the grinch wrote:I have started filling up the gaps in the tank it is going well so far just need to make a paper template cut 2 pieces check fit get it as close as posible and thats it. This is the first time I have used the plywood form like this. The last time I made a tank for my son’s bike I just made a form for both sides and filled in the middle. But this is a far better approach so far. I hope to get it all done by the end of the month. I have to make the tunnel and work out the mountings. I have a sender unit and will be putting some fittings for banjo bolts for the fuel lines. I will be welding it up with MIG using 0.6mm wire as this seems to be better for tanks. I have an old Cebora 130 for this special occasion. I prefer this for tanks as it gets into all the tight spots.
I am WELL impressed with the tank build. This is a LOT of work. Well done.
JM
Merc Estate
BRA CX 3
2 CV Dolly
2 x 250 MZs
1 x 125 4 stroke MZ
2 x 301 MZ
1 x Enfield Himalayan
1x Monkey bike
1 x Honda CT125
1 x Campervan Vivaro
1 x MZ Es250/1 and sidecar
1 x Cat
2 x Parrots
I like MIG brazing for the same reason - easier to use and you get more certainty of filling all the gaps so it won't leak.
Mind you I've only used it on Sluggy's old tank to patch the rather colander like bottom - worked a treat 'till the other side fell out of it and it cracked in half.
Getting there.
I have almost done the outside of the tank it is tacked up and I have started the underneath I may have to scrap the sender idea and put a clear pipe on the outside. I expect to start welding on Tuesday if I can finish of the fabrication in time.
The tank is done now not the best welding but it is completely leak free all pressure tested hence the rust. I just used some washing up liquid and water mix and a coolant pressure tester attachment with a car tyre valve bodged on to the end. I use between 4 and 8 psi of air( much more and as I found out the the hard way on the first tank I ever built the tunnel will try to turn inside out ). The tank mounts are made and tacked to the frame. I need to find some banjo fittings but that is not the end of the world I have made the points for the level hose. Although it is not the best welding I like the way it looks. The plan was that I would give the whole thing a skim of filler to smooth it out but I’m going for rough and ready so I think I will just clean it and leave it as it is give it a coat of rust converter and red lead it for now. I think I need to look at the foot rests and controls next shouldn’t be that difficult. I think that I will be near making a list of jobs to do soon all the big jobs are getting done.
Gears
It been a while since my last update I have not worked on the bike now for a month now. I have been really busy at work and to top it off I now have to go away for 3 months. But I did make a bit of progress before the work got in the way. I have done my gear selector I had 3 attempts to get it sorted but I got pissed off ended up getting some inspiration from the horse’s stable of all places. A simple door bolt. Took 30 minutes to make a selector from a bit of scrap box and some 16mm round bar I made 2 pivots I have not finished them yet but even with the extra play I have got good gears. Foot rests I have made a start just a simple bit of tubing I had lying around and I made a couple of braces to go from the frame to the engine.
But that will be it for a while as I’m off to Suffield Canada for a few months at really short notice. Now my deadline is blown I won’t be here but I will hopefully have a bit of extra cash when I get back I may be able to make a bit more progress. I will have to get it ready for the RBLR 1000 perhaps or something similar.
some of the pictures are a bit crap
Back soon few more weeks to push and I will be getting back on track with the build. I will have to get the other piece of crap going when I get home as I have got to have something to ride. I am hoping to be back on the build by the middle of November it will be a year then but I would hope that I can get it mocked up properly before the end of January. Ready for the side car build.
Not done much but i have had a good think about things. I have re-profiled the seat as it was a bit hard around the edge when putting my feet down. I have started thinking about the clutch. I have managed to find Vauxhall clutch flexi hose with the quick connector on one end and threaded on the other so it can use an old Lucas master cylinder and being able to use the thread means I can just make up a bit of brake pipe and it will give me more flexibility for master cylinder location i am not sure how it is all going to go yet i think that a foot clutch would be good for a outfit but if i do ride without the sidecar then its not so practicle. So i am still thinking about it i have got the brake servo from the car but it is quite a big lump maybe i can get a hand clutch working somehow.
Foot controls
Ok I’m making slow progress unfortunately I have had to put the bike on the back burner due to having to start a new job earlier than anticipated. However I have found a couple of spare hours to bodge up some master cylinder mounts and some pedals. Not pretty but will do the job I still want to get the thing done before the summer i have to get some clivis forks but but they will be easy enough to find. I’m going to make some footrests next as the pipe was just for a rough idea of where I had to put them. I have found some spare box section I have left over from another job I will use that and some flat bar or something else I have laying around.
It turns out that the quick release union on the Zafira hose is not the correct dimensions. It was too long and has a slightly bigger diameter it is also different where the chamfer is. I spent about an hour with a half round file taking the bloody thing down to size hopefully it will work or it will be Plan B not sure what that is yet. I made some new rods and put some metric clevis forks on for the master cylinders. I hope to get the clutch working today so I can see what is required to operate it as I want to see if I can make it work from the handlebars too. I will make a pipe later and bleed it up.
Hand controls
I need a front brake and a throttle to start with I am too tight to get some handle bars made from the correct stuff so the bars I have will do. I used 1” Gas pipe which is just over 26.5mm O.D and I managed to get some that’s 27mm I.D for the grips. I bought 2m of it as I thought I was bound to f%$k it up before I got it to work. I will have to make a throttle as it will be too much work to try to get something else to fit. I have been looking up internal throttle and I have decided to have a play around. My first attempt worked but it needs a lot of refinement. I have about 1.5” of pull on the cable but the slot needs to be a lot cleaner I have a new blade somewhere for my mitre saw I will try this next. I used a M6 Allen screw for the slider I think it will work but I will have to use some Loctite on the threads to prevent it coming loose.
For the brake I had a cheap copy of a CB400 master cylinder and I thought I would see if I could get it to fit. A ran a tap down the threads to make sure that I had plenty in the housing for the bolts as I would need to grind away near the bolt holes. I think it can be done but I will need to make another bracket to clamp around the bars.
Hand controls part 2
Front brake master cylinder is now mounted to the bars I used an offcut from the throttle tube and a piece of 5/8” square bar a bit of drilling and filing and its sorted. I did have to file the bars where the bolts pass to allow them to screw in correctly as the diameter of the bars was slightly too big to allow them to pass without binding. I will fill the void in the casting with some epoxy putty and clamp it to the bars to get a perfect fit to prevent any rocking later when the brake is operated it is not moving now but there are a few gaps.
I have started on the throttle I used the mitre saw but I had to make an adjustable fence as I needed more than 45 degrees for the slope 45 degrees would only allowed 25mm of movement. I still have to make the slot in the bars yet and I need a few more bits.
Bit more progress
Been fiddling around have made a stand as I have got to have a stand for MSVA and because I am having a sidecar it would need to be a centre stand. Bloody hell its fucking heavy I had to get it off the pallets on my own, well I managed to do it without dropping it on the floor but it was a bit sketchy. I have made a stand I needed a long lever to get the thing off the floor but it works. I broke my tack welds on the handle bars. This gave me a reason to make some new risers I used some box section and some threaded bar nuts. I made a mudguard bracket and I have started on the exhaust. I found a fire extinguisher in the skip and I am going to use it for all the electrics. It is getting there slowly now I just want to get all the parts made up then I can finish off all the edges before the final build. I have got another right angle gearbox coming as the PTO will be awkward to get done. I have got an Audi TT transfer box on its way along with a drive shaft. But I need to get everything else done before I can tackle that. It would be nice to get all the fabrication done before March I think I can get it done. I have started thinking about cooling I am trying to find a cheap radiator I am looking on eBay I found a couple new less than a tenner but are too big for my fitment. I am looking at VW Polo as it is about the size I am after. I have fabricated a header tank as it hat to fit in under the tank above the fuel pump. My phone will not upload so no photos today.
Well I have been getting things sorted out. I have done a few of the big problem jobs and I think I am well on the way to get the mock up done by end of March. I need to get a few more bits done. I think I will be getting to the wiring before long and It will be nice to get it running in the frame and sort out the cooling and bits. I have done the rear wheel drive flange I used the tractor PTO in the end as the Audi part is not fully connected at the flanges also it was quite a bit bigger than I thought it was. The drive shaft what a result I cut down the PTO adaptor and shortened the splined part on the CV joint it could not have been any better I don’t need to cut the shaft. I have started on the headlights I want to use 2 lamps. I have decided to stack them vertically. I didn’t like the look of them horizontal.
A bit more progress.
Just been fiddling around and done a few small jobs have started getting more of the jobs that don’t matter so much done. The fuel pump and filter are fitted I have still got to plumb everything in. I am working on a clutch hand control just in case it will operate the master cylinder. I have put the pivot behind the bar instead of in front. This has given me about 35mm of cable movement. This will allow me to ride the thing without the sidecar a bit safer. Mudguards are on rear light and a rack on the back. I am trying to get the jobs done I have made a headlight cowling I used a very technical approach as I have never used fiberglass I did some research I decided I would make a flimsy steel framework then I stretched a polyester fleece blanket around it all. I mixed up the resin and started to put it on well I should have read the instructions as I was about ¾ done and I put the resin down to get something and the result of that was the paint brush was firmly embedded in the resin as it was going off. The next day I made some more resin it turned out ok I have to finish off inside. But the blanket worked well.
Bugger.
Today’s lesson don’t please don’t leave ECU without power for too long. Well I have been sorting out a few bits made wiring harness and it was time to fire the beast up. It has been about 18 months since I had the engine running. I spent hours making the loom and checking and sorting everything out. Well needless to say it didn’t all go to plan. I had everything I needed but the dreaded pump would not come to life. Money is tight so I have spent hours and hours re checking and trying to sort it out but not a chance. So I decided when I first wanted to do it I wanted an old school fuel pump I had several options.
1 Could I put a different pump on it probably but how much was it going to cost.
2 Could I get ECU flashed probably but how much and it could also be the pump.
3 Look on Ebay find another engine for the right price.
So I am now the proud owner of a 1.8 non turbo Endura DE with mechanical pump now I Just have to make everything fit again. I have a lot of things on at home now and a lot to do now but hopefully I can get back on track.
OK
I have done some more, well quite a bit more than I expected to have to do. My Engine was from a fiesta the new engine from an escort van. Different at the front engine mounts. Different gearbox different clutch mechanism, different intake manifold now it’s too big. Well a lot of problems really. So I have been skip diving needed some stuff. Found some nice C section and some bolts. This must need to be done was just right for the engine mounts. I had to make some new gearbox mounts turned out much better. Now turbo is gone more room for my leg. Mr Pedantic at work thought that my headlight was not in fitting with the bike and when I took it out for the Photo I had to say I agreed with him so another thing to change. The list goes on things are going quite well. I started working on the sidecar well I have absolutely no experience with sidecar can’t be that hard. I started off with a dilapidated trailer. I was thinking wooden crate or something like that. Well I don’t know where that idea went. A lot of thought went in to it. I don’t want to spend any money. The trailer gave me suspension and a wheel hub. This was something that I definitely needed. I propped it up in the garden and stood back I could see it in my head, again where had the wooden crate idea gone. So I started the next day working out the new improved idea doing some drawings. I started building all going well. It’s getting quite big so I thought I had better put a brake on it. So that fucked up all my plans. But I have done it I have a few adjustment parts to make but I have tack welded everything up. I haven’t got many build photos because time is going on and I need to build it. I have been smashing it out I was off work for a week put about 75 hours needless to say it is all back in pieces. Ride to the wall is in October but I am not going to get it done in time I am not expecting to get passed MSVA without a bit of a fight. But I will still be going on my other bike.
Getting closer
Painting done
Cheap red oxide and some special offer tough black enamel spray from toolstation.
Now I had the engine running on the floor put it in the frame and changed the cut off as I had to bypass the factory pats. Well what happened was I tried to start it but it started and stopped never to start again. So I wasn’t too worried I would sort out the problem after i took it out of the bike for final assembely before I put it back. I wasn’t getting any fuel to the injectors. I have since had a good look at it took the pump off as I thought that was going to be the problem. I have never had a look inside a pump before so it was exciting times. Anyway I gave it a quick clean and stripped of the rear plate to the transfer pump first. Found the problem. I had been soldering the throttle cable a few days before there must have been a tiny bit of solder between the bottom of the fuel stop and the pump when I took it out the other day. I found a tiny flat piece of solder about 2.5mm in diameter and about the thickness of a fag paper and some bits of the broken vanes. It must of fell in when I took the stop out. I thought this was going to be costly mistake. I found the parts online for £4 so I bought a seal kit as well all for £32 delivered. Took a couple of hours. To sort it out. I put on a new water pump and refitted the injection pump. Put the new timing belts and idlers on. Cranked it over and I had fuel at the injectors. I had to give it a wiff of ether and she fired up I think I need some glow plugs. But at least we are good to go. Next job will be the gearbox probably not until next week. Ride to the wall is on Saturday and my other bike is on its last legs but it will get there and back with a bit of luck. I better take a few tools. I am not spending any money on it now. I will be pushing to get the heap of crap up and on the road before the new year.
Well I had a good day at the national arboretum it was a bit wet but worth it. My old bike made it still a bit of life in it yet. Anyway I took the gearbox off the engine Tuesday I gave it a good clean ready for stripping down. I had anticipated it taking a while but it really only took about 45 minutes to get the diff out. I have welded it up had a bit of a fiddle getting the selectors back together. If you are doing a ford gearbox the selectors need to be completely stripped to allow it all to go back together a bit fiddly but I didn’t have a manual or anything to go by. But its back together and I have refitted it on the engine. The engine is now back in the frame it was a pain getting it all sorted out back on its mounts took a couple of attempts not as easy as the other engine but its mounted.
Well what happened was.
Ok well I got the bike finished but I have a lot to sort out. I told them all I need brakes before I get it running because I would ride it anyway Danger Ride So I put some brakes on but they aint stopping much but it's too late as it was running. I took it out it was megga like riding a bear with no brakes. I must have had at least 15mins got up to about 60 easy all was going well. I thought that I had better take it back give it a quick check over and that’s when it happened. I was slowing it down sort of there was a loud pop followed by a rumbling and clonking I had no drive. I looked down and my leg was still there the drive shaft was ok. So I coasted it back in to the workshop and had a look. Well the tractor PTO unit was not up to the job to say i broke it was an understatement. Normally on the Danger Ride a sudden failure is almost certainly followed by a near death experience this was a most uneventful experience. However I had broken it but it was worth the 15 mins of fun I was a little disappointed but grinning from ear to ear. So i have started the upgrade. Remember the Audi TT transfer box got it welded on i have a few more bits to do before the next outing.
Back on track.
Problem 1
So I got the Audi transfer box these do not drive from the shaft to get the drive you need the diff from the gearbox and some imagination. I found a diff on eBay complete with the important drive collar 23 quid delivered. I needed the gear that drives the drive shaft and the end of the diff that drives the transfer box gear and the nut that holds the gear on the drive shaft. So out came the grinder and I cut it all up cleaned all the parts removed any bits that didn’t need to be there. I mocked it all up there was a bit of play and I could not be sure that all was straight for welding. I needed something to take up the slack. I found a big hydraulic washer it was just the right size tightened it all up nicely.
Problem 2
Mounting it on well it has to go on upside down that will have to do the thing is sealed unit on the casing as it gets oil from the gearbox and vents into it. I got a rubber drive and made everything fit and welded some substantial angle iron to the frame to hold the thing on. I had to get some core plugs to seal the holes that went to the gearbox and put a vent at the top by the filler.
Problem 3
Well this was a pain the gearbox is not sealed at the diff end so I had to sort it out I managed to get a piece of exhaust tube. It was close but not big enough so I had to stretch the end to make it big enough but still seal. I used a large piece of steel bar about 3” diameter and took my time to beat the tube at the end to stretch the tube wall it took a little while but I managed to gain about ½ a mm to allow it to be a snug fit. I tapered and welded the other end and attached it all to the bracket for that end of the gearbox.
Danger ride 2
Still no brakes i road it for about 45 mins it’s much better the with Audi part it’s still over geared 1-1.5 but it is better. My speedo not working but I can’t get out of 1st without brakes it’s smooth over the bumps with leading link it’s like riding a giant C90 it is a great ride. So my next problem is stopping.
Ankers
I have Finally had some time to work on the bike. I managed to get a ½” master cylinder fitted it and took the bike out I have a much better rear brake I think I can still get it a bit better. But the front is not enough. But I can stop it just about. I had another front calliper so I have taken the wheel off and fiddled around a bit until I had got good position for the pads. I made a crude carrier but it will do the job. I still have a few bits to sort out still. My daily ride has developed a nasty noise so I am having to sort that out I have another engine for it but when I get it in I will be swapping the front master cylinder from that. I think that I have a short banjo hose to link the brakes.
Getting there
I have made some progress I had to reach into my pockets I bought some bits a new set of brake shoes and wheel cylinders and bias valve for the side car fitted all of it. I had a job with the bleeding of the side car but I got them sorted out had it all ready checked the pedal gave it a good press on the pedal. Well what happened was it turns out as I found out the hard way. The ½” master cylinder was producing about 4 times the pressure required when it was all fully bled and I gave it a good shove with my foot. The bloody bias valve burst its seals fluid everywhere. I mean I spent about 14 quid on the bloody thing. So back to the drawing board for the rear brakes. I started poking around on the old interweb I found this http://www.wallaceracing.com/brake-master-cyl-calc1.php I done a few calculations on my new find. Well I didn’t really have a choice for the next master cylinder so I worked it out that a 5/8th will be working at around 850psi under light braking which is close to where it needs to be. I found that the only seals that had blown were 2 little o-rings. So got some on Ebay I checked and ordered the type correct for dot 4 brake fluid. Fixed it up bled everything again. All sorted. Now the front I finished the calliper arrangement. I put a 16mm front master cylinder on it. Bled everything again it was very soft lever almost touching the handlebars. It needed 11/16th to be standard. I didn’t have the funds. I had some adjustable levers in the garage. They made it better but still not quite there. So last ditch effort before I would need to spend more money. I took the standard lever to the vice and I gave it a little tweak. I have about ¾ spare left. So out for another danger ride I am much happier with the rear brake but I am not happy with the front. The pads are contaminated I had plenty of bite but the friction material was not really doing anything. So I gave everything a good clean with some degreaser. I went back out again determined to get something happening. Well it started off a little better but still not enough so I decided that I would keep it going until it didn’t get any better. It quite quickly got up to temperature and the brake did seem to be getting better. There was a bit of smoke so I was burning off something. Ok I got a bit carried away the brake was nearly on fire and I had boiled the bloody brake fluid. That was it then had to wait before I could sort it out. I took it out today it’s a lot better but I want more. I have made an offer for some pads hopefully I can get them cheap. I am currently on plan B for the front brake and I do have a plan C and some of the parts. Also the bloody alternator mounting has broken so I have had to fix that today. I think the engine had been dropped as the alternator casing was cracked and I had to make a spare that I had sitting around fit when I got the engine.
Alex
PLAN C
Ok it’s time for plan C I got the new pads much better but I want to feel like the bike will stop. I managed to get it on the roller brake tester. It needs to make 40% it is close but I think it will not be enough it’s not giving the required confidence when I am doing any sort of speed. So I have been anticipating this and have been thinking ahead. I had 2 choices as I had 2 different wheels and tyres to hand. I had a BMW E36 wheel and a Volvo wheel both rear wheel drive so have just got a stub axle on the front. I had a look on ebay and I had found that there are more parts available for the BMW for the tight budget that I have. I told the boss at the other workshop where I was using the brake tester my plan. It must have been the right plan he went off to his store and came back with a pair of disks and some callipers that he had replaced on his BMW track car. So it’s on I now have to get the rest of the bits I need. I managed to scrape up just about enough metal I am a few bits short but I will do some jobs to get the Cash. I will be making another link for the forks and I will be using a poly bushes for the pivot this time. I had some thick walled tube in the garage that I have weld in to some box for the bushes to fit in. I have got some Landrover lower link bushes a lad at work gave me. I am helping with the welding on his defender Chassis I would rather give him a hand with that than put my hand in my pocket. I am hoping to get most of the fabrication that I can do with the parts I have done this weekend. I will have to get a spindle made somewhere I have got the hub off ebay. I have got to move some engine mounts on the Defender and that will pay for the bit of 2” round bar that I spotted at the metal shop for Cheap. I think I have got a few other jobs that I can do to get some cash for the lathe work. I may have to make a master cylinder but I will cross that bridge when it comes to it I have got a variety of then to play with now.
Well I am getting there. Done some more work have made a swinging arm and attached it all to the forks I have made it so I have 2 options for the fork trail. The good thing that comes with any of the modifications is change. I have hopefully improved things quite a bit I intend to put a link on the brake this time to stop the C90 feel. I am in need of some lathe work this is going to hold me up. But I can keep going with other things for the moment. I will be going to the big knock in the afternoon have a look around. I have to go to somewhere next week there is an old engineering shop next door I am hoping that I can entice them with some beer tokens. I have got a piece of 2” steel bar ready to go which I will be taking with me.
Thanks Mark it looks better than it is but it will do. hopefully I will be able to find somewhere and get it sorted out.
I had a good afternoon on Saturday at the big knock. A lot to take in some of the conversions were really well done. I was hoping to see some of the big bikes but it was still worth the trip. It’s in a good spot I must have gone around the area about 3 times trying to find it but the roads are good and it was good weather. I had a good chat with a few people and I will hopefully bring the bike next year.
I done a bit more on Sunday finished off the forks I have just the front brake calliper carrier and some tabs for the mudguard and then make a new hose for the brakes.
). The tank mounts are made and tacked to the frame. I need to find some banjo fittings but that is not the end of the world I have made the points for the level hose. Although it is not the best welding I like the way it looks. The plan was that I would give the whole thing a skim of filler to smooth it out but I’m going for rough and ready so I think I will just clean it and leave it as it is give it a coat of rust converter and red lead it for now. I think I need to look at the foot rests and controls next shouldn’t be that difficult. I think that I will be near making a list of jobs to do soon all the big jobs are getting done. 
Bugger. 
