Jump to content

Custom bike build


Recommended Posts

Today I did cardboard template for battery box,

DSC_0050.JPG.c337889712971746d0df79ef34cbbd86.JPG

and after double checking for fit,

DSC_0051.JPG.54767f7aa69af654c6f65669cfa12490.JPG

 

cut the shape out of sheet metal.

DSC_0053.JPG.969f6fba3f1d2d7deaa0a698a6c3fca3.JPG

 

Now I need to trace the bend lines, do actual bending and fit it into the frame. I left some excess here and there just to be sure I won't end up with too little material, so some grinding will be necessary. It's easier to file down a bit than to add steel :D 

I thought about welding it to the frame, but decided to just fix it with couple screws. Welding thin sheet metal is a pain. 

  • Like 1

I absolutely CAN run on caffeine and hatred. But only with a dash of milk.

Challenges: Nothing new right now, focusing on current routine | #16 | #15 (Xmas mini) |  #14 | #13 | #12 | #11 | #10 | #9 | #8 | #7 | #6 | #5 | #4 | #3 | #2 | #1

Bike build

Link to post

Since last time I posted:

I finished battery box, screwed it in place

I drilled holes for rear turn signals just behind rear shocks' mounts, made custom extra long nuts to fix blinkers in place

I made a custom airbox out of 100mm dia. chimney pipe and  some 1mm sheet metal for side covers, connected it with carb with piece of rubber elbow salvaged from old washing machine

I made brackets and sorted out positioning of electric stuff (coil, rectifier etc) under the tank, made an ignition switch bracket and welded it in place

I made supports and put muffler in place (I'm using Harley Sportster 883 muffler instead of stock one)

I shaped exhaust pipe from cylinder head to muffler, now I need to weld the pieces together

I sorted out shape and position of footpeg mounts and made them, now I need to weld them in place

 

For now I'm working on front mount and latch mechanizm for the seat (I will use battery box as a glove box). With this part done, I'll take the frame to work for last part of welding and then it will be ready for powder coating. 

 

Speaking of which - I decided to powder coat the frame because of durability. And I hope I will be happy with the customization done and won't be needing much more changes :) 

I absolutely CAN run on caffeine and hatred. But only with a dash of milk.

Challenges: Nothing new right now, focusing on current routine | #16 | #15 (Xmas mini) |  #14 | #13 | #12 | #11 | #10 | #9 | #8 | #7 | #6 | #5 | #4 | #3 | #2 | #1

Bike build

Link to post

And the other side - new location for kickstand and close-up of footpeg mount.

DSC_0071.JPG.9d32ea1bac2bebc9c8cdb76dc42a96f6.JPG

 

And next thing - seat pan. Made of plywood, kerf-bent and laminated with some linen canvas.

DSC_0070.JPG.bd7df3ac71a11f3088dd8bdb028b9fb8.JPG

I absolutely CAN run on caffeine and hatred. But only with a dash of milk.

Challenges: Nothing new right now, focusing on current routine | #16 | #15 (Xmas mini) |  #14 | #13 | #12 | #11 | #10 | #9 | #8 | #7 | #6 | #5 | #4 | #3 | #2 | #1

Bike build

Link to post

Join the conversation

You can post now and register later. If you have an account, sign in now to post with your account.

Guest
Reply to this topic...

×   Pasted as rich text.   Paste as plain text instead

  Only 75 emoji are allowed.

×   Your link has been automatically embedded.   Display as a link instead

×   Your previous content has been restored.   Clear editor

×   You cannot paste images directly. Upload or insert images from URL.

×
×
  • Create New...

Important Information

New here? Please check out our Privacy Policy and Community Guidelines