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GreaseStain
05-29-2012, 11:56 AM
So i've been debating with starting a thread here.. it's more of a "De-Chop" really so I might get ostracized but I value all opinions and generally learn something with all groups so against my better judgement I'm posting.

So I started out with this about 3 1/2 years ago..
http://i276.photobucket.com/albums/kk31/inkbonessteel/012.jpg

Make a long story short there were allot of demons hiding in there jacked hard tail lopped off head stay (sorry it might look cool but I value the headwork I had done and one steady aint enough for the abuse I plan to give her) Crud in the motor etc etc

After a seized journal , a soft seized motor a seized valve, a complete rebuild new carbs a donor frame donor forks and rear wheel from a 71 bonnie allot of cursing heart ache etc etc..

here's where I am today:
http://4.bp.blogspot.com/-zxuoYesGang/T8LX0x3-_FI/AAAAAAAAAQ4/3z-GKKbxGHA/s400/2012-05-27_20-18-14_501.jpg

http://1.bp.blogspot.com/-HqDSNuL7tSg/T8LXn8JTUPI/AAAAAAAAAQg/gFYZRXWKp_o/s320/2012-05-27_20-17-10_290.jpg

And that muffler needs to kick out more I know.. it's sitting on the oil tank because it's zip tied to the frame for mock up only, not planning on leaving it there to boil the oil or anything.

So the "direction" if I can say that and not sound contrived.. is a street legal "race inspired" bike basically I've never raced on a track, and while this will prob not be my daily driver (thats what theDuc is for) I'd like to put around on it from time to time and take her out to a few track days and slowly get my feet wet with the whole track bizness I don't expect to ever enter her in a race but will certainly be taking it to the track to push it to the limit of what she can do, and if i can get the cajones to get my ass in a real race then i'll use it as an excuse to go pick up an RD or something of the like after all ill have to "explain" it to the little lady somehow why I need a new project.. And even then it would really just be for kicks and grins.

And here's a few goodies im jonesin to put on ..

http://1.bp.blogspot.com/-GfGg6EtSCZ4/T7SBMgqhr5I/AAAAAAAAAPM/RQjy9WhPXvg/s400/2012-05-16_16-46-41_453.jpg

http://lh5.ggpht.com/-BbHqIcABgmg/T7F9e3SUk4I/AAAAAAAAAO0/nbzJ4bs64G8/2012-05-14_16-46-02_59.png

Super Duper Awesome Tach from Scitsu and linkage for rear sets that still need to be made.

http://lh5.ggpht.com/-k5fGWTeKCms/T7sbHjFn3nI/AAAAAAAAAPY/0DKZspBZyWs/2012-05-21_18-40-19_689.png

And some mandrel bends from http://www.coneeng.com ( I had the headers and the muffler already) Those guys Rock! Had a great experience both from the customer service side and the over all receiving my stuff side..good ppl.

http://4.bp.blogspot.com/-tvIrXQmWQvY/T6G_AmeisxI/AAAAAAAAAKY/Tm1D3zn5t8M/s400/ENIMAGE1335999888195.jpg
And then there is this little gem.. I still can't believe it can push that much power.. it's just. so tiny..

And to wrap this up .. this is my current workspace.. well at least about a month or two ago i've cleaned up and moved a few things around since this was taken but you get the idea. It's a far cry from the dumpy cluttered one car garage that this scooter came to live in for 2 years after being dismantled and crammed piece by piece into the back of an ex girlfriends ford focus to bring it home when it was still that "chopper" atrocity in the first photo.

http://i276.photobucket.com/albums/kk31/inkbonessteel/2012-04-29_19-51-39_941.jpg

cheers

GreaseStain
05-29-2012, 9:45 PM
More updates:

Well I welded in the collector yesterday but it was wonky due to the bend angle in the headers under the bike and just looked awful.. so to the chop saw it went.

Round two
http://4.bp.blogspot.com/-x-hE6GrCrZI/T8WUHy3v5YI/AAAAAAAAARQ/ek-4TcdgKeA/s320/2012-05-29_19-05-45_717.jpg http://1.bp.blogspot.com/-uT8zlQmDLlM/T8WULr1QRUI/AAAAAAAAARY/_9EA8QnKrrY/s320/2012-05-29_19-47-32_917.jpg

And here's a side shot of the collector:
http://1.bp.blogspot.com/-tNmkAZKR5mA/T8WUS6W0T4I/AAAAAAAAARo/zEYpRXAh1PY/s320/2012-05-29_20-03-37_348.jpg

now I'm just working out distance to not interfere with the rear sets that aren't built yet.. hmm better not screw that one up..

And truthfully I must say I had to sleep on it I was considering just leaving it as it would have been 'functional' and just wrapping over the ugly bit under the bike (I hate exhaust wrap on pipes .. i've done it before in a pinch but it's not by any means my preference) After a good nights sleep I came to my sense and cut it to pieces and just started over again..glad I did.

crush1776
05-29-2012, 9:50 PM
I like where you are headed with this, you may want to check out Columbia River for mandrel bends:

http://www.mandrel-bends.com/catalog/

GreaseStain
05-29-2012, 11:20 PM
AH! Man thats the site I was looking for! I found that like i don't know maybe a year ago and didn't bookmark it, wrote it down on a scrap of paper lost it and just hunted the net looking for it, ended up buying from coneeng.com still some really great folks there but yea that site rocks thanks man. These headers will be temp only since they are a bit mangled I don't really want to pay to have them re-plated so I'll prob end up doing them again in the future when it's all said and done this should come in handy.

cheers

GreaseStain
05-30-2012, 11:35 PM
Exhaust continued:

did some additional work on my muffler today. Heres a few pics from before though just to take it from beginning to end. I had the cocktail shaker lying around so i figured I'd put it to good use.

http://4.bp.blogspot.com/-Wx5O2_bli9I/T8b-TPbXvaI/AAAAAAAAAS4/saqOPnOjJGU/s200/2012-04-21_17-37-30_891.jpg http://2.bp.blogspot.com/-Ts91Oby_JWs/T8b-HLECwPI/AAAAAAAAASs/5mqKdnBKtf4/s200/35361.jpg

with a hacksaw a file and allot of patience did this:
http://4.bp.blogspot.com/-85A6D28dsqs/T8b-FpElULI/AAAAAAAAASk/gMA5YDvAvZk/s200/35360.jpg

So today, i decided to do away with the upsweep and just come straight off the exhaust after sitting in front of the bike holding the muffler up and dozing off periodically.

So i lopped off the upsweep with the trusty chop saw (upgraded the hacksaw) and re welded the coupler piece of the muffler to the "cone"

http://3.bp.blogspot.com/-2pF-qI3gnj0/T8b94FCDz0I/AAAAAAAAASE/EHgS77UDIAg/s200/2012-05-30_20-51-42_161.jpg

http://4.bp.blogspot.com/-_RJtTwWhUrg/T8b971sUIsI/AAAAAAAAASQ/KkfjWfE5mss/s320/2012-05-30_20-52-06_309.jpg
just a tad bit of smoothing to do and ready to mount.

GreaseStain
06-02-2012, 1:44 PM
Put a few hours more in on the exhaust today, still not done but it's holding it's final (i hope) shape need to touch up a few things and then smooth out all the weld areas a bit more before I either paint it or get it plated headers are still pretty banged up not sure if I want to spend the plate money on them right now might just paint it all black even though I'd much rather it just be plated.. we'll see.. Pics:

http://1.bp.blogspot.com/-fOEyJ-xiaCk/T8pouWqZNvI/AAAAAAAAATE/gaCqE9zauqs/s320/2012-06-02_13-11-58_711.jpg http://1.bp.blogspot.com/-Yoyjm7q2qEc/T8po3Xc6HFI/AAAAAAAAATU/lTrhARtiBT8/s320/2012-06-02_14-07-38_594.jpg

http://3.bp.blogspot.com/-DJoIaXOYanw/T8poyyTU-_I/AAAAAAAAATM/pg-20BXSgh0/s320/2012-06-02_14-07-28_471.jpg http://3.bp.blogspot.com/-GBmlwPlcft4/T8ppDdiOJDI/AAAAAAAAATs/aUEsbQMIqFE/s320/2012-06-02_14-10-37_480.jpg

And the 'upskirt' shot
http://2.bp.blogspot.com/-txCN0LMloZs/T8ppHq7fDYI/AAAAAAAAAT4/JiWAEJ8EH9I/s640/2012-06-02_14-10-48_911.jpg

GreaseStain
06-03-2012, 12:18 AM
More updates:

Well in an effort to not piss off my neighbors I've been trying to do the loud things during the day and the quiet ones at night plenty of both to fill both spaces. So started removing paint from the Gas tank and addressing the oil tank which has some rust figure I'll try vinegar to remove it so wanted to do a trial run.

Now I've heard Apple cider is the best so I went to the store to pick some up and noticed it was 5% acidity and there was an extra strength 9% acidity white vinegar.. so I figured what the hey ill try both and which ever works the best will go in the oil tank and the gas tank.

Heres the oil filter screen :
http://2.bp.blogspot.com/-FXU6pHotof4/T8r9kIdfv1I/AAAAAAAAAUE/p7V9pL2NmN8/s400/2012-06-03_00-19-20_202.jpg

and just to have something awful to test with heres some throwaway slip on i have in the scrap metal bin

http://3.bp.blogspot.com/-NPEItQAd6Zc/T8r9xO7LOoI/AAAAAAAAAUc/7rT7_8DGVsc/s400/2012-06-03_00-26-45_967.jpg

Screen went into the 9% white vin.
http://3.bp.blogspot.com/-ojOYdBR6wPE/T8r9oI2dASI/AAAAAAAAAUM/zVxdW16ZHbA/s320/2012-06-03_00-20-47_997.jpg

and the scrap went into the apple cider
http://3.bp.blogspot.com/-s0dKtO12kxU/T8r91Bp5FzI/AAAAAAAAAUk/I0Ih_2yoofM/s320/2012-06-03_00-29-58_481.jpg

I'll give it 24 hours or so and check in on it, which ever works better I'll be using on the oil tank.

DanTheMan
06-03-2012, 3:29 AM
Looking good! I`m glad you had the guts to "de-chop" it. Nice work on the zorst too :cool:

GreaseStain
06-03-2012, 10:16 AM
lol thanks, it was an easy choice to make i scored the T100C frame for next to nothing and the frame it was in was F***Ked 9 ways to sunday pieces of tubing covering up catastrophic rust damage dirt and rust bits inside the frame tubes bent axle plates.. etc etc..

Well here is about 3 hours
http://2.bp.blogspot.com/-1iHZYczUJ0E/T8uKdpDibfI/AAAAAAAAAVI/x0sHUWPVrEs/s320/2012-06-03_03-43-23_349.jpg http://1.bp.blogspot.com/-OzCOKbYTvok/T8uKhh4qRmI/AAAAAAAAAVQ/CJuNcWtl9-w/s320/2012-06-03_10-22-56_680.jpg

And about 10:

http://3.bp.blogspot.com/-RuYKkt5kGG0/T8uKpsZ4S2I/AAAAAAAAAVk/_WAVEKy8BHA/s320/2012-06-03_10-27-31_21.jpg http://3.bp.blogspot.com/-EugzZ1zCutk/T8uKlcEGFXI/AAAAAAAAAVc/tEO3cxhCvwM/s320/2012-06-03_10-27-18_135.jpg



look close enough I don't think im going to worry about which one works best might mix the two and throw a few rusted test items in just to make sure nothing crazy happens and use both.

GreaseStain
06-10-2012, 1:25 AM
Well in ref to the above vinegar worked great but gotta act fast to avoid flash rust.. i was in a hurry and having to do bits and pieces when I could some of which on my lunch break so i flash rusted, for the sake of time i got some evaporust since it would eat the rust quick and coat the surface for at least a week or two till i was able to get the ducks in a row.

Here's the tank as I got it off of one of the forums
http://1.bp.blogspot.com/-ugh1HNpWEss/T9QSVFSaieI/AAAAAAAAAZE/WvxxobaQrQM/s320/2012-06-03_14-04-39_695.jpg

http://1.bp.blogspot.com/-C2GUQvS8WgM/T9QSgKL2R2I/AAAAAAAAAZQ/dmS0TGbql14/s400/2012-06-03_14-36-44_362.jpg
Vinegar

After the vinegar
http://2.bp.blogspot.com/-lFFQ8-fSPpw/T9QSJOPGpfI/AAAAAAAAAYk/NMj5kfL1f4I/s320/2012-06-05_11-15-06_401.jpg
http://1.bp.blogspot.com/-qrXXiVJgP9Y/T9QSLw5N23I/AAAAAAAAAYs/R9bgiTnmgKU/s320/2012-06-06_19-27-31_411.jpg
Flash rust.. bummer
http://1.bp.blogspot.com/-sTIt27tInuU/T9QSOgTrhqI/AAAAAAAAAY0/GUnLNx9GcWM/s320/2012-06-06_19-30-28_621.jpg
evaporust
http://3.bp.blogspot.com/-O_LoOQ-ElxY/T9QSRv-vJ7I/AAAAAAAAAY8/9DMK-mlMpu8/s400/2012-06-06_20-32-15_752.jpg
And post evaporust been like 5 days still clean as a whistle.

Also picked this up
http://1.bp.blogspot.com/-HWHzOyUOFUw/T82ge0XgzyI/AAAAAAAAAWk/I7CeTdO32U0/s640/2012-06-04_23-31-25_272.jpg
GE 1/2 HP motor
http://4.bp.blogspot.com/-oxdiW6_4RS4/T82gjFhzy-I/AAAAAAAAAWs/KZNIh1zXQco/s320/2012-06-04_23-31-51_502.jpg
Got this press for free a year or two back

http://3.bp.blogspot.com/-I3FLDlC6ZY8/T9QPfbzV5sI/AAAAAAAAAYQ/2u81s_1SXHU/s400/2012-06-09_21-28-24_381.jpg
And some hacktastic magic later motor is actually bolted to it , the brazing is a plate i welded on and drilled then bolted the motor to, base metal of the press is awful pot metal tried to mig it and to torch weld it with steel rod brazing was the only thing playing nice, walloped it with a mini sledge though and its solid - works like a champ too, just need to wire up the 3 prong cord into a main switch and an emergency cut off switch.

And.. (long random post its been hectic so they are kinda compounded on each other)
http://2.bp.blogspot.com/-ko-XfZiyQpc/T82h7iRs1kI/AAAAAAAAAW0/EP0nD1di4OU/s640/2012-06-04_23-32-24_700.jpg
Got these in .

http://2.bp.blogspot.com/-vin17o3WA8s/T82h_L66kII/AAAAAAAAAW8/q7eQei77PEY/s640/2012-06-04_23-32-49_912.jpg

And round about where they will sit. Taking my template to the shop tomorrow to have it CNC'd from aluminum, still need to work out what to do with the gear change lever .. so nice of the factory to jam those two up on each other like a couple of drunk highschool kids...


And finally to round it out a bit, a current (ish) mock up

http://2.bp.blogspot.com/-HkuyU9zLZi0/T8wwvQlwkOI/AAAAAAAAAVw/jwWTX4TXstc/s640/2012-06-03_22-05-55_954.jpg

SSWolf18
06-10-2012, 5:50 AM
A+ great work

Torch
06-10-2012, 8:11 AM
you took an amateur chopper and turned it into a worthy cafe.
I like your style, I be waiting to see the paint style and colors.

RetroRob
06-10-2012, 8:57 AM
going to be a sweet little bike, keep us informed

GreaseStain
06-10-2012, 10:18 AM
Thanks allot guys, still a long way to go with the ol girl but she's getting there, still have some seat issues to sort out (cowl is about an inch or two high at the moment) seat pan is still in pieces to fit it to the frame and just now getting into making brackets for everything but getting there anyway. Just bite the bullet and dropped a deposit with the plater they have 4 week lead time so i locked my place 'in line' and need to wrap that bit up so i can turn them over, just went with nickel plate to keep from having to paint or wrap the exhaust. Actually getting ready to take a handfull of cardboard templates down to a shop here in town to have them CNC'ed so more to come soon on that one. Also working on making new tank badges for that wards riverside tank, being a respectable 500 I just couldn't leave the '360' on the tank so I got some vinyl cut from the good folks over at Squier Designs (ill post a link when I do that write up) with a "500cc" matching diameter going to encase it in clear resin to mimic the 360 badge, paint scheme is ducati red (frame) and white on the tins with a red racing stripe .

Cheers

GreaseStain
06-14-2012, 8:34 PM
Ok So I have the benalli wards riverside tank with the "360" badges.. well now no self respecting 500cc Triumph Twin can have "360" plastered across the tank so it simply must be remedied. So I contacted the good folks at Squier Design.com http://squierdesign.com/ and worked with them to find the right vinyl design. Can't say enough good things about these folks, they worked with me and even pointed me to the resin that I used to make these. Even sent me some extra vinyl so I could try my hand at using the resin before I committed to pouring it over the final product. Highly recommend these folks - If you need racing numbers etc give em a shout.

http://2.bp.blogspot.com/-kmY3XU3_JsE/T9pk9sAdTuI/AAAAAAAAAas/zO_GGVe3jqk/s320/2012-06-13_22-42-40_581.jpg started with just a vinyl decal
http://2.bp.blogspot.com/-kmu0LRv-b4c/T9plBPvX5eI/AAAAAAAAAa0/GIYAWfQ0VYw/s320/2012-06-13_22-55-39_233.jpg poured on the "Ice Resin"

http://3.bp.blogspot.com/-tUdV-ClE9UM/T9pky1sfGMI/AAAAAAAAAac/m4Vs3uV317Y/s320/2012-06-14_17-16-01_242.jpg here it is after like 15-20 hours
http://3.bp.blogspot.com/-yadEGaJMUkw/T9pk56e4iYI/AAAAAAAAAak/wxhWqnOwzCM/s320/2012-06-14_17-16-26_101.jpg and one head on - still a bit pliable but getting more and more rigid as time goes on, manf of the resin says you can drill it when cured so im assuming it will keep hardening till then .

this was my trial test run before i dumped resin all over the final decals.

GreaseStain
06-14-2012, 8:35 PM
Ok part 2 - The actual badges

http://1.bp.blogspot.com/-pGsQtmPPv5c/T9qcHr4YnPI/AAAAAAAAAbI/ZM5TaP_XOoA/s640/2012-06-14_20-21-46_788.jpg
Need to make sure it's level and everything is held down tight its a self doming self leveling resin.

http://2.bp.blogspot.com/--intiRnciDs/T9qcLe7YphI/AAAAAAAAAbQ/GjlEiMizzxc/s320/2012-06-14_20-22-16_345.jpg
The actual resin used it's a one to one mix

http://4.bp.blogspot.com/-r6-gwEQVt74/T9qcPfB0nFI/AAAAAAAAAbY/5ElUgCB1N84/s400/2012-06-14_20-44-52_441.jpg
And now the waiting game. After this dries I'll go over it again to create a higher dome on the resin to add some extra depth.

As you can see it pools up at the end just pour it on and let it self level itself out, have to be careful not to pour too much or it can overflow the edge and be a real mess these match the diameter of the stock 360 tank badges.

GreaseStain
06-14-2012, 9:21 PM
And here's a 'mock up' of the would be badge, this is one of the extra decals I had made as a back up lightly taped on, conveys the idea anyway.

http://4.bp.blogspot.com/-mTGbYU4eHL0/T9qpZOCuRTI/AAAAAAAAAbo/-LmGLxoJnBw/s640/2012-06-14_22-13-53_722.jpg

RetroRob
06-14-2012, 10:07 PM
Love the tank, decals are a nice touch

GreaseStain
06-14-2012, 10:21 PM
Thanks, went back and forth with a few different colors that were allot more bold, tank will be a bright white with a red stripe so figured this color combo on the badge would be a bit more subtle and just kinda blend in as if it were sorta stock .. sorta..

GreaseStain
06-16-2012, 10:55 AM
Ok here is the 'final' product

After the first layer I added a second to increase the depth on the badges
http://1.bp.blogspot.com/-V-0JnKujZE4/T9y3fX_RfaI/AAAAAAAAAb8/ghRiKAQyiyA/s400/2012-06-16_01-03-23_393.jpg

First layer went on pretty clean, this one .. eh .. i used less resin so as to play it safe and not spill over the edge so it took a while to level out to the edges and I ended up having to help it along started to get pretty close to the tack time so a few spots on the edges aren't the best, dont really notice unless you get up on it, I'll prob do the other set of decals I have as a second run and run the better of the two, but for now this will do.

http://3.bp.blogspot.com/-k22TUP8P90k/T9y3i8MR82I/AAAAAAAAAcE/WXPJbEnNz0M/s400/2012-06-16_11-08-34_591.jpg

And finally here's the side by side .. i think the stock badge is actually just a tad bigger its less than half a tenth on my caliper but looks like its more in the photo

http://1.bp.blogspot.com/-b9m3x9jEMiQ/T9y3mC3eJAI/AAAAAAAAAcM/AdZ04JC9rfU/s640/2012-06-16_11-36-11_942.jpg

GreaseStain
06-24-2012, 10:37 PM
Made a bit of progress. Finished up the muffler, goes to the plater tomorrow for nickel plate.

http://1.bp.blogspot.com/-9zN3LIpC3ek/T-fJA4hpc3I/AAAAAAAAAkI/LkDuao84Upc/s320/2012-06-24_17-37-07_259.jpg http://4.bp.blogspot.com/-gc-GPh4Gh_8/T-fJaw9XalI/AAAAAAAAAkY/XZK7doHtc48/s320/2012-06-24_17-39-00_925.jpg http://4.bp.blogspot.com/-JkbtVULpLhc/T-fJPXUPhtI/AAAAAAAAAkQ/P3f7Q7vhxqA/s200/2012-06-24_17-38-00_140.jpg

got the bracket welded on and a gusset added, I've had mufflers rocket off at 70mph before ;) also drilled a hole for a safety cable.
Managed to stumble across the perfect hardware in the box O' bit's and pieces happens to fit the frame perfectly was planning on shaving the center stand mounts off but it just fit.

http://4.bp.blogspot.com/-8FHlxbaezsw/T-fJ_ltBccI/AAAAAAAAAk8/g-uaxqb8FXg/s320/2012-06-24_20-09-54_229.jpg
And I cleaned up the underside of the baffle cover that went to the old cocktail shaker. It will be plated with the muffler and attached with magic... Not sure if ill run it just making sure its plated to match if i need it, mostly to keep the inspectors at bay for issues with "open pipes" but we'll see, good to have the option.

http://4.bp.blogspot.com/-tmc9ecw_Vy0/T-fJ0G0v_2I/AAAAAAAAAks/xAL_gtbkix4/s320/2012-06-24_17-41-47_750.jpg http://4.bp.blogspot.com/-aGpnqqyeWA0/T-fJwgntZuI/AAAAAAAAAkk/3DkvPOZu8MI/s320/2012-06-24_17-39-52_702.jpg
Got the tach mount bracket drilled and mounted