An introductory build thread...cafe style

How much of that work on the frame is weld & how much is bondo?

 

With the frame we took a structural approach. Being that some main support was removed we decided to use as much metal as possible to reduce any or all flex and use the bondo to fill in the "imperfections".

 

progress:

 

We probably have 4-5lbs of wire on the bike. The body filler has metal under it.

We did more sanding today and added a battery pan under the sat. Sure Stu will post up picture later. The new metal added for support brackets were 3/8" thick.

 

You need vertical supports between the shock loop and the swingarm right where the loop starts its curve. Viewed from the side, the shock mounting loop and the swingarm form two sides of a triangle; complete that triangle.

Take a look at any modern monoshock swingarm; especially on low-mid price-range bikes where it's a welded up piece similar to yours. You'll see what I mean.

 

Funny, that came up today when we worked on it.

We have 3/8" gusset plates in the rear on top of the parent parts which are welded on both sides.

I guess that's up to Stu. Easy to add, it would take a little stress off the weld, frame (box) it out.

 

Some pictures from this weekend:
The spring before any anybody know what that rubber piece is called that is on the shock(it needs replacing):

YAY chemical stripper FTW:

I think I'll do red:


Welded, body filler, and primer:


As for stabilizing the swing arm. Mike(everlastsupport) thinks this bike lock will suffice.

 

That "rubber piece" is the bump-stop. If it needs replacing then the whole shock is probably due for a rebuild.

 

Thats what I thought it was called. Do I really need to rebuild it if its not leaking and rebounds like it should?

 

I was really excited about putting my front end together tonight. Good news the FZ600 front forks came in. Bad news yeah they were definitely damaged during shipping. Oil on the box, in the box, and all over the packaging, I am pretty sure the seals were damaged during shipping.

 

You could go ahead and ride on it to see how it performs, but rubber ages at pretty much the same rate no matter where it is, so the seals are likely past their prime. If you think the shock will last at least one riding season, then go ahead and run it.

 

I'll go with better safe than sorry

 

I think you're jumping to conclusions. If the guy you bought the forks from didn't DRAIN THEM first, it's quite possible they puked oil all over the inside of the box despite what condition the seals are in.

Fork seals are meant to keep the fork oil where it belongs when the forks are operating in a normal "service" attitude. Go tipping a filled fork in directions it was never meant to be tipped in and it will leak. If they were air-shipped, I'm sure the pressure changes wouldn't have helped either.

I would also assume that you're going to REBUILD the forks anyway which means they'll get new seals. How old was the bike the forks came off?

 

that box doesn't look very beat up. if there was shipping damage, the box would look a lot worse than it does.

CN

 

shipped ground but good to know. Yes they prob need a rebuild. #noobproblemz

 

is that another project bike in the background???

 

mike always has projects going on but this is the first bike. Mike and I put our brains together over the past couple days and decided to not do POR 15 on the frame but go with something that will really piss all the purists off. I have never seen what I am about to on a full motorcycle frame but it should be an interesting one off bike.

 

I'm sitting here waiting on an old Jeep to show for some panel/fender work and thought I would check in Stu's thread.

We've repaired a few bikes, BUT we've never cut a bike all up and put it all back together like this for sure. So I guess it's our first REAL bike project. Hahaha.

I really like the mono shock idea. Reminds me of my YZ125 (dating myself).

On the paint job, if it goes that way, people will like it I bet. I've used POR15 many times, but it's not made for cars and bikes on the outside if you brush it on for sure. It is a great product otherwise. Stu did thin it some, and we never tried to spray it.

If his other direction on paint pans out, wait and see, it will be very slick. Of course the final bike is still in his head and changes weekly sometimes. Haha

 

sorry guys no updates in a couple weeks but the frame was being prepped for its "paint." It may be another 2 weeks before I hear back from the shop. They are very busy.

 

And here we go. Transfer printing carbon fiber with blue background. No it's not old school or classic in anyway but it's my crazy twist on an old bike.