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SuzukiSavage.com
/cgi-bin/YaBB.pl General Category >> Rubber Side Down! >> Bike Build: Junkyard Dog /cgi-bin/YaBB.pl?num=1546135783 Message started by playhard67 on 12/29/18 at 18:09:43 |
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Title: Bike Build: Junkyard Dog Post by playhard67 on 12/29/18 at 18:09:43 A little back history. I'm 57 and have been riding since I was 5. Currently I have a Bagger and a Dual Sport that I ride. Back in 2007, I bought my 17 year old son his first street bike, a 2005 Suzuki Boulevard S40 (he previously had a dirt bike, a 1973 Yamaha DT125 which I still have). In 2009, he got a larger bike and my wife got her license and she started riding the Suzuki. After 2 years, she lost interest in actually riding her own bike and preferred to be a passenger on mine. Since 2011, the Suzuki sat in my shed collecting dust. In 2016 my son was killed in a plane crash. In September 2018, I decided I wanted to keep my sons first street bike. But, really wasn't interested in it as a cruiser. If I am told what is wrong with a bike, I can remove and replace most items. But, don't ask me to rebuild a carb...it's beyond my scope. After 7 years in my shed, the Suzuki obviously wouldn't start and I knew enough that the carb would need to be rebuilt at a minimum. I dropped the bike off at a shop. After 7 weeks, I got the bike back and it runs great. Here's what it looked like the day I got it back from the shop. This is my first picture post...I hope it works. http://https://i.imgur.com/UMrrGzCl.jpg I've decided i'm going to build a bobber using old "junk" parts I've purchased in various places. I think my son would approve. |
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Title: Re: Bike Build: Junkyard Dog Post by GOF on 12/29/18 at 18:19:46 Very sorry about your boy. I can't even imagine that pain. I'm riding the Savage I inherited from my dad. Looking forward to see where you go with this project. There are some members here that have done similar with their rides. I'm sure they can help you out. |
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Title: Re: Bike Build: Junkyard Dog Post by playhard67 on 12/29/18 at 18:19:47 Currently, the vision for the bike is a bobber, with wide whitewall tires, old "junk" parts, and z bar handlebars. It will be built like a rat bike. Paint will be primer black and I will have some prominent parts that will be purple (one of my sons favorite colors). Here's a teaser for what I mean about "junk" parts. http://https://i.imgur.com/eQSbmOxl.jpg I got this brake light off ebay. Don't know much about it...except it is old. I will convert this to LED. |
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Title: Re: Bike Build: Junkyard Dog Post by GOF on 12/29/18 at 18:23:34 Not junk. Repurposed! Kinda looks like something off a school bus. How big around is it? |
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Title: Re: Bike Build: Junkyard Dog Post by playhard67 on 12/29/18 at 18:26:20 I spent several hours on Dec 24th removing parts.... http://https://i.imgur.com/OnKaFXwl.jpg http://https://i.imgur.com/k3NC7XGl.jpg Here's what the bike looked like afterwards... http://https://i.imgur.com/lUJ07hrl.jpg The seat was purchased through craigslist and is also old. The seat is currently just sitting there, not attached. |
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Title: Re: Bike Build: Junkyard Dog Post by playhard67 on 12/29/18 at 18:30:38 On December 27th, I spent another couple hours removing parts... http://https://i.imgur.com/SXm1llIl.jpg This is how the bike looks today... http://https://i.imgur.com/5iez17ll.jpg My plan is to have this build complete by this summer. Stay tuned. |
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Title: Re: Bike Build: Junkyard Dog Post by playhard67 on 12/29/18 at 18:34:47 4F474E080 wrote:
Repurposed Dog doesn't sound as good as junkyard dog. ;D The total diameter of the stop light is approx. 6 inches. The lens is approx. 4.5 inches. |
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Title: Re: Bike Build: Junkyard Dog Post by GOF on 12/30/18 at 08:08:39 You are correct. Not the same ring. It really does look like a school bus stop light to me. But a really old one. Will make a cool stop light for a 'junkyard dog' build. |
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Title: Re: Bike Build: Junkyard Dog Post by Demin on 01/01/19 at 08:31:25 To mount the seat.Get a universal seat hinge kit.It will bolt to the original rear tank mount. |
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Title: Re: Bike Build: Junkyard Dog Post by Demin on 01/01/19 at 08:32:20 One of my first Savage builds.... |
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Title: Re: Bike Build: Junkyard Dog Post by playhard67 on 01/01/19 at 17:35:05 Thanks Demin, I'll look for that universal kit. Your first build looks great. Do you recall the tires? Did you like them? I'm looking to get wide whitewalls like those. |
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Title: Re: Bike Build: Junkyard Dog Post by playhard67 on 01/02/19 at 15:45:53 Removed a couple more parts yesterday.... http://https://i.imgur.com/QWEgynMl.jpg airbox, battery case, horn. I plan to use a K&N cone style air filter. I have ordered an Antigravity AG-801 battery and plan to install it at the small ledge behind the frame at the bottom. Here's what it looks like now http://https://i.imgur.com/UEJQUXQl.jpg I need to now work on the wire management to open up the center space. I think I will install most of the electronics under the seat and put on some fabricated side panels to hide them. |
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Title: Re: Bike Build: Junkyard Dog Post by playhard67 on 01/02/19 at 16:00:41 Some questions I have...perhaps someone can help me 1. How do the rear foot pegs get removed? I have the Clymer manual and didn't see anything in there. I fitted a wrench to them and tried to remove...the wrench turned not more than 1/4 turn, then I hit major resistance. I didn't want to break them. 2. I'm looking for suggestions on wide whitewall tires? 3. I'm looking for a rear fender that will hug the standard rear tire (minimal space between tire and fender) and end basically straight up from the rear axle or maybe 10 to 15 degress farther past the axle. Any suggestions? 4. I'd like to replace my handlebars with a 10" Z Bar. Anyone have recommendations on where I can get extended replacement cables and specifically what part numbers or bike model... ? Thanks for your help!! There's a wealth of knowledge on here. |
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Title: Re: Bike Build: Junkyard Dog Post by justin_o_guy2 on 01/02/19 at 20:05:42 General consensus is Rear wheel removal required to get the rear pegs out. I'm wondering if shortening the Allen wrench would work out. |
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Title: Re: Bike Build: Junkyard Dog Post by playhard67 on 01/03/19 at 15:40:27 ooops.... I guess I should have looked when I had the wheel off. No problem, I'll take it off again. Thanks. |
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Title: Re: Bike Build: Junkyard Dog Post by Eegore on 01/04/19 at 05:55:18 " I'm looking for a rear fender that will hug the standard rear tire (minimal space between tire and fender) and end basically straight up from the rear axle or maybe 10 to 15 degress farther past the axle. Any suggestions?" Blue Collar bobbers makes a custom fender for this bike and you could modify it to stop where you want. I think since this part is made specifically for the Savage it is most likely the best fit. Call them and they will most likely sell you only the parts you need if you do not want an entire kit. 4. I'd like to replace my handlebars with a 10" Z Bar. Anyone have recommendations on where I can get extended replacement cables and specifically what part numbers or bike model... ?" I've seen people here place 10" bars without modifying the cables: "1” bars. You can put 10” zbars on if you had the clubman bars not the drag bars on your stock model. I had to grind the set pin on the hand controls that set it the stock bars down." Local shops in my area make custom cables pretty cheap but that may be unique to my area. Lancer has connections on good Barnett cables, I had the wrong ends on mine and threw them out but from what I saw they were very good quality. |
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Title: Re: Bike Build: Junkyard Dog Post by playhard67 on 01/04/19 at 13:50:30 Thanks Eegore. I saw the Blue Collar Bobbers rear fenders, but it looked like you could only buy it as a kit. I don't need the kit. But, I will call them and see if they will sell only the rear fender by itself. Thanks for the suggestion. However, at this point I am having a very hard time finding a rear tire that is a wide whitewall in a 15" size. I really want the wide whitewall, so i'll keep looking for it and want to hold off on the fender until I have the tire in my hands. |
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Title: Re: Bike Build: Junkyard Dog Post by playhard67 on 01/04/19 at 15:43:21 Has anyone done a 16" rim swap for the rear wheel? Any recommendation on what 16" wheel I can use for an easy swap with minor modifications? I've contacted many tire distributors and some manufacturers looking for wide whitewall (WWW) tires in the following "recommended" sizes: 130/90-15 140/90-15 140/80-15 I have found the tire in a 150/90-15 but, have read that there may be rubbing issues with this. Although, some have used the tire with no problems. I will be adding a custom rear fender, so if I get this larger tire I will make sure no bolts, etc will rub it. If I can't find a 16" wheel that is an easy swap and allows me to get a WWW tire that will fit in the 28" diameter, then I'm going to try the 150/90-15 (Metzeler ME880) |
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Title: Re: Bike Build: Junkyard Dog Post by Eegore on 01/04/19 at 16:38:08 I've never seen a wide whitewall in anything but the 150/90-15 but I didn't have my guy look more than a month or so for them. |
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Title: Re: Bike Build: Junkyard Dog Post by batman on 01/04/19 at 17:47:17 A 150/90 15 tire is questionable to begin with,not due to fender size, but due to the crossbrace in the forward part of the swingarm (clearance) and with the tire pushed rearward may make the drive belt to tight .The avg tire may or may not fit,but ME 880 being a high mileage tire with much deeper tread will likely not without cutting away some of the crossbrace, 16, 17, 18 inch rims may require the same treatment be done to the swingarm. |
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Title: Re: Bike Build: Junkyard Dog Post by GOF on 01/04/19 at 19:23:50 I saw someone's post elsewhere that said they painted the sidewall with white flex seal. Looked good in the pictures. But that's about all I know. The other thing recommended in that thread where "port-o-walls". I remember putting these on cars in my dad's shop 40 odd years ago. Worked ok then. But no idea how they would work on a motorcycle. If they hold up like they did on cars you could even reuse them on new tires. Sometimes called porterwalls or portawalls or some variation. https://www.mooneyesusa.com/product-p/ww14.htm?fbclid=IwAR2e8jX8ycwqWzDahYPXFSW4vys9XPKbP--CMZkHX4jB1AibYSvUaazq2jU |
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Title: Re: Bike Build: Junkyard Dog Post by playhard67 on 01/05/19 at 05:24:14 Those are both good ideas. I'm still trying to hold out for a whitewall tire option, but may have to resort to one of those. Thanks. |
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Title: Re: Bike Build: Junkyard Dog Post by playhard67 on 01/06/19 at 07:50:08 I'm not a machinist, by any means. The Junkyard Dog will be a basic build using old parts. Spent a bit of time yesterday working on the rear blinkers mount. Started with three-quarter inch square stock. http://https://i.imgur.com/S4Pjrzul.jpg http://https://i.imgur.com/x0TTDJwl.jpg Cut out an access hole for the nut http://https://i.imgur.com/MTDRozWl.jpg Test fit the bar. I will be using two mounting points that were previously used for the stock fender. I looked at the thickness of the stock fender at the mounting point, and I believe this bar is no thicker than that point. I need to figure out the width of the bar (location of turn signals), then I'll build the other side. After bending down the tab, I'll be welding the corners. http://https://i.imgur.com/geZvf3el.jpg The rear turn signals are vintage Arrow KD 575 Turn Signals. I'll be converting the standard bulbs to LED. |
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Title: Re: Bike Build: Junkyard Dog Post by justin_o_guy2 on 01/06/19 at 13:29:14 What year model is the drill press? Early seventies? |
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Title: Re: Bike Build: Junkyard Dog Post by playhard67 on 01/06/19 at 14:51:49 This is my buddies drill press I borrowed. He inherited it from his deceased father who would be in his late 80's. The model is: 113.213830. I'm not sure of the age, but i'd say the 70's is a good guess. |
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Title: Re: Bike Build: Junkyard Dog Post by playhard67 on 01/11/19 at 16:43:37 I have decided to increase my rear tire from the stock 15" rim to a 16" rim using my stock hub. I've ordered the rim and spokes from Buchanan Spokes. Yes, I am doing this so I can get real wide whitewall tires... instead of painted whitewalls or Portawall whitewalls. I plan to get a 130/90-16 WWW rear tire. The manufacturer lists the Outside Diameter as 25.2 inches. I read elsewhere that the tires need to be under 26 inches. Is the .8 inches of space enough of a gap? Or should I trim the swingarm a bit? and if so, how much should I trim the swingarm? |
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Title: Re: Bike Build: Junkyard Dog Post by batman on 01/11/19 at 19:12:45 You shouldn't need to do anything to the swingarm using that size tire. |
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Title: Re: Bike Build: Junkyard Dog Post by WunGun on 01/12/19 at 02:11:00 I like those old turn signals and will be curious about how they turn out on the bike. |
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Title: Re: Bike Build: Junkyard Dog Post by playhard67 on 01/13/19 at 18:09:21 Mocked up a temporary mounting plate for my "new" headlight. I'll get a metal mount fabricated. Headlight comparison against the stock headlight http://https://i.imgur.com/DRbyYzkl.jpg Mounted on the bike http://https://i.imgur.com/kChJnYGl.jpg Front View http://https://i.imgur.com/RX1FVrll.jpg |
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Title: Re: Bike Build: Junkyard Dog Post by playhard67 on 01/13/19 at 18:13:31 painted my turn signal lenses (they were clear) with transluscent paint http://https://i.imgur.com/Y7IChXvl.jpg Turn signals http://https://i.imgur.com/2KAvAbpl.jpg Mounted http://https://i.imgur.com/vFv4R1pl.jpg http://https://i.imgur.com/xXoYlC0l.jpg |
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Title: Re: Bike Build: Junkyard Dog Post by playhard67 on 01/13/19 at 18:15:21 Mounted Air Horn. Maybe i'll be able to wake up the cagers! http://https://i.imgur.com/FYCFw12l.jpg |
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Title: Re: Bike Build: Junkyard Dog Post by playhard67 on 01/13/19 at 18:19:47 fabricated a metal plate that will be under the seat and allow me to mount all electronics onto the plate. I will fabricate a second plate that will follow the bottom of the seat, then bend down and cover all electronics. cardboard mockup http://https://i.imgur.com/Y6jL8Xil.jpg test fit. used 16 guage metal. http://https://i.imgur.com/rBi4LR9l.jpg holes drilled and cut to allow the wiring and components above the plate http://https://i.imgur.com/FENgNIvl.jpg painted http://https://i.imgur.com/Qicppl7l.jpg |
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Title: Re: Bike Build: Junkyard Dog Post by playhard67 on 01/13/19 at 18:21:55 Wiring and components routed above the plate. This is only a test fit. But, I was able to get all wiring out of the center of the bike. Looks Great. I need to fabricate a longer positive battery cable to get down under the bike (see the antigravity battery there). I'll make a metal box to safeguard the battery. http://https://i.imgur.com/ak8oTeQl.jpg |
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Title: Re: Bike Build: Junkyard Dog Post by playhard67 on 01/19/19 at 17:13:33 configured a new air intake using 2 inch PVC http://https://i.imgur.com/1rrFKLOl.jpg http://https://i.imgur.com/nfGmGAwl.jpg |
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Title: Re: Bike Build: Junkyard Dog Post by batman on 01/20/19 at 12:46:24 With the filter hanging out like that .you better pray for sunny weather. |
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Title: Re: Bike Build: Junkyard Dog Post by playhard67 on 01/20/19 at 13:22:12 I've ridden my Harley 70K Miles in all kinds of weather, with a K&N cone hanging out, including torrential downpours and have had problems only once. I'll be fine. |
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Title: Re: Bike Build: Junkyard Dog Post by playhard67 on 01/20/19 at 13:25:40 Worked on my rear turn signals. Converted them to LED. I'll add the resistors under the seat. http://https://i.imgur.com/npiLG80l.jpg http://https://i.imgur.com/AprdGtRl.jpg http://https://i.imgur.com/nsjgZoZl.jpg |
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Title: Re: Bike Build: Junkyard Dog Post by Armen on 01/20/19 at 18:18:26 Cool. Instead of resistors, you can use an electronic turn signal flasher that doesn't care about load. Only issue is if you have a single turn signal indicator light in your speedo, then you have to throw a diode or two in the mix. |
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Title: Re: Bike Build: Junkyard Dog Post by playhard67 on 01/23/19 at 18:10:32 I saw someone had done that (you perhaps). Anyway, I already have the resistors. |
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Title: Re: Bike Build: Junkyard Dog Post by playhard67 on 01/23/19 at 18:15:49 Laced up my new 16 inch rear rim from Buchanan Spokes. Mated the rim to the original hub from the stock 15 inch rim. I'll be paying someone to true the rim. http://https://i.imgur.com/f9RpqMsl.jpg Original stock rim and hub prior to disassembly and the new 16 inch rim. http://https://i.imgur.com/RNV9Vkzl.jpg Old rim and spokes http://https://i.imgur.com/nCvTmYDl.jpg New 16 inch rim, hub, and spokes http://https://i.imgur.com/JkSRiCnl.jpg |
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Title: Re: Bike Build: Junkyard Dog Post by playhard67 on 01/24/19 at 08:23:52 Test fit the tire on the rim and the whole thing on the bike. The tire is a 130/90-16. has plenty of free space at the swing arm, no need to cut it up. http://https://i.imgur.com/tVTNcWml.jpg |
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Title: Re: Bike Build: Junkyard Dog Post by justin_o_guy2 on 01/24/19 at 10:08:16 Would you tell me about the seat? Where you got it, how it sits, what it cost? |
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Title: Re: Bike Build: Junkyard Dog Post by playhard67 on 01/24/19 at 13:04:39 Trying to keep with the theme "Junkyard" Dog, most of the parts I have bought used online. Mostly eBay. But, the seat, I purchased through Facebook Marketplace. I have not ridden with the seat in place, so I cannot offer how comfortable it is; but the seat is very firm. I wanted something different than what can be purchased at Ryca or other traditional online resellers. I am still trying to figure out how best to attach the seat in the rear, given that I will be making a cover to hide the electronics and wiring which will be under the seat. Here are some pics. There is a label showing who made the seat - Jeffrey Phipps. I have no idea how old the seat is. I paid $75.00 for it. http://https://i.imgur.com/Euh3TyPl.jpg http://https://i.imgur.com/Frg8dCZl.jpg?1 The guy who sold it to me duped me. The above two pics are what he posted for sale. The picture below was taken by me after I bought it, and I sent him the pic complaining about his dishonesty. He didn't budge. http://https://i.imgur.com/M9sC5X2l.jpg?1 So, I have purchased some Black Dye, Reducer, and Resolene to dye the sides of the seat Black...like the seat in the pic below. http://https://i.imgur.com/qa3bsCPl.jpg |
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Title: Re: Bike Build: Junkyard Dog Post by justin_o_guy2 on 01/24/19 at 15:44:48 Thanks, I found the guy. Florida. |
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Title: Re: Bike Build: Junkyard Dog Post by playhard67 on 01/24/19 at 17:51:14 just to be clear, I did not buy mine from Jeffrey Phipps. He was not the guy that duped me. I bought the seat from some guy in PA. I looked on Phipps website...looks like he does awesome work. |
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Title: Re: Bike Build: Junkyard Dog Post by justin_o_guy2 on 01/24/19 at 23:48:37 I understood, but it's better to be clear than risk it. |
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Title: Re: Bike Build: Junkyard Dog Post by Hiko on 01/25/19 at 00:45:37 Making the edges black will improve it a lot IMHO |
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Title: Re: Bike Build: Junkyard Dog Post by playhard67 on 02/04/19 at 17:51:05 I think I finally got my electronics set up the way I like it..... only took three different configurations. Mounted between the rear frame rails using two original fender mounts. Leaves the center of the bike wide open. http://https://i.imgur.com/8dbcuTvl.jpg http://https://i.imgur.com/PTMGZd9l.jpg http://https://i.imgur.com/EI3XeJfl.jpg http://https://i.imgur.com/PvXxHOsl.jpg |
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Title: Re: Bike Build: Junkyard Dog Post by batman on 02/05/19 at 22:27:49 I think I would have extended the base of the plate and used the old battery box mounting bolts to better secure the base , rather than wire ties ,that are subject to snap ,due to wind pressure or vibration ,and bolted the rectifier tight to the plate for the same reasons and to shed more of it's heat. |
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Title: Re: Bike Build: Junkyard Dog Post by playhard67 on 02/06/19 at 07:12:28 Batman, I wasn't sure if I bolted the rectifier directly to the plate and allowed the heat to disperse through the metal... would it make the plate too hot for the other components on the other side of the plate? I don't know how much heat it will dissipate. I didn't think about those bolts for mounting the bottom of the plate (that's a great idea), because I am already using those 4 bolts for another purpose. But, there is really no reason why I can't use those bolts for both. Hmmmm..... Thanks for the suggestions. |
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Title: Re: Bike Build: Junkyard Dog Post by batman on 02/06/19 at 08:15:14 Seeing how the plate is exposed to the air ,I doubt it would hold enough heat to damage any of the other components . I would be worried that the rectifier ,spaced out from the plate may vibrate(over time) enough to damage it's mounting points, as the back of it is not solid metal, but more like a frame work, with ears on each end that the mounting bolts pass through. Suzuki created a flat surface ,built into the fender for a reason (I believe) ,they could have chosen to mount it as you have it would have been much easier /cheaper ,but they didn't. (that should tell us something) |
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Title: Re: Bike Build: Junkyard Dog Post by ZSteele on 02/06/19 at 09:14:37 In the last photo the little pod filter is on the breather hose correct? If so shouldn't it ideally be pointed up? I'm fixing to replace my airbox with one as well. Edit: Also! Have you fired her up? I'm curious how it sounds with that absolutely huge filter. I know mine got noticeably louder with the pod filter versus the standard airbox. |
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Title: Re: Bike Build: Junkyard Dog Post by playhard67 on 02/06/19 at 13:02:19 Batman, I'll make the change to the rectifier and keep an eye on the plate for overheating. However, I think I am going to switch the plastic zip tie with a metal hose clamp to hold the plate down at the bottom.... see how that works for me. If it looks like it is coming loose, I will make the change to the metal plate to utilize the battery mounting bolts. ZSteele, I have seen other bikes on this forum with the small pod filter mounted as I have it. I cannot tell you if this is correct or not. No, I have not fired it up. It will be several months before I start it. The gas tank is off and will have work done to it, then painted. Plus, I am planning to enlarge the exhaust port and fabricate a larger diameter custom exhaust. Once I do that, I will fire it up when I am prepared to have my carb rejetted for the expected increased air input and exhaust |
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Title: Re: Bike Build: Junkyard Dog Post by ZSteele on 02/06/19 at 14:57:21 Looking forward to the day, bike looks great! |
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Title: Re: Bike Build: Junkyard Dog Post by batman on 02/06/19 at 19:44:20 Zsteele, The hose is arched going over the top of the motor for a good reason, the tube breaths in and out , when the piston moves down it relieves some of the air pressure under it ,in the power and intake strokes ,helping the motor to use less power. In the process the air carries oil fumes and mist , water vapor and possibly gas vapors.( gas and water vaporize at 125 & 89 F -oil temper in the bottom of the motor runs at least 270F) The heavier oil mist collects on a screen just inside the head ,the oil fumes , water and gas vapors pass down and out the hose. and when the piston moves up in the compression and exhaust, this(good) oil on the screen is carried back into the motor. If you point the filter upward ,the vapors (oil pollutants which could cool and condense ) would also return to the motor. water and gas make poor lubricant . So would the dust in the outside air carried in when the piston is moving up thus the need to filter it . |
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Title: Re: Bike Build: Junkyard Dog Post by playhard67 on 02/10/19 at 14:33:37 Got some work in this weekend.... Used 1 1/2" angle iron to mount my TC Bros rear fender to the swing arm. Welded the angle iron to the swingarm. http://https://i.imgur.com/OTiVhwkl.jpg Cut small pieces of 1/2" thick wood and taped to the inside of the fender to use as a spacer between the tire and fender. http://https://i.imgur.com/XIZ9e7fl.jpg Cut the fender http://https://i.imgur.com/2m62ARCl.jpg Took a stock TC Bros sissy bar and made some modifications using an oxy-acetylene torch and arc welder http://https://i.imgur.com/Uu7VrG2l.jpg Welded tabs to both sides of the swing arm http://https://i.imgur.com/lG3JnBvl.jpg Installed http://https://i.imgur.com/FOc8GMfl.jpg http://https://i.imgur.com/gclpIUDl.jpg PS: the rear of the seat isn't mounted yet http://https://i.imgur.com/ZPw9GFzl.jpg |
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Title: Re: Bike Build: Junkyard Dog Post by playhard67 on 02/16/19 at 09:18:41 Finally got around to the seat. I purchased it through Facebook Marketplace, and the seller hid the fact that there was writing on the back of the seat when he listed it, and I bought it. Oh well..... ended up dying the leather edges black to hide the lettering. http://https://i.imgur.com/XReGWe5l.jpg http://https://i.imgur.com/QiicUvOl.jpg Cut the Pro Dye 50/50 with the Dye Reducer. Ended up putting on three coats. Will treat the entire seat with the Resolene tomorrow. http://https://i.imgur.com/DzL1Yujl.jpg Finished with the Dye. http://https://i.imgur.com/PKmXge4l.jpg |
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Title: Re: Bike Build: Junkyard Dog Post by DieselBob on 02/16/19 at 13:19:08 Great solution on the seat. And no one will ever know. Looks like you're having fun and moving things along a nice brisk pace. Keep it up! |
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Title: Re: Bike Build: Junkyard Dog Post by playhard67 on 02/18/19 at 17:28:49 I've been going back and forth on the exhaust. I thought I was going to enlarge the port and make a custom header/exhaust. But, I've been reading on here that the best results are with a Dyna Muffler. Are there certain (Dyna) years I should be looking for? Should I stick with an actual OEM Harley Dyna muffler..or look for aftermarket mufflers that fit a Dyna? Any help is appreciated. Thanks. |
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Title: Re: Bike Build: Junkyard Dog Post by playhard67 on 02/18/19 at 18:12:05 OK, I found Serowbot's thread from 2011. I ordered a Dyna muffler - P/N 65747-94 off ebay. |
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Title: Re: Bike Build: Junkyard Dog Post by playhard67 on 02/24/19 at 13:56:16 almost done fabricating... Added $3.00 flea market ape hangers. With the 16 inch apehangers...needed to extend my wiring http://https://i.imgur.com/BEtqFExl.jpg extended by 12 inches http://https://i.imgur.com/pDmWCyyl.jpg Headlight bracket / extension was required since the headlight is so big http://https://i.imgur.com/9kjgoUPl.jpg http://https://i.imgur.com/dFUcjeHl.jpg http://https://i.imgur.com/SSNnd1Wl.jpg The cables need to be extended by 17 inches. Will send them out. http://https://i.imgur.com/vc3b2nml.jpg Stop light installed http://https://i.imgur.com/GtGMvnXl.jpg http://https://i.imgur.com/kJWkPnPl.jpg Tank needs a bit more work, then ready for paint http://https://i.imgur.com/DPSDxDhl.jpg The bike as it sits tonight http://https://i.imgur.com/UZuo4zpl.jpg |
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Title: Re: Bike Build: Junkyard Dog Post by playhard67 on 02/27/19 at 17:49:58 a buddy of mine did a couple welds on my tank..... i'm getting excited. Almost time to start painting and putting it back together. |
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Title: Re: Bike Build: Junkyard Dog Post by Justjoshin on 03/03/19 at 16:54:51 Nice work! Some good ideas for the electronics for sure. I have might have to use that idea on my build! |
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Title: Re: Bike Build: Junkyard Dog Post by playhard67 on 03/09/19 at 15:06:40 putting it back together..... got my cables extended by 17 inches http://https://i.imgur.com/fvBzDtWl.jpg The $3.00 flea market ape hangers had a bunch of paint overspray on it. It cleaned up great using paint stripper http://https://i.imgur.com/jesPUYXl.jpg Extended cables and wiring installed, ape hangers cleaned up and new classic grips installed. Not sure if I will leave the mirrors where you see them, or move them to each side on the bar. http://https://i.imgur.com/tp2L47Vl.jpg I saw a picture of someone else that had mounted a bottle opener on their bike. I liked it. These pics were taken last week prior to painting the tank. http://https://i.imgur.com/wVJRf4ul.jpg http://https://i.imgur.com/HhSsxcBl.jpg Painted the tank (rattle-can) and installed the fuel sight gauge http://https://i.imgur.com/RX29fEVl.jpg |
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Title: Re: Bike Build: Junkyard Dog Post by playhard67 on 03/10/19 at 16:02:53 wrapped my stock exhaust, painted it, then cured it in the garage oven. http://https://i.imgur.com/UNzwYt5l.jpg I won't be able to work on the bike for the next 3 to 4 weeks.....so I thought I'd do a little photo shoot. Basically, I need to put on the wheels/tires, headlight and tail light, then wire all lights and blinkers.... http://https://i.imgur.com/w2iEypJl.jpg http://https://i.imgur.com/hyI4S6Cl.jpg Hooked up a Dyna muffler. http://https://i.imgur.com/q1kGGKQl.jpg http://https://i.imgur.com/C2hXYHKl.jpg |
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Title: Re: Bike Build: Junkyard Dog Post by DragBikeMike on 03/11/19 at 01:49:22 Playhard, I really love where your goin with the JYD. It's just so unique. Those little touches like the sight gage on the tank and the bottle opener, they're KILLER. That little scooter is gonna be a real crowd pleaser. You're gonna get loads of attention everywhere you go. |
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Title: Re: Bike Build: Junkyard Dog Post by playhard67 on 03/11/19 at 15:50:41 Thanks DBM, I'm looking forward to getting it finished just in time for riding season! |
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Title: Re: Bike Build: Junkyard Dog Post by playhard67 on 03/21/19 at 15:01:27 while waiting on parts that are being powder coated, I got some graphics made..... This bike build is in honor of my son (the bike was his first street bike back in 2007) who was killed in a plane crash. He walked this earth 9810 days... http://https://i.imgur.com/C9lPNhpl.jpg Labeled my fuel sight gauge... http://https://i.imgur.com/6em7Nu8l.jpg I designed the font on the sight gauge to match my sons favorite hat he wore while in high school... http://https://i.imgur.com/EzDX0N6l.jpg I should be done the build in the next couple weeks. Just in time for riding season! |
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Title: Re: Bike Build: Junkyard Dog Post by Dave on 03/21/19 at 16:01:10 Doesn't appear you will be riding your motorcycle (or wearing your son's hat) to the Sunday Social at church. :-? |
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Title: Re: Bike Build: Junkyard Dog Post by madmikesmech on 03/25/19 at 10:34:43 Great work and great post this far PlayHard67! The whole project is looking GREAT |
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Title: Re: Bike Build: Junkyard Dog Post by madmikesmech on 03/25/19 at 11:43:59 Probably a dumb question Playhard, but while researching the Antigravity battery site, they state "Use only Lithium specific Motorsport Chargers to charge this battery! Do not use Lead/Acid Chargers". Did you have to do any mods to the charging system to use the antigravity lithium battery? |
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Title: Re: Bike Build: Junkyard Dog Post by verslagen1 on 03/25/19 at 12:02:38 606C69606466687E60686E650D0 wrote:
There shouldn't be any problem with the bikes charging system and the LiPo batteries. The issue is with modern battery chargers that have auto desulfinating circuits that will destroy a LiPo battery. |
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Title: Re: Bike Build: Junkyard Dog Post by BayRider on 03/25/19 at 13:16:57 I would use a Buck converter for controlling LED voltage. The voltage goes up and down a bit on a charging system and can fry LEDs. https://www.ebay.com/p/Lm2596-Dc-dc-Buck-Converter-Step-Down-Module-Power-Supply/1279738126?iid=251993145103&chn=ps These are the bomb for running other DC voltages off a DC supply. 3B272A32232A392F7D7C4B0 wrote:
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Title: Re: Bike Build: Junkyard Dog Post by madmikesmech on 03/25/19 at 14:27:41 7B687F7E616C6A68633C0D0 wrote:
There shouldn't be any problem with the bikes charging system and the LiPo batteries. The issue is with modern battery chargers that have auto desulfinating circuits that will destroy a LiPo battery.[/quote] Thanks Versey! Good to know |
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Title: Re: Bike Build: Junkyard Dog Post by playhard67 on 03/25/19 at 17:36:31 Looks like I missed a bit today. Glad Versey answered your LiPo question MadMike. I have a Lithium battery on another bike and have had no problems with the bike charging system....but, know that I can't use a standard trickle charger on the battery. BayRider, I haven't finalized the wiring yet. I do have the resistors already just haven't hooked it all up (my taillight and headlight are at the powder coaters). How do these Buck convertors work? is it one per LED? |
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Title: Re: Bike Build: Junkyard Dog Post by playhard67 on 03/31/19 at 18:54:34 Got a call from the powder coater. While sandblasting the headlight bucket, he noticed there were 4 dents that had been bondo'd. He removed the bondo and gave me the bucket back to fix. I pounded out the dents, then used JB Weld to smooth out the bucket. This pic is prior to sanding. The JB Weld will allow the powder coat to adhere and will be able to withstand the high temp oven. |
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Title: Re: Bike Build: Junkyard Dog Post by batman on 03/31/19 at 19:06:57 JB weld is epoxy based ,not sure it will hold up to a temperature much over 150 F ,how high is powder coat at? |
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Title: Re: Bike Build: Junkyard Dog Post by justin_o_guy2 on 03/31/19 at 19:23:36 B KwikWeld cures to a dark grey color, is rated at a tensile strength of 2424 PSI and will withstand temperatures up to 300ºF. The curing process for powder coating is normally done in a special oven; the coating has to be exposed to a temperature range of 350 to 400 degrees . https://www.jbweld.com/products/highheat-epoxy-putty HIGHHEAT EPOXY PUTTY $ 7.99 HighHeat is a hand mixable epoxy putty stick specifically formulated to bond and repair materials that will be exposed to high temperatures in automotive and industrial maintenance applications. It cures to a tough, hard bond with little to no shrinkage. This industrial-strength product outperforms conventional epoxy putties at high temperatures and sets in 1 hour at room temperature. After 8 hours, it can be drilled, tapped, machined, ground, filed and painted. HighHeat is rated at a tensile strength of 800 PSI and cures to a machine grey in color. It is able to withstand continuous heat exposure of 400ºF and intermittent heat exposure to 550ºF GREAT FOR Before I dropped the cash for the bucket, I'd take a piece of metal approximately the same thickness, JB weld some of it and see if it survives the powder coat process. |
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Title: Re: Bike Build: Junkyard Dog Post by batman on 03/31/19 at 20:51:25 Good info thanks JOG. I watched a video using an oven designed for powder coating and it was set to 400F and found out not to use mom's oven , as after it can't be used to prepare food later. |
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Title: Re: Bike Build: Junkyard Dog Post by playhard67 on 04/01/19 at 03:40:15 Thanks for the replies. My powder coater said that JB Weld would be fine. I didn't realize that there is a heat difference between the kwik weld and original formula. Looks like Kwik Weld can withstand up to 300 degrees, while original weld can withstand up to 500 degrees. Shoulda' went with the original formula..... Looks like I have some decisions to make. |
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Title: Re: Bike Build: Junkyard Dog Post by Dave on 04/01/19 at 04:14:10 I have been powder coating at home, and trying to fill dents is a big problem for me. I have tried JBWeld, and it does hold up to the powder coating temperature long enough to get it baked. My problem with it is the powder isn't attracted (electrostatic) the same as it is the bare metal.....and the finish turns out badly. I have also tried LabMetal. It is supposed to apply like body putty and you can sand it. The problem is that it uses a solvent like acetone and it sets up so fast you get very little time to spread it.....you only get one pass before the surface is dry. It sands very hard, and it doesn't feather edge well.....so the finish shows a fine line and the powder cures differently so you can see where the LabMetal is. There is a YouTube video that shows a fellow painting a motorcycle tank black after using LabMetal and it works perfectly - I tried using it about 20 times and it never worked for me. The product needs to be fresh and it goes bad in the can....there is an expiration date on the can. I tried both types multiple times - one cures at room temperature and can be baked in a powder coating oven once....the other type needs to be baked and it can be heated multiple times. I have also tried using Eastwoods Lead kit. You only get one try to make it right.....unlike body filler you can't add more and re-sand/file - as adding heat and more solder melts everything and you are starting over. There is supposed to be some new wonder "filler" for powder coating - I don't know what the name is. |
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Title: Re: Bike Build: Junkyard Dog Post by DragBikeMike on 04/01/19 at 12:53:30 I am currently testing JB Weld products in preparation for my cylinder head mods. Regular JB Weld is rated at 500F continuous and 600F intermittent. The regular JB Weld can take the heat. But as Dave stated, he has tried it and it doesn't take the powder coat well. He mentioned problems with the electrostatic attraction. JB Weld also makes a product called "Extreme Heat". Don't confuse it with the "High Heat" putty log. The Extreme Heat product is paste, single component (no hardener), and it is good to 2300F. I don't see adhesion strength as too much of a problem in your cosmetic application. The Extreme Heat paste is loaded with steel fines. That might work better with the electrostatic adhesion issue. Looking at your picture of the headlight shell, I believe I see proud areas that are going to look bad once its coated. If you have a shrinking hammer and some dollies, you might want to try and shrink the proud areas so they don't stand out after you use the filler. Considering that you want to powder coat, maybe you could try brazing or silver soldering to fill in the dents, and then carefully blend as if it was body filler. To me, that would be a project that required some major league skills. Why not just use the old tried and true body filler and glazing putty followed up by a beautiful coating of lacquer or polyurethane paint? I bet it will look real nice. |
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Title: Re: Bike Build: Junkyard Dog Post by playhard67 on 04/01/19 at 18:44:36 Wow, Thanks for all the replies and personal experience. Has anyone tried this: Thermobond-3 http://www.thermobond3.com/index https://www.powdercoatingonline.com/thermobond-3-powder-coating-metal-repair-filler/ |
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Title: Re: Bike Build: Junkyard Dog Post by batman on 04/01/19 at 20:56:31 I would think a " junkyard dog " to have dents, I would have left them an powder coated anyway(. women dig scars ? ::) |
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Title: Re: Bike Build: Junkyard Dog Post by playhard67 on 04/02/19 at 03:39:25 HaHa, you are absolutely right Batman...and I was thiiiiiiis close to leaving the dents on the bucket. But, one dent in particular was in a prominent spot and I just couldn't do it. |
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Title: Re: Bike Build: Junkyard Dog Post by playhard67 on 04/02/19 at 03:40:57 Time to remove the Kwik Weld. smh |
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Title: Re: Bike Build: Junkyard Dog Post by DragBikeMike on 04/02/19 at 11:49:14 That Thermobond 3 stuff looks interesting. If you use it, let us know how it works. Thanks for the links. |
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Title: Re: Bike Build: Junkyard Dog Post by playhard67 on 04/02/19 at 15:46:24 797F700C0E090D3D0 wrote:
I ordered it directly from the company in CA. I should have it in time for the weekend. I'll write up a report on it. |
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Title: Re: Bike Build: Junkyard Dog Post by playhard67 on 04/05/19 at 05:49:43 I got the Thermobond-3 yesterday and was able to put it onto the headlight bucket. This filler is specifically made to be powdercoated over. Looks like it is on pretty thick....... lots of sanding ahead for me this weekend. I called this company before I applied it so I could talk with a technical rep. They had a rep call me back within an hour, and she (Colleen) went over the entire process. Answered all questions. She told me I have her cell phone and to call her if I had anymore questions. Great service. You stick the tub into the microwave for no longer than 15 seconds...then stir. Then, if needed, another 15 seconds then stir. I put it in for 30 seconds total. It is supposed to be the consistency of Silly Putty. http://https://i.imgur.com/XTTKxYDl.jpg Apply the product to the bucket and press on it hard for 30 seconds with your GLOVED hand. Need to keep the oils from your skin off the product. It should not be thicker than 1/4 inch. If needed, you can apply additional layers after curing inbetween. Again...I'm not looking forward to sanding this. http://https://i.imgur.com/Vjkjpojl.jpg Thankfully I have an oven in my garage. Depending on the temperature in the oven, will depend on how long to cure it. At 375 degrees it should be left in the oven for 10 minutes. At 400 degrees, for 7 minutes. http://https://i.imgur.com/NS09Xgal.jpg Here's what it looked like after 10 minutes. Looks like the top of the bucket was too close to the top of the oven, so that got cooked a little more. It did not crack, so I should be ok. http://https://i.imgur.com/arBnD8el.jpg This product cannot be wet sanded, and no other liquid should be applied to it. Any liquid applied to the product at this stage will introduce the possibility of out-gassing and blistering. |
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Title: Re: Bike Build: Junkyard Dog Post by Dave on 04/05/19 at 06:05:23 Wowee! That looks like a lot of sanding! To get something really smooth - I have always needed to use filler, then sand, then more filler, then sand.....each time the results are smoother. I can't see how the fill/sand and fill/sand process works when they stuff goes on so thickly! |
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Title: Re: Bike Build: Junkyard Dog Post by playhard67 on 04/05/19 at 06:33:12 I wasn't sure how much to put on...because pressing down with my palm would leave an indentation. Anyway, I'll use a power sander to get most of it off, then do hand sanding. |
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Title: Re: Bike Build: Junkyard Dog Post by playhard67 on 04/06/19 at 12:30:49 I know my abilities....and there's a reason this bike is called Junkyard Dog. I was able to sand the headlight bucket, and while it may not be perfect, I am not looking for perfect. It's ready to drop off at the powdercoaters.... I believe it will look very nice once it gets powder coated. PS: The Thermobond-3 was easy to sand and feather. We'll see what it looks like once it has the powdercoat on. http://https://i.imgur.com/k5U1KnGl.jpg |
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Title: Re: Bike Build: Junkyard Dog Post by sandmanred on 04/06/19 at 14:55:31 Wow, looks great. I'll be interested to see the final results and hear what your powder coater has to say about it. |
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Title: Re: Bike Build: Junkyard Dog Post by playhard67 on 04/06/19 at 15:53:20 Sneak Peek.....got my taillight back from the powdercoater. Before and after (minus the lens in the after pic) http://https://i.imgur.com/fglSPFsl.jpg |
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Title: Re: Bike Build: Junkyard Dog Post by playhard67 on 04/12/19 at 16:37:41 Got the last part back from my powder coater...the headlight bucket. The color is the same as the taillight, just the lighting is different. I cannot see the edges from the Thermobond-3. It sanded and feathered out well. It looks great to me. I positioned it the same way as the above pic, so you can see for yourself. I'll be spending Saturday completing the build. Although, it may take me a bit longer to wire all lights. |
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Title: Re: Bike Build: Junkyard Dog Post by LANCER on 04/12/19 at 16:59:02 I really like what you chose for the tail light ! |
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Title: Re: Bike Build: Junkyard Dog Post by playhard67 on 04/12/19 at 17:01:42 The taillight color is the color... the headlight is the same color, but looks different because it is under lights. |
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Title: Re: Bike Build: Junkyard Dog Post by justin_o_guy2 on 04/12/19 at 20:33:23 I did bodywork for three years. I didn't envision such a good outcome. I had to bite my fingers to not respond to your I'm not looking for perfection statement with Well, I'd say you're not gonna be disappointed... I'm impressed, and you must be thrilled. |
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Title: Re: Bike Build: Junkyard Dog Post by justin_o_guy2 on 04/12/19 at 20:36:09 404D424F495E1E1B2C0 wrote:
I expect everyone else does too. You might consider some kinda security screws to make sure you have the lens when you get on it. |
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Title: Re: Bike Build: Junkyard Dog Post by playhard67 on 04/13/19 at 16:17:00 Finally got the bike together and took it out for a spin. Feels Great! Still need to wire all lights/blinkers. http://https://i.imgur.com/XXk9CAFl.jpg http://https://i.imgur.com/aJtQyA3l.jpg http://https://i.imgur.com/ij9VeINl.jpg http://https://i.imgur.com/nRUo62al.jpg http://https://i.imgur.com/7UT2QVMl.jpg THE Junkyard Dog..... http://https://i.imgur.com/hqLyPMCl.jpg http://https://i.imgur.com/LFVsGdml.jpg |
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Title: Re: Bike Build: Junkyard Dog Post by playhard67 on 04/13/19 at 17:00:53 before and after pic |
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Title: Re: Bike Build: Junkyard Dog Post by DieselBob on 04/13/19 at 17:12:46 - And the hood of some R series Mack is missing its bulldog. Nice touch! |
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Title: Re: Bike Build: Junkyard Dog Post by SavageMan99 on 04/15/19 at 01:10:12 I've used ceramic coatings applied with a help. It would stick to epoxies well. |
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Title: Re: Bike Build: Junkyard Dog Post by playhard67 on 04/16/19 at 15:45:38 Trying to confuse people. I would like to remove this Suzuki emblem from the triple clamp. Before I mar it up....is it as simple as getting a sharp edge under the emblem and lifting it off? |
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Title: Re: Bike Build: Junkyard Dog Post by madmikesmech on 04/22/19 at 09:00:49 Playhard67, the J.Y.D turned out super! A+ work man love the look you achieved! Mike |
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Title: Re: Bike Build: Junkyard Dog Post by Dave on 04/22/19 at 09:11:18 5C404D55444D5E481A1B2C0 wrote:
Yep....just some 2 sided foam tape holding it on. Try some good dental floss. Park the bike in the sun to get it warm first. |
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Title: Re: Bike Build: Junkyard Dog Post by justin_o_guy2 on 04/22/19 at 09:23:35 If floss fails, try monofiliment |
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Title: Re: Bike Build: Junkyard Dog Post by playhard67 on 04/22/19 at 13:48:15 Thanks guys. I used fishing line to get it off. |
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Title: Re: Bike Build: Junkyard Dog Post by playhard67 on 04/22/19 at 13:55:15 Welp.....I am 100% Done with the build......for now. Hooked up all lights and blinkers. Added the LED Flasher Module from superbrightleds.com - Part number LF1-S-FLAT. So much easier than adding resistors. Thanks for the help. Took the bike out for a 20 mile test spin. Everything felt great. I may need to get the carb rejetted....had a little bit of backfire. But, will ride it for a bit before I commit to getting the carb work done. I am not sure about the look of the seat and the huge gap between the frame rails and the seat. But, I'll ride it this way for the summer and if I decide to make a change to the seat (custom seat hugging the frame rail), I'll do that next winter. For now....time to enjoy the bike. I'll post some final pics. |
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Title: Re: Bike Build: Junkyard Dog Post by playhard67 on 04/22/19 at 13:57:17 Got my 60's style Bell 500 helmet and goggles to complete the look. |
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Title: Re: Bike Build: Junkyard Dog Post by playhard67 on 04/22/19 at 13:58:51 taken at a local reservoir |
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Title: Re: Bike Build: Junkyard Dog Post by playhard67 on 04/22/19 at 13:59:38 taken at a local reservoir |
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Title: Re: Bike Build: Junkyard Dog Post by playhard67 on 04/22/19 at 14:00:19 taken at a local reservoir |
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Title: Re: Bike Build: Junkyard Dog Post by playhard67 on 04/22/19 at 14:01:04 taken at a local reservoir |
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Title: Re: Bike Build: Junkyard Dog Post by playhard67 on 04/22/19 at 14:02:22 Caught the rear blinker when it was on.... |
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