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Discussion Starter #22
Dang Buzzer - that is nice work! I need to take some Tig welding lessons from you.
Ha Ha, it would be a short lesson! there are some great videos on YouTube on TIG welding... I have to say my new set helps, its fantastic and much better than the one I use at my mates fabrication company.

Sometimes it the little details that give the greatest pleasure… I needed some headlight brackets but they look terrible when you just crush the end in the vice… so I made this little tool to shape the ends.

 

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Ha Ha, it would be a short lesson! there are some great videos on YouTube on TIG welding... I have to say my new set helps, its fantastic and much better than the one I use at my mates fabrication company.
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I am actually OK with steel and stainless steel, but I only seem to blow holes in aluminum. I guess I need more practice (in my spare time)...
 

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Discussion Starter #24
I have been on holiday for a few weeks, hence no updates... Now as winter approaches I will be spending a bit more time in the garage!

For now, I have finished the GPS speedo, and think I will use it. It worked well on test in the car, and the warning LEDs are very bright.







 

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Discussion Starter #25
I sat for a long time in the garage, imagining how I could make the footrests. I knew exactly where they should be as I want the riding position to be “just Right” like my other bike. one important factor was some sort of rubber mounting. the design proved to be difficult, and after mocking some up in plywood, I came to the conclusion it would actually be quite difficult. In the end I have used the footrest assemblies off a Multistarada, which combine all the attributes I wanted, with the bonus they were an easy fit! I have also braced the frame. A considered decision… so many of these bikes break their crankcases. hopefully this will prevent that.

The throttle linkage is also now done… The right throttle action can make the world of difference to how a bike rides. I bought a cheap twist grip and played around with different diameters until it felt right. I will make a replacement now to the correct dimensions.

Sign the weather is getting cooler... I have moved to the other side of the garage, near the radiators!



 

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Nice job on the peg arrangement, very clean. Curious on how and why though. 1st gen Multi pegs is a straight bolt up? How did it change the position from the original ST peg location?

Thanks much,

Scott L.
 

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Discussion Starter #27
Thanks! I changed the pegs because I want a more upright riding position, the pegs are now a bit lower, and quite a bit further forward. I had an ST4 for a few months, loved the bike, but hated the riding position...

They pretty much bolt on. the crankcases are much the same dimensions. what you cant see is there is a piece of 10mm all-thread that runs from one side to the other, inside the hollow swinging arm pivot. this braces the top and works well, and retains the rubber mounting. I would want to try some first with the standard exhausts though...
 

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Discussion Starter #28
Made a couple of items in the last few days... first I have mounted the front mudguard, made some stays out of alloy tube, complete with formed ends to make them look better, and also less prone to cracking.

Also finished off the tank plate and mounted the ignition switch. this took a while as I panel beat it out of some alloy plate into a compound curve. I made a tool to press the raised portion to add a little strength, and make it look a little better. I have mounted it with some 5mm anti vibration rubbers. Of course all will need a polish, but that all comes after the mock up stage!





 

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Discussion Starter #29
Took the frame in to my mates factory today to fully weld it… its easier on the big bench, and his gas is a 10th of the cost of my small bottle at home! I noticed the cracks on the underside of the cross over frame tubes, both sides! really glad that I braced it now. I don’t feel its the best designed frame…



 

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Discussion Starter #30
well I dye pen tested all the welds on the frame today, all OK apart from the obvious ones...

been stripping the wheels tonight, first I had problems getting the front bearings out as the inner spacer tube is a tight fit and I could not get on edge of the bearing to knock it out, ended up grinding a piece of flat with a tang on... this soon had it our. MUCH harder were the cush rubbers... I simply could not get to the back of them to get them out. I made a split collet in the end and pulled them out with a big socket!







 

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Discussion Starter #32
Bit of a departure from bike building just for a change... thought I would share a couple of other projects I have done recently... One bike related... a table lamp for my study made from a scrap 1000DS piston and barrel. Not bike related, a fire pit come BBQ that I made Stainless Steel. I had the dish spun out of a 750mm diameter blank of 6mm stainless 316. its an interesting process! Initially it was going to be just one grill, but my wife said she wanted a separate veggie grill... hence the two! Bonus brownie points! its been used a lot over the summer, when the BBQ is done, the grills come off, and we throw a few logs on and it becomes a fire pit!










 

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Discussion Starter #33
I did the tappets… pleased to say they were all in tolerance! I also took the cams out to check the rockers, they were pretty near perfect, which was a relief!

Took the frame to the powder coaters… but he called me today to say there were marks on one of the frame and he was not happy to coat over them… they must have been under the original paint with filler in them! I took it back home and just touched them with a sharp drill and TIG welded them up and sanded them down.

I have also Etch primed the engine ready for a coat of 2K silver tomorrow. It took a lot of hours to remove the paint. I was lucky to find 5 LTR of old stock paint stripper which should keep me going a long time. the modern stuff is next to useless. I masked the engine off, a tip i picked up when I was an apprentice in a Bentley dealership for making gaskets was to tap around the gasket material with a plastic hammer... I do the same masking off.. put the tape on and go around the edge with a small plastic hammer. you get a perfect edge!







 

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Discussion Starter #37
I see a lot of builds spoilt by detail, and have been guilty of it myself in the past, in particular withe old plated parts... One thing I gave been meaning to do for a long time is have a go at DIY plating. Well I did some today and I have to say I am quite pleased with the results! I have used the blue passivate but there is a yellow gold one in the kit.



 

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Fabulous skills. Impressive.
 
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