is needed. It will sit 3 or 4 mm away from the subframe so the bolt can go through a bit. Coil pack will sit around 7 or 8 mm away from the head and well away from the fuel tap etc. Heat shouldn't be an issue given the zorst will be wrapped and well away. Subframe pics will come when complete . . . .
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cheekybugger
True Stormer
98' Black - Needs a Wash . . . Sold. 2014 899 Panigale.
Posts: 1,156
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Post by cheekybugger on Dec 4, 2009 17:59:13 GMT 10
Have achieved a little bit over the past few days. Everything takes longer than you think, or is more difficult, or relies on a tool I don't have or some such bollocks. Anyway, I have got the bottom part of the exhaust re-route done. Here is a comparison between what I did, and what I had done at the 'professional' exhaust place; And here is how it looks on the bike . . . Next week I get my pipe-bender. With that I will be able to fit up the upper part of the exhaust. I have to keep myself in check as I really really really want to hear how it sounds! Sorry no Subframe pics this time . . . :-(
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shayne
Omnipresent
1998 Blueprint
Posts: 8,639
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Post by shayne on Dec 4, 2009 18:46:43 GMT 10
Exhaust heat is not going to be good for your shock temp.
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cheekybugger
True Stormer
98' Black - Needs a Wash . . . Sold. 2014 899 Panigale.
Posts: 1,156
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Post by cheekybugger on Dec 4, 2009 18:55:16 GMT 10
True - it will be wrapped with ceramic tape to keep the heat in and then out the end. The stuff is 2 mm thick so I think there is a good chance it'll keep a fair bit away from the shock and my bum!
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Post by vtrfighter on Dec 5, 2009 14:12:35 GMT 10
Sorry no Subframe pics this time . . . :-(
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cheekybugger
True Stormer
98' Black - Needs a Wash . . . Sold. 2014 899 Panigale.
Posts: 1,156
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Post by cheekybugger on Dec 6, 2009 11:02:52 GMT 10
So here is the subframe mod I made. Not much different, but looks heaps neater. You can stop crying now VTRfighter :-P I also did a little more work on my electric latch . . . The Reflector has been photoshopped in :-) Here is an idea of how big my regulator is; Was thinking of mounting it underneath the new top cowl and having a PC fan over it . . . . but then I thought I could put it under the new subframe up the back near the Rego Plate mount. No worries about it getting enough air there, however, being out in the open like that poses another question. Will the crap that comes up off the tire and the general weather be an issue? It is a sealed unit and the wiring will be sealed/weather proofed. Thoughts?
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raven
Honourable Member
2000 SP-1
Posts: 783
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Post by raven on Dec 6, 2009 13:07:15 GMT 10
You'd have to think that accumulated road crap on the cooling fins would reduce the cooling efficiency, but then again I assume that such a labour of love will be kept well detailed anyway, so will it really be an issue for you? And good on you for your DIY attitude, anyone can just buy bits to bolt on
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Post by fail on Dec 7, 2009 7:48:16 GMT 10
Looking awesome so far.. love your work. Wish I knew how to weld.. this stuff fascinates me.
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