Discussion
Started a build thread on another forum for the supermono I'm building so thought you lot may want a butchers. It's a tight fisted build and not just a spunk money on cnc this and titanium that type exercise. Now rather than post the whole lot I'll just link to the forum (there's probably a few of you on there anyway)
http://www.trackdayriders.co.uk/tdr/forum/oh-bugge...
http://www.trackdayriders.co.uk/tdr/forum/oh-bugge...
So in the midst of a house move garage delivery and general tornado battered existance that is my life at the moment, I stupidly trawl fleabay looking for an RS125 chassis to sling a single into. Well beer induced I come across something that fits the bill and it includes spares etc. Now taken that as it's an ex race bike it will be a touch tired but won't have been spannered (or bodged in a crisis) by a weed induced teenager vainly attempting to keep it going so he can nip over to sandras and get his wick sticky.
Now I knew it was a bloody stupid idea as I can't use the work van and the only thing i've got with a towbar is untaxed and on sorn. Well never say die! ( or more accurately oi quit throwing those at me it really really hurts ) i take one quick look at my shopping shed, a seat leon and set to work ripping all the seats out. Ever eager I decide that a drivers seat is essential so keep that firmly bolted in. Well off I set to the deepest darkest regions of south Yarksire (I'm from Lancashire and they all talk reet funny round there) I rock up at this fellas house and I'm sure he thinks i'm a care in the community patient. Anyway I placate him and reassure him that I'm allowed out and have a note from my mum to prove it (she even made sure my mittens had that piece of string attatched to them)
He offers to show me the bike running I say don't bother the lump is coming out anyway. Well undetered he fires it up anyway (funny enough it involved me being behind him out of breath and sweaty. From push starting it! I know what you were thinking ) and then it happened! The smell of castrol747 and the ring a ding ding of a two banger!!!!! Oh crap I'm getting all misty eyed and nostalgic again. No i must be strong! He then mentions it comes with nigh on enough spares to build another bike sans motor. An idea hits me!! I thank it for hitting me and ask it to p
s off.......to be continued as i'm at work and i'm supposed to be working
Right, so where was I before work inconveniently got in the way? Oh that's right, there I was with Kate Beckinsale wearing that pvc/corset jobby from underworld, a bucket of lard and two bacon butties (brown sauce none of ketchup crap) Oh hang on wrong forum!
So anyway i've now got to squeeze a bike two full fairings, three seat units, wets on wheels, forks, spare frame, paddock stands and various boxes of spares in ( not bad for £510 and a tenners worth of juice) and still retain the ability to drive without crashing or being royaly reamed by plod.
Mission accomplished (appologies re quality it was dark etc)
I'll sling a pic up of what it's supposed to look like later as they aren't on my phone.
Now I knew it was a bloody stupid idea as I can't use the work van and the only thing i've got with a towbar is untaxed and on sorn. Well never say die! ( or more accurately oi quit throwing those at me it really really hurts ) i take one quick look at my shopping shed, a seat leon and set to work ripping all the seats out. Ever eager I decide that a drivers seat is essential so keep that firmly bolted in. Well off I set to the deepest darkest regions of south Yarksire (I'm from Lancashire and they all talk reet funny round there) I rock up at this fellas house and I'm sure he thinks i'm a care in the community patient. Anyway I placate him and reassure him that I'm allowed out and have a note from my mum to prove it (she even made sure my mittens had that piece of string attatched to them)
He offers to show me the bike running I say don't bother the lump is coming out anyway. Well undetered he fires it up anyway (funny enough it involved me being behind him out of breath and sweaty. From push starting it! I know what you were thinking ) and then it happened! The smell of castrol747 and the ring a ding ding of a two banger!!!!! Oh crap I'm getting all misty eyed and nostalgic again. No i must be strong! He then mentions it comes with nigh on enough spares to build another bike sans motor. An idea hits me!! I thank it for hitting me and ask it to p
s off.......to be continued as i'm at work and i'm supposed to be workingRight, so where was I before work inconveniently got in the way? Oh that's right, there I was with Kate Beckinsale wearing that pvc/corset jobby from underworld, a bucket of lard and two bacon butties (brown sauce none of ketchup crap) Oh hang on wrong forum!
So anyway i've now got to squeeze a bike two full fairings, three seat units, wets on wheels, forks, spare frame, paddock stands and various boxes of spares in ( not bad for £510 and a tenners worth of juice) and still retain the ability to drive without crashing or being royaly reamed by plod.
Mission accomplished (appologies re quality it was dark etc)
I'll sling a pic up of what it's supposed to look like later as they aren't on my phone.
Pics of what it's supposed to look like
Well I've had all afternoon at work and the odd nap between jobs (why do other drivers on the motorway get so pissy when you catch a few ZZZs
) to make a decision and seeing as I've enough bits to throw a roller together I'm going to give the bike a spruce up and rag the tits off it on a few trackdays, which will keep me entertained between going blind trying to shoehorn a thumper into the other chassis.
Well the dirty little wench has dropped her drawers and is now languishing bare arsed in the garage just waiting for me to oil her up and give her a good seeing to.
Now I suppose I could just check the tyre pressures, splash a bit of fuel in it and just spank it round a track, but I guaransoddingtee I will be on my old saggy tarmac scraping arse faster than a warm up lap wannabee (it's a bit like banging a lass from behind and dropping the old 'yer mum's better at this than you' line. You know that f**kers gonna be one hell of a wild ride )
So regarding the thumper the possibilities are firstly my favourate the temperamental Husaberg 650 (04 onwards as the 03 even with the bearing mods can be a pain and the stators are sh*te) the ktm lc4 ( little down on power to the berg but still 55 ponies standard) or keep it in the family and bang a pegaso lump in there. We shall see.
Well, stripped it down for a condition check and the two stroke fumes seem to be wearing off a touch (still going to have one of each out of all the bits mind)
As expected there were one or two lurking issues largest one being this
Not a major problem in the grand scheme of things but it'll work out cheaper throwing another frame in than having it welded up. I'll still use it as a test fit frame for working out the new mounts etc.
Just got to ply my mate with copious amounts of beer to loosen his grip on a pegaso languishing in his garden ( he uses it to commute on but i'll just tell him he's fat and needs to ride a pushbike to work instead)
Given the smoker a once over. Repacked all bearings, readjusted everything.
Stripped the loom down and ditched all the superfluous bits etc
Also reglassed and patched up a fair bit of one of the fairings. The newer version stuff was pretty crap so went back to the 2003 style kit. No intention to paint it to be honest as whenever I have fresh paint a visit to A&E is in the cards.
So bar one or two small items it's ready to ride. Haven't done a blow by blow of the rebuid as it's all a bit Rolf Harris 'can you tell what it is yet?' Yes! It's a bloody RS125!. Just waiting to land a suitable single and we'll get down to buisness chucking a mono together.
Edited coz i'm a spaz
Well I've had all afternoon at work and the odd nap between jobs (why do other drivers on the motorway get so pissy when you catch a few ZZZs
) to make a decision and seeing as I've enough bits to throw a roller together I'm going to give the bike a spruce up and rag the tits off it on a few trackdays, which will keep me entertained between going blind trying to shoehorn a thumper into the other chassis.Well the dirty little wench has dropped her drawers and is now languishing bare arsed in the garage just waiting for me to oil her up and give her a good seeing to.
Now I suppose I could just check the tyre pressures, splash a bit of fuel in it and just spank it round a track, but I guaransoddingtee I will be on my old saggy tarmac scraping arse faster than a warm up lap wannabee (it's a bit like banging a lass from behind and dropping the old 'yer mum's better at this than you' line. You know that f**kers gonna be one hell of a wild ride )
So regarding the thumper the possibilities are firstly my favourate the temperamental Husaberg 650 (04 onwards as the 03 even with the bearing mods can be a pain and the stators are sh*te) the ktm lc4 ( little down on power to the berg but still 55 ponies standard) or keep it in the family and bang a pegaso lump in there. We shall see.
Well, stripped it down for a condition check and the two stroke fumes seem to be wearing off a touch (still going to have one of each out of all the bits mind)
As expected there were one or two lurking issues largest one being this
Not a major problem in the grand scheme of things but it'll work out cheaper throwing another frame in than having it welded up. I'll still use it as a test fit frame for working out the new mounts etc.
Just got to ply my mate with copious amounts of beer to loosen his grip on a pegaso languishing in his garden ( he uses it to commute on but i'll just tell him he's fat and needs to ride a pushbike to work instead)
Given the smoker a once over. Repacked all bearings, readjusted everything.
Stripped the loom down and ditched all the superfluous bits etc
Also reglassed and patched up a fair bit of one of the fairings. The newer version stuff was pretty crap so went back to the 2003 style kit. No intention to paint it to be honest as whenever I have fresh paint a visit to A&E is in the cards.
So bar one or two small items it's ready to ride. Haven't done a blow by blow of the rebuid as it's all a bit Rolf Harris 'can you tell what it is yet?' Yes! It's a bloody RS125!. Just waiting to land a suitable single and we'll get down to buisness chucking a mono together.
Edited by wolf1 on Monday 20th May 19:47
Edited by wolf1 on Monday 20th May 19:49
Edited coz i'm a spaz
Edited by wolf1 on Monday 20th May 19:52
Well after a very unproductive and boring sunday morning with nothing to do but surf the world wide w*nk bank. I cleared up the tissues and ventured forth into the world in search a tractor engine for the mono. Having bagged a suitable victim on beerbay I set forth to a very unsunny Nottingham.
Four hours later and I'm locked up in the garage rubbing a big piston'd throbbing machine
Well no time like the present to see how much misery I've let myself in for.
I offer up the swingarm and check there's room enough for the rear mount. A very small amount of jiggery pokery with the top hat style spacers in the swingarm and they'll do for the moment.
Next up is the big one! Will it fit inside the frame?
Well that's a resounding yes, with the odd tweak to come.
Now trying to get the rear mount anywhere near the swingarm pivot then the old lower mounts for the 125 lump will have to go.
5 mins later
Nah! Feck off! It can't go this well so early on. Or maybe it's lulling me into a false sense of security before it leaves me in the corner rocking back and forward, dribbling and muttering.
Now remember this is just the initial roughing out, so nothings going to be bang on in the early mockup stages.
Got to pick up the correct swingarm pivot bolt tommorow to find out exactly how close the swinger is to the engine cases and start looking at lining sprockets etc up prior to roughing out the front mounts.
Four hours later and I'm locked up in the garage rubbing a big piston'd throbbing machine
Well no time like the present to see how much misery I've let myself in for.
I offer up the swingarm and check there's room enough for the rear mount. A very small amount of jiggery pokery with the top hat style spacers in the swingarm and they'll do for the moment.
Next up is the big one! Will it fit inside the frame?
Well that's a resounding yes, with the odd tweak to come.
Now trying to get the rear mount anywhere near the swingarm pivot then the old lower mounts for the 125 lump will have to go.
5 mins later
Nah! Feck off! It can't go this well so early on. Or maybe it's lulling me into a false sense of security before it leaves me in the corner rocking back and forward, dribbling and muttering.
Now remember this is just the initial roughing out, so nothings going to be bang on in the early mockup stages.
Got to pick up the correct swingarm pivot bolt tommorow to find out exactly how close the swinger is to the engine cases and start looking at lining sprockets etc up prior to roughing out the front mounts.
Being honest I never thought this would go so swimmingly but spank my arse and call me Petunia stuff just keeps lining up with minimal tweaking dunno.
Anyroad I started looking at getting the rear mount done so that the original layout of the RS swingarm is retained. This meant driving out the two steel top hats from the back of the motor mount (not an easy task as I had to make a lipped drift) Then I put the swinger back into the frame and measured how much room I had to play with. It was 118.5mm between the spacers with everything pushed out towards the frame. Now the rear mount on the engine came in at 110.5mm with the two steel top hats removed giving me 8mm to play with. Now obviously I wasn't going to get it bang on 118.5mm as that would leave no room to jiggle when assembling. So I set about taking a big fat chunk out of the brim of the top hats (easiest way to explain it really) I took the brim down to 2.5mm on both of them which would give me an overall width of 115.5mm at the rear mount (believe me you need this as a minimum as lining the motor and swinger up is a bh as it is)
Swingarm in as per original and the adjuster on the right hand side of the frame wound back.
Top hats from the motor in to establish how much needs removing.
Top hats ground down to 2.5mm at the brim/lip (I ran a chamfer round the edges prior to re fitting them in the motor to ease assembly) The tall one in the background is one of the swingarm spacers.
Where the top hats locate at the rear of the motor
Measuring the casing width.
Test fit with swingarm spacers (Less screwing around trying to juggle a frame, motor, swingarm and pivot bolt)
Assembled the swingarm into the frame using a thinner bar than the original pivot bolt and the swingarm fouls the back of the engine casing. Using a small belt sander I dressed the leading edge of the swingarm and the re tested the fit.
This took quite a few refits till I got it bang on so the correct pivot bolt would fit and the swingarm would just about clear the engine casing.
Swingarm in and shock and linkage etc fitted.
Now that's what I call fag paper clearance
Bit too low at the front for my liking even though the waterpump lines up inside the frame void.
Just for the hell of it I sling the original front mounts in to see what I have to fabricate. Fook me the buggers only line up thumbsup
Pushes the waterpump up clashing with the frame but I'm still resisting having to run the pump off the crank as it means more machine work.
I sling the original lower mounts in to see how much I have to lengthen them and how big the spacers have to be (packed with washers temporarily)
Using the original mounts (they'll get beefed up later) means the fairing and rad mounts are original. I compare the RS and the twin Ktm rads and the surface area is close enough to allow me to use the original RS item.
Right now for that waterpump! After a bit of pattern making I trim back the frame edge to clear the pump. I alter it slightly to allow the motor to be tilted forward making engine removal easier.
Playing around now, looking where I'm going to place the fuel tank. Not decided on a smaller under tank cover one or in the tail piece.
Starting to mock up the cooling system.
Got to source some piping for the exhaust so I can make a start on building that. Need to decide on an endcan as well as it's location will dictate the routing of the pipes etc.
Anyroad I started looking at getting the rear mount done so that the original layout of the RS swingarm is retained. This meant driving out the two steel top hats from the back of the motor mount (not an easy task as I had to make a lipped drift) Then I put the swinger back into the frame and measured how much room I had to play with. It was 118.5mm between the spacers with everything pushed out towards the frame. Now the rear mount on the engine came in at 110.5mm with the two steel top hats removed giving me 8mm to play with. Now obviously I wasn't going to get it bang on 118.5mm as that would leave no room to jiggle when assembling. So I set about taking a big fat chunk out of the brim of the top hats (easiest way to explain it really) I took the brim down to 2.5mm on both of them which would give me an overall width of 115.5mm at the rear mount (believe me you need this as a minimum as lining the motor and swinger up is a b
h as it is)Swingarm in as per original and the adjuster on the right hand side of the frame wound back.
Top hats from the motor in to establish how much needs removing.
Top hats ground down to 2.5mm at the brim/lip (I ran a chamfer round the edges prior to re fitting them in the motor to ease assembly) The tall one in the background is one of the swingarm spacers.
Where the top hats locate at the rear of the motor
Measuring the casing width.
Test fit with swingarm spacers (Less screwing around trying to juggle a frame, motor, swingarm and pivot bolt)
Assembled the swingarm into the frame using a thinner bar than the original pivot bolt and the swingarm fouls the back of the engine casing. Using a small belt sander I dressed the leading edge of the swingarm and the re tested the fit.
This took quite a few refits till I got it bang on so the correct pivot bolt would fit and the swingarm would just about clear the engine casing.
Swingarm in and shock and linkage etc fitted.
Now that's what I call fag paper clearance
Bit too low at the front for my liking even though the waterpump lines up inside the frame void.
Just for the hell of it I sling the original front mounts in to see what I have to fabricate. Fook me the buggers only line up thumbsup
Pushes the waterpump up clashing with the frame but I'm still resisting having to run the pump off the crank as it means more machine work.
I sling the original lower mounts in to see how much I have to lengthen them and how big the spacers have to be (packed with washers temporarily)
Using the original mounts (they'll get beefed up later) means the fairing and rad mounts are original. I compare the RS and the twin Ktm rads and the surface area is close enough to allow me to use the original RS item.
Right now for that waterpump! After a bit of pattern making I trim back the frame edge to clear the pump. I alter it slightly to allow the motor to be tilted forward making engine removal easier.
Playing around now, looking where I'm going to place the fuel tank. Not decided on a smaller under tank cover one or in the tail piece.
Starting to mock up the cooling system.
Got to source some piping for the exhaust so I can make a start on building that. Need to decide on an endcan as well as it's location will dictate the routing of the pipes etc.
Only got chance for an hour or so in the garage today so decided to fab a set of downpipes from the original KTM ones. Originally they ran up the right hand side of the motor tight against the barrel. Now this would have been ideal for an under seat pipe but would have meant heat shielding issues and not being able to stick a fuel tank under the tail unit (only if needed but I like to keep options open this early in the build) So it's going the same way as the original RS pipe. Havent decided if it'll be a under motor one or the more traditional way.
The step in the left pipe (as viewed on the pic) is where the pipe slips inside giving some tweak movement as the exhaust ports aren't level, they point away from each other which makes traditional manifold setup a no go.
Enough clearance for the rad (I've had closer on standard bikes!) plus they'll be getting wrapped and once all the shakedown stuff is done I'll probably do a better job and do one from scratch.
Found room for the RS header tank. Needs one as the KTM one was incorporated in the right hand rad.
The step in the left pipe (as viewed on the pic) is where the pipe slips inside giving some tweak movement as the exhaust ports aren't level, they point away from each other which makes traditional manifold setup a no go.
Enough clearance for the rad (I've had closer on standard bikes!) plus they'll be getting wrapped and once all the shakedown stuff is done I'll probably do a better job and do one from scratch.
Found room for the RS header tank. Needs one as the KTM one was incorporated in the right hand rad.
In keeping with the I'm throwing money at f**k all ethos of the project it was time to look at the rest of the exhaust. As i'd already ruled out an under seat jobby I looked at a more traditional fittment for it. Now I wasn't happy that I could get something reasonable looking, functional, not to restrictive and partially protected from when I inevitably launch the fooker up the track!
Well the answer came in what most sane people would have either thrown in the bin or launched at next doors cat as it curled out another one in your front garden.
It's ugly, oversized and more battered than a slappers fanny!
Time for a bit of surgery!
The sum of all the parts minus a bit of packing and a sh*t load of graft.
Rough look at the layout of the final product. It'll look a shed load better once fettled and slung under the motor.
Well the answer came in what most sane people would have either thrown in the bin or launched at next doors cat as it curled out another one in your front garden.
It's ugly, oversized and more battered than a slappers fanny!
Time for a bit of surgery!
The sum of all the parts minus a bit of packing and a sh*t load of graft.
Rough look at the layout of the final product. It'll look a shed load better once fettled and slung under the motor.
Getting pretty close to starting the motor to check it's ok and things do as they are told before actually riding it. Now seeing as the kickstart shaft is now buried out of reach in the frame, there's no lecky boot and I still haven't built a starter roller, it'll be off to a mates garage where he has an MOT brake roller set up that should have plenty of poke to spin the motor over (First person who suggests bump starting it the old fashioned way can come and help try an unknown untested 600ccplus single and I'll have the ambulance on standby to patch my sides up after splitting pissing myself watching someone attempt something so futile )
Must remember to make sure I fit a kill switch and a front brake firstly as this could end up as one of those multi million view videos on youtube (never gona happen! I have a face for radio and a voice for newsprint!! )
)Must remember to make sure I fit a kill switch and a front brake firstly as this could end up as one of those multi million view videos on youtube (never gona happen! I have a face for radio and a voice for newsprint!!
)Shortly after partaking of a few small beveridges (I do my best and stupidest work after a couple and I've had more than a couple :burp: ) I decided that waiting to trailer the tractor to my mates tomorrow was going to be a pain in the arse and I've got no sodding patience so off to the garage I wobble. Now as I previously mentioned even my more than ample buttocks aren't going to slam down on that back end hard enough to prevent the rear wheel locking whilst futilely attempting to bump start planet earth!
Now towing it behind the father inlaws shogun was contemplated and disregarded as he's a bloody hopeless driver and half deaf to boot (nothing to do with me being a little squify either) So what the hell do I do? I've got the boys little blata quadard, maybe I could weld it to the bike lift and try it as a roller starter? NOPE! I forgot I'd knackered the clutch trying to do burnouts on it
.Aha! brainwave!
two minutes with the disc cutter and 2 minutes with the welder I sling together this abomination.
Pull the gear linkage off (It runs through the centre of the kick shaft) and whack the bugger on.
Three full kicks with the decomp pulled in to clear the bore, two quick pumps of the throttle, choke on, find tdc and them pop it just past to the sweet spot, take another swig of millers and give her a good hard boot!
Nothing! Ok rome wasn't built in a day. Another good boot and waaaafeckinghhooooo it rumbles into life. Grab the throttle give it a quick flick and sh*t me deaf the downpipes blow straight off the manifold, as dipsh*t here had forgotten to wire them up till i get some springs :dozey: Big arsed blue jets of flame firing out of the manifold stubs may look funny as f**k but my ears were ringing as the garage is small and the doors were shut.
well that done I boot her up again and f**k me she's as loud as I'd expected. That should quieten down a touch as I packed the can with acousta-fil packing which should expand and tighten up once it warms up for the first time. Now as much as I wanted to test my iPhone decibel app I decided it was prudent to quit dicking about as the neighbours with be throwing bricks and petrol bombs at the garage any minute now if I continue.
Edited by wolf1 on Monday 20th May 19:55
Been having a play running it up. Few things I need to sort such as a small leak from the waterpump gasket (two bolts had sheared in housing so no real clamping force till I sort that out) I'm probably going to need a baffle for the pipe as it's 95Db at tickover (inside garage so a compromised result) or rethink the system again. Like an idiot I forgot to fit any oil breather pipes so it threw oil out of the breather stubs. Quickly threw some pipe on and routed it up to the seat subframe into a container. Probably going to need to fabricate a decent baffled oil catch tank for it.
Probably going to have to make the fuel tank a bit larger and relocate it somewhere more sensible
Probably going to have to make the fuel tank a bit larger and relocate it somewhere more sensible
Worked out how to do that moving pictures thing without asking one of the kids to show their ludite father how to do it.
Snap Crackle and POP
Needs the carb setting up correctly but I'm happy it's close enough to run the bike. Got a baffle on order so I'll see if I can bring the noise down a touch. Don't want to be the naughty ned in the sound testing area all the time. Anyone know the formula for testing a 640 single?
Snap Crackle and POP
Needs the carb setting up correctly but I'm happy it's close enough to run the bike. Got a baffle on order so I'll see if I can bring the noise down a touch. Don't want to be the naughty ned in the sound testing area all the time. Anyone know the formula for testing a 640 single?
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