Thumper Club Forum

Technical => Project Progress => Topic started by: guest868 on February 16, 2010, 09:53:13 PM

Title: Shedbrewed #3
Post by: guest868 on February 16, 2010, 09:53:13 PM

Quick history lesson, I lent a running DR600 out and it came back not running and with a now ex-mate.

1985 DR600 that was in good working order-

(http://i97.photobucket.com/albums/l230/phatphord/dragon/DSC00059.jpg)

Then got lent out and returned with engine internals looking like this-

(http://i97.photobucket.com/albums/l230/phatphord/bikes/IMG_1530.jpg)

(http://i97.photobucket.com/albums/l230/phatphord/bikes/IMG_1531.jpg)

After a slow parts gathering and assembling the engine is back together-

Head assembly with R/D Ti valve spring kit-

(http://i97.photobucket.com/albums/l230/phatphord/DSC00371.jpg)

Wiseco +3mm piston, necessary due to bore damage-

(http://farm3.static.flickr.com/2446/3606210293_b158b7d8af.jpg)

Assembled head in background, new balance chain-

(http://farm4.static.flickr.com/3320/3606210301_c1e6cd31df.jpg)

The engine has been completed for some time now, but this is the only pic I can find-

(http://i97.photobucket.com/albums/l230/phatphord/bikes/IMG_2549.jpg)

Do you really want the spec?

+3mm rebore and Wiseco 97mm piston (620cc)
Joy #209 race grind cam
R/D Ti top valve set
Ported head
Polished and relieved rockers
Heavy duty clutch springs
Keihin FCR39 carb
Headers still to be made to adapted HRC design including reverse cone and Remus BSB ti silencer.

I had a little piece together with some parts in the shed-

(http://i97.photobucket.com/albums/l230/phatphord/bikes/view_test.jpg)

The SR500 tank got chopped about-

(http://i97.photobucket.com/albums/l230/phatphord/bikes/DSC00175.jpg)

tap bungs fitted-

(http://i97.photobucket.com/albums/l230/phatphord/bikes/IMG_3113.jpg)

and a new filler bung fitted and then primed-

(http://i97.photobucket.com/albums/l230/phatphord/bikes/IMG_3112.jpg)

(http://i97.photobucket.com/albums/l230/phatphord/bikes/IMG_3116.jpg)

I regret priming the tank, and wish I'd just shellac'd the underside of the modified tank. Still, can't dwell on things.
I tried a few cheeky piece togethers-

(http://i97.photobucket.com/albums/l230/phatphord/bikes/IMG_3097.jpg)

and then sort of lost interest until my mate Al dropped the new yoke off.
Been back out tonight after sourcing a new top head bearing and things are rolling again...

(http://i97.photobucket.com/albums/l230/phatphord/bikes/DSC00328.jpg)

Tank colour is Ferguson Stoneleigh grey, but may change. Not sure. I am very much feeling a brown saddle though.

http://shedbrewed.blogspot.com/ for more updates when they happen, and other mutterings.

Title: Re: Shedbrewed #3
Post by: guest288 on February 16, 2010, 10:10:02 PM

That looks good, obviously very talented and have a good eye!

Title: Re: Shedbrewed #3
Post by: guest7 on February 17, 2010, 12:00:56 AM

Nice stuff, keep us posted

GC

Title: Re: Shedbrewed #3
Post by: guest868 on February 19, 2010, 07:10:29 PM

Well an early finish today (by 30mins) meant I got to spend some time titting about working on the bike. Now I have the awesome yoke from my mate I am able to get it on wheels which meant I could see how much I needed to drop the back end.
Conveniently I am able to just drill two holes in the stock llinkages to drop the back down, and Hagon have responded to my query regarding a firmer spring for the Hagon shock on the bike. So today was decision day, does it go Bratty, or does it go OE+?
Well it's going OE+.

The seat unit I tried looked fine, but was just a little too long, so can go back in the shed for the TR1. Some picamatures then-

From the rear-

(http://i97.photobucket.com/albums/l230/phatphord/bikes/DSC00336.jpg)

From the front ish-

(http://i97.photobucket.com/albums/l230/phatphord/bikes/DSC00338.jpg)

and then from the side with me trying to work out silencer position using some twine-

(http://i97.photobucket.com/albums/l230/phatphord/bikes/DSC00340.jpg)

It is stupidly simple and unbelieveable how the SR rear guard fits, the bloody bolt holes couldn't line up better. I've got a list of jobs for tomorrow; I need to cut off and move the tank mounts, prep the tank for paint, locate the second spare SR sidepanel I have so I can extend them both, and also drill the top yoke to mount the instruments. Thankfully my mate has given me a couple of pilot holes already for that.
Chuffed.

Title: Re: Shedbrewed #3
Post by: guest868 on February 20, 2010, 07:04:24 PM

Well, I didn't get as much time to work on the bike today as planned, but I still managed to get the grinder fired up for some cutting action. I cut the stock tank mount and moved it back to allow the SR tank to line up. Something I'd been hoping for also happened; the bolts allow the SR seat to lock in place at the front. Happy days.

(http://i97.photobucket.com/albums/l230/phatphord/bikes/DSC00342.jpg)

Was good to get back to welding, even though it's not as neat as I'd like. I took the chance to grind off the stock welds that were messy as well, and run some tig beads into it.
Next step was to sort the filler bung. Al had lathed down the BSP bung for me, and taken some of the excess thread off, but it was still too proud of the tank. I marked up and cut about 1/4 inch off before rewelding the two parts. I also welded my breather (s/s bleed nipple) and wings onto the bung. A quick polish and I'm pretty happy.

(http://i97.photobucket.com/albums/l230/phatphord/bikes/DSC00343.jpg)

Next things that need attention are the front tank mounts, the lock stops (oh yes I'm going back in time for them, get guessing) and the rear master cylinder mount.

Title: Re: Shedbrewed #3
Post by: guest7 on February 21, 2010, 10:48:28 AM

 :o You talented sod!  ;)

GC

Title: Re: Shedbrewed #3
Post by: guest40 on February 22, 2010, 01:57:47 AM

I'll back up GC on that one, wow. and only 1 bike lifter too plus a freezer, a BBQ, a workmate(still working the logistics on that one) and a park bench... did I miss any? Brilliant!

Title: Re: Shedbrewed #3
Post by: guest868 on February 22, 2010, 03:43:05 PM

You can never have too many bike stands Kurt!  ;D
Yesterday was a mixed day, spent a lot of time staring at the bike in various guises.

(http://i97.photobucket.com/albums/l230/phatphord/bikes/DSC00345-1.jpg)

but decided to go with what I'd set out to do. I managed to drill the frame for the tank front mounts. Albeit in the wrong place. Never mind will have to redrill in the right place.

(http://i97.photobucket.com/albums/l230/phatphord/bikes/DSC00344.jpg)

After fannying about staring at the bike for far too long and umming and ahhing I setled for what I'd planned and snapped a few pics.

(http://farm3.static.flickr.com/2697/4376518586_2514140ef0_o.jpg)

(http://farm3.static.flickr.com/2715/4375769695_e467b6cf25_o.jpg)

(http://farm5.static.flickr.com/4038/4376518828_a424120a22_o.jpg)

Meh.

Title: Re: Shedbrewed #3
Post by: guest868 on February 22, 2010, 09:45:17 PM

Fogranger

(http://farm5.static.flickr.com/4015/4380363522_2c8c40088a_o.jpg)

I love a good wet lay

(http://farm3.static.flickr.com/2730/4380363240_52c751f264_o.jpg)

Title: Re: Shedbrewed #3
Post by: guest7 on February 22, 2010, 10:27:27 PM

Tell us more about that top yoke, it looks the bollocks.

GC

Title: Re: Shedbrewed #3
Post by: guest868 on February 23, 2010, 09:07:37 AM

When I started this project I looked at building a 600 version of the 450 motos - http://450moto.com/ as a wonder as to what could be done with older bikes for some track fun. I had a front and rear end of an FZR600 3HE in the shed from an earlier abandoned TR1 project I was building for a mate (he welched and bought a flip light Kat), and they nearly went onto the SR500 I built, but time, or lack of it meant otherwise.
Whilst the front end fitted in well enough, there wasn't enough ground clearance left with the forks as stock. I ummed and ahhed about the various ways of dealing with the problem, including slugging the forks, or getting longer stanchions made. I had a brainwave about using a stepped top yoke to lift the front end, and after talking it over with my friend Al (who has access to edgecam, CNC machines and lathes) he said he would make me a stepped yoke to my sketches. There were tweaks along the way, including the lovely way the bottom bar clamp is located into the yoke, and the smooth front. It turned out very nice indeed.
How's that?

Title: Re: Shedbrewed #3
Post by: guest7 on February 23, 2010, 11:21:55 PM

Cheers for that, it's a nice bit of kit and an elegant solution to the problem.

GC

Title: Re: Shedbrewed #3
Post by: guest868 on March 13, 2010, 05:07:01 PM

It's been a day of painting. Some good,some not so good. For some reason the candy concentrate separated in the gun and left me with flecks of solid. Two options; carry on with a dark coat of candy, or bin the candy off and blow some other flat colour on. I stuck with the candy, but I'm not that happy with it.

(http://farm5.static.flickr.com/4024/4429063949_aa396d0d98_b.jpg)

Still got to flat back and clear coat once it's cured.

Title: Re: Shedbrewed #3
Post by: turkeyuk on March 13, 2010, 05:50:38 PM

Nice work, im after a threaded weld in filler bung to fit a monza cap, where abouts did you get it? cheers, Paul.

Title: Re: Shedbrewed #3
Post by: guest868 on March 13, 2010, 07:02:30 PM

Quote from: turkeyuk on March 13, 2010, 05:50:38 PM

Nice work, im after a threaded weld in filler bung to fit a monza cap, where abouts did you get it? cheers, Paul.

2" BSP female socket welded into tank, 2" male BSPT bung turned to round from hex. Will see if I can find where I got it from. Was about £15 for the pair I think.

Title: Re: Shedbrewed #3
Post by: turkeyuk on March 13, 2010, 07:24:18 PM

cheers, that would be great ;D

Title: Re: Shedbrewed #3
Post by: guest868 on March 13, 2010, 07:29:09 PM

It was DM Stainless- http://www.dmstainless.co.uk/index.php?main_page=product_info&products_id=182 But i'm sure you could get hold of the size you need from a good plumbing supplies.

Title: Re: Shedbrewed #3
Post by: guest868 on April 01, 2010, 09:18:06 PM

Been cutting and buffing

(http://farm5.static.flickr.com/4010/4482019733_b772999584_o.jpg)

Title: Re: Shedbrewed #3
Post by: guest868 on April 12, 2010, 10:07:14 AM

Tried a quick piece together to see if I was definitely going the SR look way.

(http://i97.photobucket.com/albums/l230/phatphord/bikes/IMG_4248.jpg)

I think so. Waiting for some material swatches to come through for the seat, and for the tubing and bends so I can start making the exhaust.

Title: Re: Shedbrewed #3
Post by: Ian on April 16, 2010, 10:49:26 PM

Definately got the "SR" look..keep up the good work

Ian :)

Title: Re: Shedbrewed #3
Post by: guest868 on April 24, 2010, 06:36:38 PM

Wasn't happy with the brown so repainted parts of the bike, in a nice restrained colour.

(http://i97.photobucket.com/albums/l230/phatphord/bikes/IMG_4254.jpg)

(http://i97.photobucket.com/albums/l230/phatphord/bikes/IMG_4256.jpg)

Ok I lied about the restrained part.

Title: Re: Shedbrewed #3
Post by: guest27 on April 24, 2010, 07:56:01 PM

WOW!!!!! Tarts drawers or what?

I like it.

Mind it does not go down like te aformentioned drawers mind - would not look so good....

R

Title: Re: Shedbrewed #3
Post by: Ian on April 24, 2010, 11:40:33 PM

Couldnt have put it better myself Rog

Ian :D

Title: Re: Shedbrewed #3
Post by: guest868 on May 12, 2010, 09:20:55 AM

Made the mounts up for the new tail light last night and began stripping the FZR caliper for the front.

(http://i97.photobucket.com/albums/l230/phatphord/bikes/DSC00426.jpg)

and a manky caliiper-

(http://i97.photobucket.com/albums/l230/phatphord/bikes/DSC00368.jpg)

Pistons are out now and cleaned up ok, caliper split to clean the inside. Any suggestions for how best to clean the years of mank from it? It will be resprayed black when done.

Title: Re: Shedbrewed #3
Post by: guest146 on May 12, 2010, 03:54:50 PM

Bugger thats a mess. Whilst wandering round the Stafford auto jumble I spotted a barrel and piston for a single but it was Massive and must have had near on a 5" bore Is that from one of these? I thought my NX650 was a big piston but this one put it to shame

Ken

Title: Re: Shedbrewed #3
Post by: Ian on May 12, 2010, 09:07:19 PM

That looks very similar to the SRX front caliper (probably is the same knowing Yamaha). Vapour blasting is the best way to clean it up..other than that a toothbrush and some sort of cleaner will usually get into the nooks and crannies,this is the hard way that I usually end up doing as I cant justify spending money on fancy cleaning.

Ian :)

Title: Re: Shedbrewed #3
Post by: guest868 on May 13, 2010, 09:59:34 AM

I set to with a brass brush and some nitromors and it came up good. Next stage is priming and painting. Then I have to do the rear as well...

Title: Re: Shedbrewed #3
Post by: guest868 on May 25, 2010, 08:54:22 PM

I had a very talented young lady paint some numbers on the unholey sidepanel, numbers with a little twist-

(http://i97.photobucket.com/albums/l230/phatphord/bikes/IMG_4547.jpg)

(http://i97.photobucket.com/albums/l230/phatphord/bikes/IMG_4549.jpg)

all hand painted. Very pleased.

Title: Re: Shedbrewed #3
Post by: guest7 on May 25, 2010, 10:44:09 PM

An homage to Derek Minter?

I'll get my coat (actually it's an anorak)
GC

Title: Re: Shedbrewed #3
Post by: guest868 on May 27, 2010, 06:29:38 PM

Busy day

(http://i97.photobucket.com/albums/l230/phatphord/bikes/IMG_4617.jpg)

(http://i97.photobucket.com/albums/l230/phatphord/bikes/IMG_4620.jpg)

(http://i97.photobucket.com/albums/l230/phatphord/bikes/IMG_4623.jpg)

(http://i97.photobucket.com/albums/l230/phatphord/bikes/IMG_4628.jpg)

pleased.

Title: Re: Shedbrewed #3
Post by: themoudie on May 27, 2010, 11:30:56 PM

Aye, going well Shed!  ;D

Hailstorms up here, with temperature down to 4degreesC, as they take an hour to pass over. Not a lot of outdoor assembling going on!

Hope the wiring goes well.

Regards, Bill.

Title: Re: Shedbrewed #3
Post by: SHimmer45 on May 29, 2010, 09:54:54 AM

what sort of thing have you got in mind for the exhaust?

Title: Re: Shedbrewed #3
Post by: guest868 on May 31, 2010, 04:15:09 PM

Quote from: SHimmer45 on May 29, 2010, 09:54:54 AM

what sort of thing have you got in mind for the exhaust?

Alright Lee, 2-1 headers, feeding into 2" pipe running under engine, into reverse cone megga with a Titanium silencer.

Title: Re: Shedbrewed #3
Post by: SHimmer45 on June 03, 2010, 06:13:20 PM

sounds good tom ;D.

been lurking in here for a little while, seeing as im in the market for a small thumper/twin....
and some interesting projects of course

Title: Re: Shedbrewed #3
Post by: guest868 on August 19, 2010, 07:36:16 PM

Well, some action. Saddle arrived today, very pleased with it.

(http://farm5.static.flickr.com/4073/4908023408_e8d3c7e61c_z.jpg)

Best get on with it then.

Title: Re: Shedbrewed #3
Post by: guest1120 on August 27, 2010, 08:02:23 PM

Excellent report! Keep the pics coming!

Title: Re: Shedbrewed #3
Post by: guest868 on September 05, 2010, 07:12:49 PM

I spent the weekend making the exhaust system up.

(http://i97.photobucket.com/albums/l230/phatphord/bikes/DR_pipe_full.jpg)

Chuffed.

Title: Re: Shedbrewed #3
Post by: themoudie on September 05, 2010, 11:07:46 PM

And so you should be! ;D

Tubes usually become elliptical at best with me!  ???

More often unintentionally 'cobra-hood' like! This has been made a 'feature', by a well known serpent seller.

At least there is progress. Out again today, so no progress again in the workshop. Ride 'Sally' whilst the sun shines and the 'West' was best today!

Toodle pip, Bill.

Title: Re: Shedbrewed #3
Post by: SHimmer45 on June 14, 2011, 12:42:44 PM

hmmmm nice work  ;D