Building a bike with an DM950TD

Henk · Post by **Henk** » Mon Dec 26, 2011 9:22 pm

Hello,
I am building a dieselbike, Never thought it would burned so much time.
My ambitions are high, I build one with reasonable power, Daihatsu 3 cyl. about 24 Kw.
I used the rear end of a Dneprframe and the rest I made of pipes to become a frame for fitting the big engine and gearbox.

Post by **Stuart** » Mon Dec 26, 2011 10:57 pm

Looking good Henk

coachgeo · Post by **coachgeo** » Tue Dec 27, 2011 7:57 pm

what gear box do you intend to use?

Henk · Post by **Henk** » Wed Dec 28, 2011 4:44 pm

I use an Dnepr gearbox, 4the 1:1 finaldrive from solo.
I have a set 4the overdrive in the drawer , not using yet but when the bike has the papers I will experiment with this new gearing.

The rear is provided with new self adjusting bearings with seal. Axial forces are transferred with a single ball.

Henk · Post by **Henk** » Wed Dec 28, 2011 4:48 pm

Another pict. for clearity.

boutje · Post by **boutje** » Fri Dec 30, 2011 5:17 pm

Nice build henk.
I will follow this.

Are you also active on motor-forum.nl ?

Henk · Post by **Henk** » Fri Jan 06, 2012 10:17 pm

Fitting the engine in the frame.
Every step is a lot of work.

I blasted the frame with glass and painted with 2pack industrial primer, after the primer I painted theframe with black 2pack polyurethane topcoat. The topcoat is only for spraying. But painting with a brush is possible but not so smooth.

Fitting the gearbox to the engine is a job where you have to measure everything. The firsttime I did it wrong. The pict is the second flange.

Sphere · Post by **Sphere** » Sat Jan 07, 2012 8:59 pm

Make no mistake, Henk milled that flange from a solid piece of aluminium. Or should I say slab

Henk · Post by **Henk** » Sun Jan 08, 2012 6:47 pm

Yes, is was a solid disk alumnium.
I bought it in Germany (internet) and they shipped it to my home.
Lucky we have a big lathe at the maintanance department. For a few apple-cakes they made the flange.

Another pict from the fuel-tank.
The red primer is very thick and sticky. It's like a tough sirup.
The topcoat is a carpaint, the color is old colour from VW, bast-beige.

In the top is made an littletube for even the pressure to avoid vacuum in the tank, the shield is protecting the hole for rain etc.

Dougy · Post by **Dougy** » Sun Jan 08, 2012 7:59 pm

Its starting to come together fast and is looking good Henk, keep posting regular updates please, and stop making it look so easy !

Henk · Post by **Henk** » Mon Jan 09, 2012 8:42 pm

Hi Dougy, thanks for the positive reaction.
Nothing goes easy, while I place the pict. I remember the hard labour it cost's.

Here a pict from an self made tool to dismantle a rear shockbraker. It is rough but I don't believe I will use this tool very much.
After repair the shockbrakers I painted them over.

I found a pict. from the very early beginning of welding the frame.
The steering section, I don't know the right name, just cut on a lathe and welded a key-house on it.

Post by **Crazymanneil** » Mon Jan 09, 2012 9:23 pm

You are making some phenomenal progress there! Impressive stuff, like the bike too.

Neil

Henk · Post by **Henk** » Tue Jan 17, 2012 7:43 pm

The lugs on the aluminium frontfork are to weak for a steel mudguard to my opinion.
I use the fork of a BMW K100. It consists of 2 front legs each apart and connected in the crownplate.
I suspect these came from a type with integrated mudguard instead of a mudgard mounted on the frontfork.

I have an steel mudguard from an Dnepr, 6kg steelplate, to heavy for 4 M6 lugs. the size is near 1/4 inch . So I made the mudguard by myself.

I copied the mudguard in polyester, peace a cake. Before I put the polyester on the mudguard I waxed it in.
Waxed the mold 4 times to, so the epoxy couldn't attached to it.
I put some carbon-aramide cloth inside the polyester mold and put the epoxy on the cloth. I used a paintbrush to handle the Epoxy.

The first one was a failure, I didn't mixed the Epoxy in the exact proportions. The mudguard stays soft.
The second time the Epoxy hardened.

The shape of the mudguard isn'n flawless, need more time to sand the rim's for a smooth look.
Paint the Epoxy with a primer , sand it for more smoothnes and prayed it over with a topcoat.

The pictures are an uncoated Epoxy mudguard,

A steel (original) mudguard sandcolour. The Primered Epoxy mudguard red.

The Epoxy Mudguard weights about 300 gram.

Sphere · Post by **Sphere** » Tue Jan 17, 2012 7:48 pm

Nice little mod to make your bike lighter. All 10hp Enfield owners should try this

XLerate · Post by **XLerate** » Wed Jan 18, 2012 3:22 am

Excellent build there, Henk! Very clever ideas adding a lot to the finished machine. Sure is going to be a fine little rig, very nice work!

andrewaust · Post by **andrewaust** » Wed Jan 18, 2012 1:32 pm

What an extremely awesome build, cannot wait to see the finished product. Great work Henk

A

Henk · Post by **Henk** » Thu Jan 19, 2012 8:09 pm

Sphere wrote:Nice little mod to make your bike lighter. All 10hp Enfield owners should try this

The mudguard is suprisingly stiff compare to it's lightweight . It sure would save some kg.
On my bike it is pure to prevent excessive forces on the aluminium lugs. Lightweight is a bonus .

Henk · Post by **Henk** » Sat Jan 21, 2012 8:49 pm

I have (some time ago) dismantle the gearbox completely and build it together with new bearings and a 1:1 4the gear.
To get it right I bought a defect gearbox and cut it in half.See pict.
So I got the distance's of the gears right when fitted in the half cut gearbox. It's russian so nothing is sure.

Henk · Post by **Henk** » Wed Jan 25, 2012 7:16 pm

Connection frame and steer.

Henk · Post by **Henk** » Tue Jan 31, 2012 7:54 pm

The dieselbike partly mounted together.
Those little things for finishing it right consumes costly time.

coachgeo · Post by **coachgeo** » Tue Jan 31, 2012 11:30 pm

Looking Sveeeet

skoleskibe · Post by **skoleskibe** » Tue Feb 21, 2012 12:09 am

wow, what a build, makes my MZ Yanmar look bleak in comparison.
regards

Post by **Stuart** » Sat Feb 25, 2012 12:06 am

Yeah, it's looking great

Well done that man

Henk · Post by **Henk** » Sat Feb 25, 2012 6:26 pm

Thank you.
I am wiring some things but there is few space to mount relais and yhat sort of stuff.
Some of those little things are time consuming to get it right.

Henk · Post by **Henk** » Mon Jul 02, 2012 7:35 pm

It's a while ago I give an update.
The project is slown down.
I am wiring the bike, not an easy work like the old petrolbikes I wired in the past.

coachgeo · Post by **coachgeo** » Tue Jul 03, 2012 3:37 am

Mucho Thanx for the update. Nowwww Getter Done!

Henk · Post by **Henk** » Sun Dec 09, 2012 7:01 pm

Building is in progress,
I am wiring the bike.

I have no pict. because electric wire's aren't that interesting.

I have to connect many thing's with an extra relays, the standart BMW shalters are to weak for the current of some part's.

Henk · Post by **Henk** » Fri Feb 08, 2013 5:41 pm

Wiring is completed.
Watercooling is in progress.
Hard to find the right rubberhoses for the cooling.

I cut the rubber hoses out the enginecompartiment of some car's , the cars wil be shredded anyway.

Make some aluminium couplers and connect the hoses together.

Looking for an expansionvessel.

Henk · Post by **Henk** » Tue Feb 26, 2013 8:09 pm

The expansionvessel for coolingwater is almost ready.

coachgeo · Post by **coachgeo** » Tue Feb 26, 2013 8:42 pm

Expansion vessel? Please explain it's purpose in this build?

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