|
SuzukiSavage.com
/cgi-bin/YaBB.pl General Category >> Rubber Side Down! >> el burro pequeño - a scrambler build /cgi-bin/YaBB.pl?num=1420917964 Message started by strang on 01/10/15 at 11:25:50 |
|
Title: el burro pequeño - a scrambler build Post by strang on 01/10/15 at 11:25:50 The tank staring has begun. gt380 |
|
Title: Re: A Scrambler Build Post by strang on 01/10/15 at 11:26:33 gt185 |
|
Title: Re: A Scrambler Build Post by strang on 01/10/15 at 11:27:27 honda not sure what |
|
Title: Re: A Scrambler Build Post by GBG on 01/10/15 at 17:43:10 I vote for the gt380. |
|
Title: Re: A Scrambler Build Post by gizzo on 01/10/15 at 20:30:59 Me too. |
|
Title: Re: A Scrambler Build Post by paulmarshall on 01/10/15 at 22:49:50 I like the 185. I think the 380 dwarfs making the engine look small. |
|
Title: Re: A Scrambler Build Post by GBG on 01/11/15 at 08:16:18 I do agree with Paul, but where's the fun in stopping for gas? |
|
Title: Re: A Scrambler Build Post by Dave on 01/12/15 at 04:09:01 It tried a Honda 360 tank first, and the tunnel for the frame turned out to be really narrow and it would have taken a lot of work. If you are willing to cut the top frame tube and make the dual tubes narrower where they join the single top tube over the engine - you will have a lot more options for what tank to use. I used the GT380 tank on my bike, and I like the look...however the GT185 tank may be a better visual match. A lot of folks recognize that the tank is a Suzuki tank....and they expect the bike to be much older than it is. The tank is a bit tall and wide which makes getting it to fit a lot of work - but I can go 160 miles before I need to switch over to reserve. The only real down side for me is the back of the tank is pretty wide, and most Cafe seats are far narrower than the back of the tank. http://i62.tinypic.com/ws8r2c.jpg http://i60.tinypic.com/adkqhk.jpg http://i57.tinypic.com/11iim0y.jpg It did take a lot of work to make the tank fit on my bike. Because I needed the top fork yoke to clear the top of the tank - I had to heat and pound the bottom of the tank in order to get the tank to sit low. I then had to make a notch for the top of the the engine to clear the tank at the cam chain bump on the head, and I had to move the petcock location back about an inch. I also used the Raptor petcock with the short stem, from the Big Bear quad or something like that. http://i59.tinypic.com/imnho4.jpg http://i57.tinypic.com/30tp20n.jpg http://i57.tinypic.com/oiw22o.jpg |
|
Title: Re: A Scrambler Build Post by Dave on 01/12/15 at 04:59:25 How about using an 8 gallon BMW tank? |
|
Title: Re: A Scrambler Build Post by strang on 02/21/15 at 12:38:30 Ended up going for the GT185 tank. It has a few advantages: - the Suzuki Savage petcock is an exact swap. 8-) - said petcock fits without modification as it clears any obstacles on the left side and sits between engine and choke lever pretty much perfectly. http://i330.photobucket.com/albums/l432/mike_odonovan/petcock.jpg (http://s330.photobucket.com/user/mike_odonovan/media/petcock.jpg.html) It also takes the LS650 front tank rubbers. 8-) Also I wanted to be able to have passengers and therefore wanted a smaller tank length wise so we have little more arse room. Yep the GT185 capacity isn't great but is actually a shade larger than the Ryca tank so I'm sure it will do as a round town bar hopper. Following in others footsteps (Dave's) with slight variations, used the old tank mounting points and the old seat mount to create a holder for the GT tank hook. Works great: http://i330.photobucket.com/albums/l432/mike_odonovan/under%20tank.jpg (http://s330.photobucket.com/user/mike_odonovan/media/under%20tank.jpg.html) |
|
Title: Re: A Scrambler Build Post by strang on 02/21/15 at 12:46:46 mid section just needed at bit of mouse mat to cushion the contact point: |
|
Title: Re: A Scrambler Build Post by strang on 02/21/15 at 12:47:42 welded a nut on each side at the front: |
|
Title: Re: A Scrambler Build Post by strang on 02/21/15 at 12:49:23 bit of threaded rod with a penny washer welded on to give the rubbers a bit more to hang on: |
|
Title: Re: A Scrambler Build Post by strang on 02/21/15 at 12:51:03 voila: http://i330.photobucket.com/albums/l432/mike_odonovan/seat%20support.jpg (http://s330.photobucket.com/user/mike_odonovan/media/seat%20support.jpg.html) |
|
Title: Re: A Scrambler Build Post by strang on 03/01/15 at 11:40:05 Support for rear subframe done. Nuts are welded on the underside so I can bolt the subframe on and off for a while while I sort out mounting brackets for mudguard etc. Much easier to weld on the bench than in situ with my level of skills methinking. http://i330.photobucket.com/albums/l432/mike_odonovan/front%20tank%20mount%20finished.jpg (http://s330.photobucket.com/user/mike_odonovan/media/front%20tank%20mount%20finished.jpg.html) http://i330.photobucket.com/albums/l432/mike_odonovan/mid%20frame%20bolts.jpg (http://s330.photobucket.com/user/mike_odonovan/media/mid%20frame%20bolts.jpg.html) http://i330.photobucket.com/albums/l432/mike_odonovan/front%20frame%20bolts.jpg (http://s330.photobucket.com/user/mike_odonovan/media/front%20frame%20bolts.jpg.html) |
|
Title: Re: A Scrambler Build Post by strang on 03/14/15 at 13:16:06 Mudguard is on. Used these paint tin openers to make tabs. Saved a lot of time and hassle. Love the little things: http://i330.photobucket.com/albums/l432/mike_odonovan/ProDec-Paint-Can-Opener-Painters-Tin-Opener-PCAC001.jpg (http://s330.photobucket.com/user/mike_odonovan/media/ProDec-Paint-Can-Opener-Painters-Tin-Opener-PCAC001.jpg.html) Bend 'em cut 'em weld 'em: http://i330.photobucket.com/albums/l432/mike_odonovan/mudguard.jpg (http://s330.photobucket.com/user/mike_odonovan/media/mudguard.jpg.html) http://i330.photobucket.com/albums/l432/mike_odonovan/mudguard%202.jpg (http://s330.photobucket.com/user/mike_odonovan/media/mudguard%202.jpg.html) As of now: http://i330.photobucket.com/albums/l432/mike_odonovan/whole%20bike.jpg (http://s330.photobucket.com/user/mike_odonovan/media/whole%20bike.jpg.html) |
|
Title: Re: A Scrambler Build Post by justin_o_guy2 on 03/14/15 at 14:59:45 Bravo... predrilled, proper size, just bend, cut and weld... |
|
Title: Re: A Scrambler Build Post by strang on 03/15/15 at 06:06:58 Actually it should be: Strip the galvinised coating, bend 'em, cut 'em, weld 'em. Much more of a pain grinding/wire brushing the galvinised stuff off after you've got a small curved shape. Don't ask me how I know. |
|
Title: Re: A Scrambler Build Post by justin_o_guy2 on 03/15/15 at 06:46:10 I didn't notice the galvanized ... yea,, snot good,, I hold my breath. |
|
Title: Re: A Scrambler Build Post by strang on 04/24/15 at 14:24:16 High Pipe materials: - all 1.5" mild steel 1.5mm wall tube - re-use stock header - 180 bend, 3" bend radius - 35 degree bend - chopper style baffle Tacked up: http://i330.photobucket.com/albums/l432/mike_odonovan/exhaust%201.jpg (http://s330.photobucket.com/user/mike_odonovan/media/exhaust%201.jpg.html) http://i330.photobucket.com/albums/l432/mike_odonovan/exhaust%203.jpg (http://s330.photobucket.com/user/mike_odonovan/media/exhaust%203.jpg.html) http://i330.photobucket.com/albums/l432/mike_odonovan/exhaust%204.jpg (http://s330.photobucket.com/user/mike_odonovan/media/exhaust%204.jpg.html) |
|
Title: Re: A Scrambler Build Post by strang on 04/24/15 at 14:39:50 Got an Suzuki Intruder headlight for free. Same as Savage except has metal shell and different mounting hole spacing. Welded on new mount to make it fit Savage spacing: http://i330.photobucket.com/albums/l432/mike_odonovan/headlight%20bottom.jpg (http://s330.photobucket.com/user/mike_odonovan/media/headlight%20bottom.jpg.html) |
|
Title: Re: A Scrambler Build Post by strang on 05/15/15 at 13:05:49 Reworked a bit of mesh off an Ikea light shade :P : http://i330.photobucket.com/albums/l432/mike_odonovan/headlight%203.jpg (http://s330.photobucket.com/user/mike_odonovan/media/headlight%203.jpg.html) http://i330.photobucket.com/albums/l432/mike_odonovan/headlight%202.jpg (http://s330.photobucket.com/user/mike_odonovan/media/headlight%202.jpg.html) http://i330.photobucket.com/albums/l432/mike_odonovan/headlight%201.jpg (http://s330.photobucket.com/user/mike_odonovan/media/headlight%201.jpg.html) |
|
Title: Re: A Scrambler Build Post by TC on 05/15/15 at 23:56:03 That headlight is dope! |
|
Title: Re: A Scrambler Build Post by strang on 05/16/15 at 12:13:21 thanks TC ;) Bit more done today, easy-peasy electrics panel: http://i330.photobucket.com/albums/l432/mike_odonovan/panels.jpg (http://s330.photobucket.com/user/mike_odonovan/media/panels.jpg.html) seat pan and side panels on: http://i330.photobucket.com/albums/l432/mike_odonovan/seat%20pan.jpg (http://s330.photobucket.com/user/mike_odonovan/media/seat%20pan.jpg.html) |
|
Title: Re: A Scrambler Build Post by justin_o_guy2 on 05/16/15 at 21:39:20 Good to see something of value from Ikea. I went to check one out, didn't dig it, turned around to leave and got told I'd hafta walk all the way through the store to exit. Im not big on turnstiles, not being a COW, and not being allowed to leave by the nearest exit feels a bit pushy to me. Unless that policy change s, I don't think I will be going back. |
|
Title: Re: A Scrambler Build Post by Art Webb on 05/16/15 at 22:18:51 shoulda hopped the turnstyle, what're they gonna do, scold you? ;D nice work on that headlight |
|
Title: Re: A Scrambler Build Post by justin_o_guy2 on 05/16/15 at 23:42:26 My family would have been mortified. They were embarrassed enough at the scene I made..Had I been alone, it would have worked out different. I can't say that there Was a turnstile, I just mentioned I dislike them. They definitely had employees " Guiding the way" , former frustrated and constipated hall monitors from school, no doubt. |
|
Title: Re: A Scrambler Build Post by strang on 05/17/15 at 04:40:17 Yep with you on Ikea, never go there for same reasons even though I have one round the corner from me. I say this grill came from Ikea, but it came to me via a skip (dumpster). I've become a big fan of skips since I started welding - I find the prices and customer service very good. |
|
Title: Re: A Scrambler Build Post by Art Webb on 05/17/15 at 08:01:50 Ah dumpster finds, love em I remember fondly when I lived on the same block with a bicycle shop, much Dumpster diving JOG I probably would have REALLY embarrassed your family lol Unless their employees wanted to physically restrain me, I woulda gone out the door I wanted too "sir, you can't go that way" "Oh no? watch me" ;D |
|
Title: Re: A Scrambler Build Post by strang on 07/21/15 at 13:15:50 seat foam done. bit shabby but hopefully the guy whose gonna sew it can make it look pretty :P http://i330.photobucket.com/albums/l432/mike_odonovan/seat%20foam%202.jpg (http://s330.photobucket.com/user/mike_odonovan/media/seat%20foam%202.jpg.html) http://i330.photobucket.com/albums/l432/mike_odonovan/seat%20foam.jpg (http://s330.photobucket.com/user/mike_odonovan/media/seat%20foam.jpg.html) thinking of leaving the rear fender on the swingarm/bobber style just for a bit of spice - what you recon? |
|
Title: Re: A Scrambler Build Post by Art Webb on 07/21/15 at 21:03:13 A tight to the rear wheel fender wouldn't really go with the scrambler look IMO, but it's your build, not mine there's not much foam on that seat |
|
Title: Re: A Scrambler Build Post by Gary_in_NJ on 07/22/15 at 05:28:56 Thanks for the update. |
|
Title: Re: A Scrambler Build Post by strang on 08/05/15 at 14:51:11 Finally finished the mid-controls and have incorporated a centre stand. My phone was running out of battery so will take some more pics tomorrow but I think you get the general idea. Same as the ryca setup more or less but uses the central engine bolt location and a chunky tab welded onto the frame about 2 inches towards the back. Same type of engine bolt goes through these two chunky tabs - the centre stand pivots on this bolt in the space between the 2 welded tabs. There is also another flat bar going between the two mounting brackets underneath, this provides rigidity and also a brace for the stand when in park position. Centre stand is from a xs650 that I cut up and made to work. Any advice on mounting the spring? I have tacked up 2 tabs but a spring that I tried just couldn't handle the load and unsprung itself. I need one about 55mm for how it's tacked at the moment. It seems the spring needs to expand quite a way when it's in park mode. What type of spring are these called? Anyway it all works well and clears the multiple obstacles within the savage setup. Much better for cramped city parking, much more stable than a side stand, and now I can take my back wheel off (and maybe the front) without a jack. Happy in the end. http://i330.photobucket.com/albums/l432/mike_odonovan/side%20stand.jpg (http://s330.photobucket.com/user/mike_odonovan/media/side%20stand.jpg.html) http://i330.photobucket.com/albums/l432/mike_odonovan/right%20side%20controls.jpg (http://s330.photobucket.com/user/mike_odonovan/media/right%20side%20controls.jpg.html) |
|
Title: Re: A Scrambler Build Post by verslagen1 on 08/05/15 at 15:12:27 4C4B4D5E51583F0 wrote:
How long should the spring be when the stand is up? and down? |
|
Title: Re: A Scrambler Build Post by Dave on 08/05/15 at 15:24:11 I think your spring on the center stand is not going to work. I believe they normally go over center so that they are pulling the stand into the locked position when parked.....and that the length of the spring really doesn't change much in either position. It appears you spring will be half as long when folded up....and that the spring is trying to pull the stand up even when parked. I will see if I can get a photo of the center stand on my bikes. |
|
Title: Re: A Scrambler Build Post by gizzo on 08/05/15 at 15:45:04 And, there's usually a big spring with a smaller spring inside it. So you can have 2 weaker springs instead of stretching the bajeezus out of one tough spring. |
|
Title: Re: A Scrambler Build Post by strang on 08/06/15 at 04:30:36 Yeh will have another go at the spring mounting - just rushed it at the end of the session. Mistake I am yet to heed. Looking at every scoot on the way to work this morning - spring mount needs to be close to the axis of the stand so that spring only stretches a minimal amount. Tonight I'll have another go :) |
|
Title: Re: A Scrambler Build Post by Dave on 08/06/15 at 04:37:25 I found a photo that may help. The spring attachment point on the frame need to be very close to the pivot point for the center stand, the mounting point on the stand can be farther away. When the stand goes down, the spring needs to flop over the center of the pivot point - so that it helps to hold the stand into the upright position. http://i60.tinypic.com/2hrpogg.jpg In order to allow the spring tension to move "over center" when there might be something in the way.....some applications use a curved piece of metal to allow the tension to move around the obstacle. Here is a plate used on a Honda CB750. http://i58.tinypic.com/2udwakn.jpg It looks like you could move your spring to the outside of the stand, and use the footpeg mount to attach a post to hold the spring. It needs to be in a place that is "over center" for the stand in both the up and down positions....so that the springs helps to hold the stand in either position. |
|
Title: Re: A Scrambler Build Post by strang on 08/06/15 at 05:27:23 Yes Dave that's the xs650 stand I used - with a slight trim of the feet, the bottom half is exactly the right width to clear the belt on one side and the tyre on the other. May not work with standard position exhausts though as I think right side foot may get caught up in muffler. I actually bollocked around with angled feet centre stand (fail) but then stumbled on the xs650 one in a box of junk and it fit perfect. The savage doesn't have the cross brace on the frame that could be used as the top mount as on the xs650. I'm gonna have a go at mounting from the right bracket to the side of the right foot tonight and see how I go. I'm new to this fab from scratch shite but I is learnin' loads. Like maybe don't open such a large can next time... ;D Thanks for photos. |
|
Title: Re: A Scrambler Build Post by strang on 08/06/15 at 13:05:16 left side - cut the connecting rod at the RH thread end and re-threaded with die. http://i330.photobucket.com/albums/l432/mike_odonovan/left%20side.jpg (http://s330.photobucket.com/user/mike_odonovan/media/left%20side.jpg.html) |
|
Title: Re: A Scrambler Build Post by FerousBastard on 08/07/15 at 06:13:09 Definetly interesting that centerstand, how much did you have to trim off to get it to fit? |
|
Title: Re: A Scrambler Build Post by strang on 08/08/15 at 03:04:45 I had to cut the top section off and weld on a new section as I mounted it completely differently to the way the xs650 stand was originally. Trimmed the feet just 10mm or so for width, When I take it off next, I will take some comprehensive photos. I cut my hand on the grinder the other day so am a bit hobbled for a few days. Have sorted out decompression lever though, gonna start wiring tomorrow - I wanna take it for a spin by the end of next week :D |
|
Title: Re: A Scrambler Build Post by FerousBastard on 08/08/15 at 05:43:08 Ambitious! Looking forward to seeing the result |
|
Title: Re: A Scrambler Build Post by strang on 08/09/15 at 10:33:10 Started electrics today. New coil position and bracket made from generic bookshelf brackets. http://i330.photobucket.com/albums/l432/mike_odonovan/coil%201.jpg (http://s330.photobucket.com/user/mike_odonovan/media/coil%201.jpg.html) http://i330.photobucket.com/albums/l432/mike_odonovan/coil%202.jpg (http://s330.photobucket.com/user/mike_odonovan/media/coil%202.jpg.html) |
|
Title: Re: A Scrambler Build Post by justin_o_guy2 on 08/09/15 at 10:52:18 I cut my hand on the grinder the other day .. OUCH! Man, that doesn't take long to do. Things what move metal move skin Very efficiently, causing very little wear on IT, ... Nearly Every encounter I've had with the bench grinder has been shallow and seems like the friction cauterized the cut, once I got the radius of the edge ground in,, it didn't bleed near as much as a regular cut like that. You got a hand held grinder, cut off grinder and wire wheel grinder? Torch? I couldn't see the pics of the book case bracket. I'm always happy to see problem solving like that. Tools, shops, Hmmm, Boy, like dropping a woman in a mall.. |
|
Title: Re: A Scrambler Build Post by FerousBastard on 08/09/15 at 10:57:52 36292F2835320333033B29256E5C0 wrote:
Yep, can attest to this. Got a 4cm scar running up my left index finger from an encounter years ago; took all but 0.1 of a second and the grinder didn't even slow down. Hope you weren't as unlucky Strang. |
|
Title: Re: A Scrambler Build Post by strang on 08/09/15 at 15:11:58 Handheld grinder, course flap wheel, "too hot in here to wear safety gloves", one slip, index finger joint is propelled towards the sharp end - recipe for a trip to your local casualty dept. Everything's intact and stitched up, so counting myself lucky. I'm cracking on - with gloves ;) Today I also realized how newbie I was to have the tank sit so low on the frame - I have basically no room for the loom down the centre ::) I messed around for hours today and have rerouted it along the sides, but it's very tight. Gonna look at it again tomorrow, but if I have to - would it be structurally dubious to run it up through the central square pipe? Would need a pretty large hole at the neck end for the handlebar connections to pop through, that's the structural question mark. Anyone done this? |
|
Title: Re: A Scrambler Build Post by Dave on 08/10/15 at 04:24:50 As the bike comes from the factory, the wiring harness runs down the side of the frame, not on top. You won't have much luck running the wiring harness through the center of the square tube - unless you figure a way to get the huge connector down the tube.....or eliminate the large connector for a bunch of little ones. Cutting a big hole in the tube is not a very good idea....as the tube is what holds the bike together! I did run my throttle cable down the inside of the square tube - the Mikuni round slide carb has the trottle cable coming out the top, and the cable needed a long radius to work best.....going through the top tube helped to ease the radius and make the cable work smoother. |
|
Title: Re: A Scrambler Build Post by strang on 08/21/15 at 14:22:55 thanks Dave, wiring is in progress down the sides now. Muffler finished: http://i330.photobucket.com/albums/l432/mike_odonovan/muffler%201.jpg (http://s330.photobucket.com/user/mike_odonovan/media/muffler%201.jpg.html) http://i330.photobucket.com/albums/l432/mike_odonovan/muffler%202.jpg (http://s330.photobucket.com/user/mike_odonovan/media/muffler%202.jpg.html) http://i330.photobucket.com/albums/l432/mike_odonovan/exhaust%204_1.jpg (http://s330.photobucket.com/user/mike_odonovan/media/exhaust%204_1.jpg.html) http://i330.photobucket.com/albums/l432/mike_odonovan/exhaust%203_1.jpg (http://s330.photobucket.com/user/mike_odonovan/media/exhaust%203_1.jpg.html) http://i330.photobucket.com/albums/l432/mike_odonovan/exhaust%201_1.jpg (http://s330.photobucket.com/user/mike_odonovan/media/exhaust%201_1.jpg.html) http://i330.photobucket.com/albums/l432/mike_odonovan/exhaust%205.jpg (http://s330.photobucket.com/user/mike_odonovan/media/exhaust%205.jpg.html) Carefully used the edge of a diminished cutting wheel to buzz off the GT185 tank mounts. Glad I did, plenty of rust having fun underneath: http://i330.photobucket.com/albums/l432/mike_odonovan/tank%201.jpg (http://s330.photobucket.com/user/mike_odonovan/media/tank%201.jpg.html) |
|
Title: Re: A Scrambler Build Post by FerousBastard on 08/22/15 at 01:49:21 That exhaust looks ace, very cool 8-) Will be looking forward to hearing how it sounds. |
|
Title: Re: A Scrambler Build Post by Dave on 08/22/15 at 04:10:34 Did you put some steel or glass wool around the perforated core? That really helps to cut down on the sound (until it burns out). (This will basically be a straight pipe and may be difficult to jet to run smoothly). Or.....did you put a plug in the middle of the core so the exhaust has to pass through the holes to the outer shell and the back into the core on the way through the muffler? (This will be easier to get to run smoothly as the pressure waves will be broken up more). |
|
Title: Re: A Scrambler Build Post by strang on 08/22/15 at 06:32:42 Didn't bother with the packing. Perforated tube has 2 plugs - front one has some holes in it, 2nd plug is intact. Figured this would move gases around quite a bit. I recon it will be tunable and loud, which I'm happy with. |
|
Title: Re: A Scrambler Build Post by Dave on 08/22/15 at 06:40:07 5A5D5B48474E290 wrote:
Having the perforated tube act as a baffle (rather than a resonator), will make the engine run smoother as it will help to cancel the pressure waves. The only thing you have working against you is that the chamber is small......not a lot of room for the pressure pulses to bounce around and lose their energy. It will however be much quieter than anything that just goes straight through. |
|
Title: Re: A Scrambler Build Post by strang on 08/27/15 at 08:34:41 cheers Dave - hopefully it'll be just big enough. re: Flint - I think your asking me? The footpegs are in line with the bottom of the frame, positioned in between the rear motor mounting bolt and the stock muffler mount (both of these locations used as mounting points for plates). I fooked around for ages with a couple of locations and found this was best with sportster handlebars and an upright riding position. I'll endeavour take some pics this weekend with a proper camera; I am aware the picks in this thread so far have been quite dire. |
|
Title: Re: A Scrambler Build Post by Flint on 08/28/15 at 19:23:11 Thanks for the reply Strang, where you have placed the pegs looks about where I would want them. |
|
Title: Re: A Scrambler Build Post by strang on 10/25/15 at 04:20:56 redid passenger handles and combined with indicators. |
|
Title: Re: A Scrambler Build Post by strang on 10/25/15 at 04:21:56 now to painting |
|
Title: Re: A Scrambler Build Post by Gus on 10/25/15 at 11:00:54 I love the direction this build is headed. Nice work and good ideas. Excellent!!! |
|
Title: Re: A Scrambler Build Post by xaman on 10/25/15 at 13:57:26 7B74637E757D2875767E281A0 wrote:
I second that. Nice work! |
|
Title: Re: A Scrambler Build Post by Art Webb on 10/26/15 at 09:49:00 and I third it really cool idea with the signals |
|
Title: Re: A Scrambler Build Post by strang on 10/26/15 at 14:33:13 Thanks. Really appreciate your kind words gentlemen. Keeps me getting down that shed. Going for the stripped look on the tank. Am going to brush on 2 part clear coat. http://i330.photobucket.com/albums/l432/mike_odonovan/tank%201_1.jpg (http://s330.photobucket.com/user/mike_odonovan/media/tank%201_1.jpg.html) http://i330.photobucket.com/albums/l432/mike_odonovan/tank%204a.jpg (http://s330.photobucket.com/user/mike_odonovan/media/tank%204a.jpg.html) I ended up using jb weld as there were 2 pinhole leaks in the badge mount area that I found with a torch. Actually not anything to do with my close shave handy work, just from rust sitting behind the badges. Have now filled with jb weld - was previously thinking of giving the inside of the tank a rinse with phosphoric acid to kill any rust that side. Now I've jumped the gun with the jb weld - is this now out of the question? Anyone know how jb weld and phosphoric acid interact? Will test in the morning but if someone's been there am all ears. |
|
Title: Re: A Scrambler Build Post by Gus on 10/26/15 at 15:51:20 That is a good question. |
|
Title: Re: A Scrambler Build Post by Gus on 10/26/15 at 15:51:43 That is a good question. |
|
Title: Re: A Scrambler Build Post by Dave on 10/26/15 at 17:50:02 I don't believe JB Weld and Phosporic acid with have any problem - but unfortunately JB Weld does not hold up to exposure to gasoline. It will break down over time and get gooey. The best way to fix those pinholes is to clean up the metal - dent them in just slightly with a pick or nail, and solder them using a good flux for steel and solder without flux. |
|
Title: Re: A Scrambler Build Post by strang on 10/27/15 at 03:10:41 I'm going to go the POR15 tank liner route. There are probably more pinhole leaks on the way so hope the POR15 will sort the whole tank. Lost it a bit yesterday as got impatient and was looking for a quick fix to get riding. This build is teaching me patience. |
|
Title: Re: A Scrambler Build Post by Dave on 10/27/15 at 04:04:35 585F594A454C2B0 wrote:
With this E10 ethanol fuel today....just about every steel tank should have some kind of lining applied - especially vintage tanks that have gone through some rusting previously. Once the tank has had some rust inside it is very hard to stop it from rusting again. The POR15 is a good sealer....the Caswell Plating kit is good as well - but does require a warm shop when you use it. If the temperature is too cold it is really thick and hard to make it move around inside the tank. |
|
Title: Re: A Scrambler Build Post by Art Webb on 10/27/15 at 15:30:04 Caswell is good stuff I went on RYCA's website and they do still make the Standard, it's the CS2, with the scrambler being the CS2s, the diff being the high pipe and the dual sport tires Heck, I might do a scrambler, too, I do like acting goofy on dirt roads Gotta get the CC paid up before I do that though |
|
Title: Re: A Scrambler Build Post by strang on 10/28/15 at 04:04:23 I went with por15 as Caswell isn't distributed as widely here so is more expensive. The badge areas seem to be the worst affected areas on the tank by far, rest of the tank looks like just surface rust, the badge area has dimples where the rust has penetrated. These jap badge mount areas are just stretched to make the indent and so are very thin to start with. Dumb. I tried tig welding the hole at first and that was a no go and made the hole bigger, even with the welder on the lowest setting. I managed to weld it up again but it aint pretty. Me dumb. I've now managed to get access to a good propane torch setup so I'm considering doing this: - cutting out the badge mount areas. - cut metal patches to fit the badge areas. - braze on new patches using "fluxed silicon bronze rods": http://www.ebay.co.uk/itm/171952756962?_trksid=p2057872.m2748.l2649&ssPageName=STRK%3AMEBIDX%3AIT - line inside with POR15 sealer. - finish outside with 2k. Does this seem sensible? I don't care about the tank looking slick, ascetically I want the bike to be like the old speedway bikes that me and my cousins used to watch when we were kids in 1970s Australia - so a bit patched up is cool for this build. |
|
Title: Re: A Scrambler Build Post by Dave on 10/28/15 at 05:29:59 Brazing puts a lot of heat on the tank and will result in a lot of warping and grinding. I would cut some thin steel sheet that can be set into the recessed area for the tank badge, you will need the edges to be really clean. (You could also use brass or copper if you wanted that contrast). Then with a acid based flux made for steel - tin the edges with solder. You can then solder in the steel sheet without warping the tank. The tinning can be done with a propane torch - but the final soldering of the joint should be done with an iron, as you can control the heat better. Solder really is a good way to connect steel together.....this metal plate for the relocated petcock is soldered into place. It is really easy once you have the proper flux and solid solder. Acid core can be used - but the acid keeps floating up to the top and is kind of messy. http://i49.tinypic.com/5zmdm8.jpg |
|
Title: Re: A Scrambler Build Post by strang on 10/28/15 at 14:00:45 thanks Dave very helpful as usual. Is this flux ok (I have some already)? http://www.ebay.co.uk/itm/171939397445?_trksid=p2057872.m2749.l2649&ssPageName=STRK%3AMEBIDX%3AIT Was gonna buy this 60/40 solder: http://www.ebay.co.uk/itm/Solder-Wire-Lead-60-40-40-60-High-Grade-Lead-Free-General-Purpose-Plumbing-DIY-/261949834192?var=&hash=item3cfd6d43d0:m:mdPEAya8cm0jDwYLuKph5Nw Here's a video I found of the process. He seems to get good results: https://www.youtube.com/watch?v=watHkrMQQOs |
|
Title: Re: A Scrambler Build Post by Art Webb on 10/29/15 at 20:31:04 Dave has not yet realized that whe next we meet, he will teach me to solder hehehehehe |
|
Title: Re: A Scrambler Build Post by Dave on 10/30/15 at 03:03:41 111610030C05620 wrote:
The flux doesn't look like it is suitable....the listing states: Metals this flux can be used on. Copper, Zinc Coated, Nickel plated, Silver etc. What you want to find is an "acid flux"....not rosin. Do a search in your area and see what you can find. I got mine at Graingers....most likely you will need to go to an industrial supply, really good hardware store, or get it online. My flux is a liquid and I apply it with a Q-tip. I looked at Youtube and was surprised how badly most of the folks are at soldering steel.......most of them to a really sloppy job. With a little practice you can do a much better job than they do in most of those videos. The solder is pulled toward the heat, and a much better job is done if you heat the part and melt the solder by placing it on the heated part.....don't hit the solder with the torch flame or it just melts and drops onto the floor. This guy does a really nice job of soldering....however you aren't going to have to heat up this much of an area. https://www.youtube.com/watch?v=LIkvP55UbxM For the small area/joint you want to do....you won't need nearly that much heat. The cool thing is that it is easy to practice this....some scrap metal, the flux and solder, a torch...and you can practice. You can find good solder at flea markets and yard sales - you want acid core or solid solder (rosin core doesn't work on steel). Solder is not good at filling wide gaps - but it will work on small holes. |
|
Title: Re: A Scrambler Build Post by strang on 10/30/15 at 05:33:57 Forgive me Dave but this tank came up on ebay.com up this morning for $130 and I decided to bite the bullet and pay shipping and charges from the US side of the pond. gt185 NOS tank: http://i330.photobucket.com/albums/l432/mike_odonovan/gt185%20nos%20tank.jpg (http://s330.photobucket.com/user/mike_odonovan/media/gt185%20nos%20tank.jpg.html) I don't have endless time or skills so decided to play safe. |
|
Title: Re: A Scrambler Build Post by strang on 10/30/15 at 13:41:53 Centre stand fully functional - ended up making the spring adjustable. http://i330.photobucket.com/albums/l432/mike_odonovan/finished%20stand.jpg (http://s330.photobucket.com/user/mike_odonovan/media/finished%20stand.jpg.html) http://i330.photobucket.com/albums/l432/mike_odonovan/finished%20stand%202.jpg (http://s330.photobucket.com/user/mike_odonovan/media/finished%20stand%202.jpg.html) |
|
Title: Re: A Scrambler Build Post by Art Webb on 10/31/15 at 12:42:17 Center stand? be still my heart |
|
Title: Re: A Scrambler Build Post by chzeckmate on 11/01/15 at 01:19:20 There's something sort of steampunk about it. Your solution may be overly complicated, but so is a Rolex. I love it! Nicely done! |
|
Title: Re: A Scrambler Build Post by strang on 11/01/15 at 10:02:00 thanks chzeck - I agree on the overkill ;D But I fooked up the position of the second spring tab so many times (!!!) that I just wanted a way that was guaranteed to get the right spring tension. Also now changing the spring isn't a fight, and hopefull I can get some more life out of the spring by giving it more tension further down the road. Save myself a fortune, ha. The xs650 stand that I hacked is a bit on the heavy side I think, I might cut it down a bit. I have the whole thing off the bike and on a table ready to paint so will take some better photos for those interested next time I'm in the garage. |
|
Title: Re: A Scrambler Build Post by chzeckmate on 11/01/15 at 10:08:49 I figured that's why you did that. I thought it was a very clever way to manage that problem. I'm definitely eager to see more. |
|
Title: Re: A Scrambler Build Post by Art Webb on 11/02/15 at 10:10:20 That's one reason I'll do the kit if I do a build, I'd likely NEVER get that right haha The lack of center stands on modern bikes is one thing that really aggravates me Folks who never had a bike with one just can't really appreciate them |
|
Title: Re: A Scrambler Build Post by strang on 11/13/15 at 06:48:46 NOS gt185 tank fell through (flakey ebay seller) and gn250 is a bit too long for my seat, so am crackin' on with me old mucker gt185 tank: Rust seems just surface rust except the badge area so cut that out: http://i330.photobucket.com/albums/l432/mike_odonovan/tank%20side%20hole.jpg (http://s330.photobucket.com/user/mike_odonovan/media/tank%20side%20hole.jpg.html) made some patches and named the bike: http://i330.photobucket.com/albums/l432/mike_odonovan/tank%20patches.jpg (http://s330.photobucket.com/user/mike_odonovan/media/tank%20patches.jpg.html) |
|
Title: Re: el burro pequeño - a scrambler build Post by strang on 11/14/15 at 09:06:35 http://i330.photobucket.com/albums/l432/mike_odonovan/badge%20close_zpsvlkqgly8.jpg (http://s330.photobucket.com/user/mike_odonovan/media/badge%20close_zpsvlkqgly8.jpg.html) http://i330.photobucket.com/albums/l432/mike_odonovan/tank%20badge%20whole_zpsempczqeg.jpg (http://s330.photobucket.com/user/mike_odonovan/media/tank%20badge%20whole_zpsempczqeg.jpg.html) Went ok. Used professional jewelry type propane torch with a large nozzle for a bushy flame. Can get very good control with this setup it seems. I think soldering on a spherical shape is hard for a first go. I did a test on a couple of flat bits and it was dead easy. With the curve of the tank it was much harder; the solder wants to slip around everywhere, or go under the badge area and slip into the tank. Pesky solder. Was pretty worried about this job, so well happy this evening it turn out ok. I went overkill again ;D |
|
Title: Re: el burro pequeño - a scrambler build Post by Dave on 11/15/15 at 04:30:05 I think it really adds to the "Rat Bike" look......good job. And.....soldering a seam like that works much better with an "iron" instead of a torch. Watch for these at yards sales and flea markets. |
|
Title: Re: el burro pequeño - a scrambler build Post by strang on 11/16/15 at 08:47:24 Cheers Dave, I took your advice and started with an electronics soldering iron but it didn't work very well. I see what you really meant now. The bike's look is progressing at one with my skill level |
|
Title: Re: el burro pequeño - a scrambler build Post by Art Webb on 11/16/15 at 09:37:37 I've never seen irons like those, all I have is a plug-in iron |
|
Title: Re: el burro pequeño - a scrambler build Post by Dave on 11/16/15 at 10:23:31 01121417050202600 wrote:
These are the irons they used in shops - or roofers use them when working on copper roofs and gutters. In the shop they often have a small furnace run by gas they put them in.....and when one cools down you throw it back into the furnace and get another one. My neighbor is a roofer and he has a small furnace that uses charcoal to heat the irons on the job site. I heat mine up with a propane torch. |
|
Title: Re: el burro pequeño - a scrambler build Post by Art Webb on 11/17/15 at 15:19:47 nice! |
|
Title: Re: el burro pequeño - a scrambler build Post by Gus on 11/18/15 at 21:08:41 003B3621303C27213A323F20530 wrote:
Dave, I was a telephone cable splicer for the old Bell System early in my career. We used those irons all the time working in man holes. Amazing how long they stay hot. |
|
Title: Re: el burro pequeño - a scrambler build Post by SinglesGoinSteady on 11/18/15 at 21:49:43 Looks pretty rad Strang. I like the tank for sure. The chopped Ryca tank does not hold much. |
|
Title: Re: el burro pequeño - a scrambler build Post by justin_o_guy2 on 11/18/15 at 23:22:26 I have one of those irons.. hangs on my antique tools display. |
|
Title: Re: el burro pequeño - a scrambler build Post by strang on 11/22/15 at 12:38:14 Decided it needed at proper vintage trials hobbled together front mudguard, so I hacked up one I found on ebay: http://i330.photobucket.com/albums/l432/mike_odonovan/scrambler%20mudguard_zpslkvjoems.jpg (http://s330.photobucket.com/user/mike_odonovan/media/scrambler%20mudguard_zpslkvjoems.jpg.html) http://i330.photobucket.com/albums/l432/mike_odonovan/mudguard%202_zpsrg8j8kqq.jpg (http://s330.photobucket.com/user/mike_odonovan/media/mudguard%202_zpsrg8j8kqq.jpg.html) |
|
Title: Re: el burro pequeño - a scrambler build Post by Art Webb on 11/23/15 at 10:48:25 Perfect |
|
Title: Re: el burro pequeño - a scrambler build Post by strang on 11/28/15 at 13:55:37 SinglesGoinSteady wrote on 11/18/15 at 21:49:43: Looks pretty rad Strang. I like the tank for sure. The chopped Ryca tank does not hold much. The gt185 tank I'm using holds only a touch more than the Ryca (stock 10.5 ltrs / Ryca = 9.5 ltrs / GT185 =9.8 ltrs) - for me a big tank capacity isn't a priority as even in Spain, which is the most barren place I have done any riding, there is a gas station in each town and they are only 50miles inbetween max. Anyway I like stopping for gas = piss, snack, drink and maybe a chat with da locals. welded on a saddlebag support and used a number plate to stop any bag wandering into the spokes: http://i330.photobucket.com/albums/l432/mike_odonovan/rear%20number_zpshjacjihg.jpg (http://s330.photobucket.com/user/mike_odonovan/media/rear%20number_zpshjacjihg.jpg.html) Centre stand is great. Here's a couple of photos: http://i330.photobucket.com/albums/l432/mike_odonovan/centre%20stand%203_zpsga0ycewo.jpg (http://s330.photobucket.com/user/mike_odonovan/media/centre%20stand%203_zpsga0ycewo.jpg.html) http://i330.photobucket.com/albums/l432/mike_odonovan/centre%20stand%202_zpstklmgomi.jpg (http://s330.photobucket.com/user/mike_odonovan/media/centre%20stand%202_zpstklmgomi.jpg.html) Went all out this week and got her on the road, quick shot before it started raining, ahh England: http://i330.photobucket.com/albums/l432/mike_odonovan/on%20street%202_zpshvoohlss.jpg (http://s330.photobucket.com/user/mike_odonovan/media/on%20street%202_zpshvoohlss.jpg.html) http://i330.photobucket.com/albums/l432/mike_odonovan/on%20street%201_zpsbyrdtwj9.jpg (http://s330.photobucket.com/user/mike_odonovan/media/on%20street%201_zpsbyrdtwj9.jpg.html) Still loads of tidying up to do (seat covering, lithium iron battery and box, hiding wiring etc etc.) but big smiles happening so far. |
|
Title: Re: el burro pequeño - a scrambler build Post by Art Webb on 11/29/15 at 09:11:16 man that is sweet! |
|
Title: Re: el burro pequeño - a scrambler build Post by strang on 11/29/15 at 10:56:24 Cheers Art :D |
|
Title: Re: el burro pequeño - a scrambler build Post by Gus on 11/29/15 at 20:21:30 I agree with Art;'even roughed in it looks good! Keep up the good work. |
|
Title: Re: el burro pequeño - a scrambler build Post by Dave on 11/30/15 at 03:41:12 Strang: It looks great! When you get a new rear tire - try the 130/90-15 size and it may reduce the cruiser rear tire look a bit. Get the pulley cover back on the engine....I would hate to see your pant leg get caught in there. I had my shoe come untied and the lace went into the slots on the stock cover.....and it yanked my foot up off the peg before the lace broke - I would hate to think what might happen if your pant leg caught caught. When you cover your seat.....consider putting one of those straps across the middle (like for a passenger hand strap). Even though a rider never may use it - I think it helps to visually brake up the long flat seat and make it look better. |
|
Title: Re: el burro pequeño - a scrambler build Post by strang on 12/01/15 at 14:24:23 cheers Dave got loads to do yet: respoke rear wheel to 17" lithium iron battery and box tidy wiring clean up engine side cover powdercoat headlight. get seat covered. and yes sort the pulley cover. but was nice to go round the block a few times before the winter sets in proper and check the ergonomics which are now perfect for me. |
|
Title: Re: el burro pequeño - a scrambler build Post by Dave on 12/01/15 at 15:24:43 The 17" rear wheel will give you a lot more tire options, and will look more appropriate on a Scrambler. And as an added bonus it makes it far easier to access the valve when checking air in the tire. It is a shame when winter arrives in some ways. It does allow time to tear the bike down for major changes without missing any rides - but it sure does make the winter seem long! |
|
Title: Re: el burro pequeño - a scrambler build Post by DesertRat on 04/16/16 at 19:37:06 I need more details on the center stand, how/where is it mounted to the bike? |
|
SuzukiSavage.com » Powered by YaBB 2.2! YaBB © 2000-2007. All Rights Reserved. |