Saturday 31 December 2011

2012 - year of the cowboy boot!

Just dug out my cowboy boots, they are gonna be BIG in 2012!

How do I know? Cos I'm gonna be wear them on the bike till they drop off my feet!

Have a good piss up one and all, time for me to get steamboated!

Wednesday 28 December 2011

Self medicating

I refuse to be ill on my time off, so I'm self medicating with the single barrel JD.

Tuesday 27 December 2011

Scout 741 stroker project for sale

Indian 741 / junior scout stroker project for sale.

As with most projects I have squirrelled away a good hoard of spare parts, and something has to give..

This is a pretty good starting point for a nice racer project, the stroker rods and flywheels are Harley 45, which allows for a tasty 750cc rather than the more doslie 500cc that the stock 741 motor generates.

All the big parts are here to build a bike with, the intention was for a Brit gearbox to be used with this setup..

Anyways, drop me a message at tc@customxs650.com if your interested and want more info and pictures....

Tuesday 20 December 2011

Frame build Day 2

First job of the day for me (no I didnt just stand round all day - I did at least 3 things....) was to clean an old headstock up to use as a guide for today (a new one will be turned up by my sensei at a later date).

I already had chrome bearing cups as can be seen in this picture...



Much measuring was needed to sort the rake of the headstock out, The white pole is the line of the forks, and the red mark where the spindle for the wheel will be. The flat bar on the end of the jig (attached to the bottom of the jig) will be the ground level when all is finished...



To get the flowing lines sorted it was time to get the tube bender out. Toddy has a very impressive bender bolted to the floor of the workshop. Great bit of kit it is too...



Tube was cut to length, then sanded to remove all the crap on the outside of the tube, then it was cleaned with thinners to get it as clean as possible. Toddy informs me that this it ensure that there isnt any crap that would both scratch the tube and damage the formers....

Prior to bending both the tube and the formers were suitably greased up to allow a smooth draw of the curve.

There was much tooing and froing with the tubes over to the engine in the jig throughout the day to get things right.

We started with the bottom of the engine and the big curve that would follow the crankcase.... some thin bar was used to rough the curves...



Straight tube...



and during the bend...



It went slightly over, so with some heat applied with toddys fag lighter he "relived" the bend (if thats the right word?!?)



And into the jig to see how it looked...



Now i missed some photos here, but to give the frame a nice goose neck, and to match the engine another small curve was made to kick back from the generator and then backup to headstock.

This was done loosely on the bender, and looked not bad -  Toddy then refined all the curves with plenty of heat. what a difference it made to the whole look of the tube....



During this process the frame moved a bit in that it wasn't aligned down the center line of what would be the bike. Again heat and tweaking ensued to get it right.

Hopefully this picture will allow it to make a bit more sense...



The ends then had to be trimmed and profiled to meet the angles of the headstock....



and here is the bottom rail completed! another long task to get done, but well worth all the extra effort!



Next up was the top tube. The tank would cover the middle of the tube,so we decided on bending to give the desired angle to interconnect with both the headstock and the bottom tube. 

The tunnel for the tank will have a V shape to sit on top,but the bend will not be visible....





This sportster tank has had the tunnel mod for another bike toddy made, so you see how the bend is not part of the look of the bike...



Final job for the day was to make a brace for the frame. The same level of care and attention was given to making this...



Again, the tank is just to mock up..



and from a different angle..




I'm absolutely stoked with how this is going. I honestly thought this would be a quicker process, but as we all know toddy doesnt do things by halves. Each curve and individual element is carefully thought through (with a fag and a cuppa), and refined until he is happy. 

Hopefully you guys have an idea of the time that goes into a well thought out frame through this.

Unfortunately I have family stuff to do the next couple of days,but we'll keep putting progress of the build up as it goes.

Cheers Toddy - i'm still beaming from ear to ear!

Monday 19 December 2011

45 Frame Build Starts at Toddys

ok, so todays progress.....
The car was laden like santa's sleigh full of parts old and new!
As toddy said, today would involve getting the engine jigged up - I had no idea how long a frame would take to build, so hopefully you can see on here how long it takes....

First up Toddy had to work out how the engine could be mounted onto the jig so that it was lined up with the centre line of the bike. Unlike the Japper engines and BSA engines, the Harley mounts seemed to be a bugger. 2 mounts either side of the engine at different heights...this is the bottom of the engine, and you can see 2 of the mounting holes.



Toddy set about making the mounting plates with locating holes. Lots of measuring and attention to detail with the plates (didnt get any photos, but you'll see them at a later point...)

Many cups of tea and a breakfast delivered to the door and they were all done...



Photos of the important bits!

next up toddy needed to make some supports to go between a recycled saddle for the jig. They needed to be perfectly level,and provide enough height so that Toddy could get the bent tube that will curve around the engine in and out.

Again more measuring and cups of tea...

To get the supports perfectly level toddy cut the box section roughly to size, then used his milling machine to get them perfectly the same height. On top of the supports a bar with corresponding mounting holes was marked and drilled with pinpoint precision.

these box sections were then tacked into place, checking each leg was at 90 degrees after each tack (the heat moved the bars from upright)

Finally for the one side, the top bar was welded on top, again ensuring everything lined up.....

A car jack was used to support the engine while it was connected at one end of the engine....



and the man in action.....



Toddy reckoned a slight twist in the legs, so a metal bar was used to counter the twist slightly.

The engine was tightened on the one side, supported by the jack, and then Toddy could measure the other side (as it was flush to the mount, hence level....)

The same process of cutting and milling struts, plus a top bar was undertaken, then tacked in place with the same level of accuracy.



And then......

One perfectly leveled and centered engine on the Jig.....



Heads on....



how fucking cool is that!!!!!!!!!!!



so that took us from about 9.30 till 5, a few tea breaks (you can rush perfection) and plenty of chat, and me standing about and getting in the way...

Tomorrow we'll start the bending !

Wednesday 7 December 2011

Wheel me

45 wheel arrived after a 2 month delay...
Just picked up a triumph one for the rear as well and some lovely Firestone rubber for them both!

Wednesday 30 November 2011

45 Project

I've been sitting on this frame for a while. Its still over in the states with Mr Bearpaws at the moment, but I'll be getting it shipped shortly. The bike I wanted to base this build on was a Zero bike built by Shinya, and I've found that it was a bike using a VL frame.

I have a set of I beams that can be used with this project, so it looks like I'll use this frame instead of building one with Toddy. It may need a bit of work, I believe there is a dent in the top tube that will need to be sorted, but for a 30's frame its supposed to be in good nick.

I got Bearpaws to put his 45 engine in it, and it fits it a treat!

I absolutely love the castings on this frame, and would love to keep as much as possible showing on the final build....

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i'd love to make a letterbox style tank to fit inbetween the tubes - reminiscent of a 101 indian style....

Saturday 26 November 2011

It lives!!! Mwah-hahahaha!

I haven't been as good at updating the blog recently, basically I got it wired (again) and then it ran once. Couldnt get the bugger going again. Then I've been back out this morning to try a few things that had been suggested to me...

Swapped the ht leads round and It fired up a treat, but it doesn't like coming off the choke. Had to kill it as there was oil once again, but with a pinch of the oil feed pipe nut that seems to have sorted it.
Some white smoke coming from the left hand cylinder, but I guess that's normal for a rebuilt engine...

Still not consistently running. Got it running twice, but still proving to be a right bugger to start. Had to come in as it's absolutely hoofing it down!

The missis heard it, so it's not a dream- I have her proof. It is camera shy though, so no video as she buggered off to the shops when I got it running the second time.

Materials are ordered for the side shelter, so that will be going up next weekend with any luck.

Happy boy today!

Oh, and cheers for the help ogri, you win a chocolate mouse

Crankcase, your a star for offering to come over. I might still hold you to it when I've a cover over the roof to get it running properly.

Got a couple of improvements I'm gonna make:-

the bike pedal has been destroyed with all the kicking over so that needs replacing for something more sturdy

The peatock seal has been eaten by the petrol so that needs fixing.

The splitter in the fuel line is a pain in the arse, and looks a bloody eyesore. I think I'll put a tap for each carb

Kickstand needs to be properly welded on.

Thursday 17 November 2011

Well done me!

As I'm such a good boy, I got these baby's for my custom 45 project. Shaun sorted out a deal for me, and I picked them up this evening.

Yeh, I paid the extra for the box too, but it's super cool!

Wednesday 16 November 2011

Indian junior scout stroker project up for grabs

Thought I'd put the feelers out if anyone was interested in a junior scout stroker project. As with all bikes, parts seem to stack up, so I have a spare basket sitting there. With all I have on and with my Indian waiting to be worked on I can't see me getting round to this one... It's not eating or drinking so I'm not in any rush to get rid, and there may be a few more bits to negotiate along the way...

Basket would consist of:-

Junior scout front frame section (lighter version of a 741 frame which were later  used for racing)
Rear frame section - currently plunger but could be put back to hardtail
Makings of a 750cc stroker 741 scout engine (500cc as stock) including Harley wl flywheels and rods, cases, heads, cylinders etc
Rear wheel
One tank side - right (it's better than none!)
Bars

The loose plan was to emulate Steve's sport scout and run a tele front end, and a Brit gearbox with it...

Could be interested in swaps for something interesting...

Email me if your interested for pictures /more info.

Wednesday 9 November 2011

Repop I beams on order

Gonna be ordering a set of repop I beam springers for the 45 project this week through Shaun.

Can't wait to get them!

Sunday 6 November 2011

45 Mag

Picked up the magneto for my 45 engine this morning!

Got almost everything I need to get started on that bike now, can't wait.

Thursday 27 October 2011

45 time

Plans are being put into motion for the 45 project.

Knocked up an engine stand today, gonna be putting up a shed to build the engine in at the top of the garden that is free from iron filings and the like!








Rain, Rain go away!







Had enough of this bloody rain holding me back with the bike, so I had a word with myself and got out there working on it!

Not so many photos due to the rain but ticked off the list was:-

Fit the new spindle that toddy shortened for me (no more stunt pegs)
Pulled the bike out and cleared all the crap from around it
Turned the bike round to make the wiring easier
Welded on the kickstand (so pleased that's on!)
Installed the Boyer system in the head, and set the timing
Fitted the clutch cable (although it needs adjusting)
Widened the hole in the fakey oil bag
Made up the ht leads and tightened up the spark plugs


Tonight's bollock is that the exhaust clamps didn't appear to fit into the engine!

Need to have another look, but think I'm gonna have to cut them AGAIN!

Fiendishly close to finishing now!

I did have to give into the rain after 3 hours, it was hammering down!

Wednesday 26 October 2011

What goes round comes back around

Been flat out with work, which means no bike time. Got home today after an especially long and shit day, poured myself a hefty glass of bourbon and checked the post.

Ogri from dirty bobbers sent me a load of brass nuts and bolts. I'd sent him a bike light a while back, and he sent some t shirts before that...



I bloody love the camaraderie between the guys I've met with the bikes! Long may the ebb and flow of parts and rusty shit continue!

A top bloke, and this is his blog:-

http://metalflakemormon.blogspot.com/





- Posted using BlogPress from my iPad

Monday 24 October 2011

Oil Tank and Kill Switch

Recalled an old petrol tank that I originally donated to mr bobcat and gave it a clean up with the scotch pad



I intend to use it for both the oil bag and electrics holder by compartmenting it to house the electrics.

I picked up this killer button and surround a while back. It's gotta be a kill switch for this bike. I intend to put a kill switch behind it in the compartment. I turned up this holder for it tonight so I can sink it into the tank



And this is the holder I turned up....



I'll weld the holder flush into the tank once I have worked out how to mount the switch and welded it together to a waterproof seal.

Monday 17 October 2011

Stock Bike Running



Spent a bit of time yesterday getting my stock (ish) xs650 back running. a bit of wiring, and a charge of the battry and it was up and running! Only thing is that it looks like its going next weekend, a mate wants a project, and its just sitting there at the moment, so its time for it to go..


Pretty  gutted as its one of those bikes I had plans for, but there is only so much a guy can do with limited time and space. It will be put to good use with a first time builder close to me, so I guess i'll still be seeing it on a regular basis!

Saturday 15 October 2011

Front end done

Shaun lent me some tools to get the forks back together. I didn't realise that you had to use a threaded section to pull the stantions back up to be held with the yokes.

Unfortunately the tool that Shaun lent me had the wrong thread on it, so it wouldnt screw into the ends of the stantions.



I improvised and turned up some nylon to screw into the stantion.



Worked a treat....





Really pleased with how they are looking!

Also made a quick headlight mount...



Had a nice headlight in the stack, had to scotchbrite it to dull down the chrome, and it's looking ace!



The only issue I have is the front wheel spacing. It's very tight between those skinny forks, and with it being a twin leading / trailing shoe (delete as appropriate) this is about the only place it will sit. This obviously doesnt give me the right angle for the torque arm...