Anyone for Cafe........here we go again :-)

  1. lchris21

    lchris21 Member

    Messages:
    1,182
    Location:
    South Wales
    No just 3 pot. Same as I used on my last build. Opposing piston tend to be bulky towards the hub side hence why I abandoned the radial calipers off the gsxr. You can use them with a custom hub available from the states.....but they cost a few bucks !!!
     
  2. lchris21

    lchris21 Member

    Messages:
    1,182
    Location:
    South Wales
    11 months :whistle:..................time just flies by these days. Its been a busy year what with a new job etc... 2017-18 Winter build season is upon us, time to "try" and get some garage time on the DR800.

    Right, where was I?

    Back to the front end, after chopping and changing the forks/brakes I left off deciding to make a new spindle for the bottom yoke. The original Aprilia one was too short, plus the bottom bearing was not sitting correctly onto the lower clamp.

    Time to fire up the lathe, first time for a few months :D
     
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  3. lchris21

    lchris21 Member

    Messages:
    1,182
    Location:
    South Wales
    After a root around in the back of the shed, and disturbing a few spiders I found the forks and got them on to see how it looked....
     
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  4. lchris21

    lchris21 Member

    Messages:
    1,182
    Location:
    South Wales
    Been chopping and changing my ideas for tank/seat combo's over the last few months. Still undecided, but got the angle grinder out and started removing some metal work to get a better idea. Changed my mind again about a tank, so going to wait till one turns off before chopping any more stuff off. Slow start to the build season, but progress all the same.....lets see how much time I can get on it over the coming dark winter months :welder:
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  5. Cris B

    Cris B Every day welding is a school day

    Messages:
    450
    Location:
    Sefton
    Nice. Are you going to keep the Dunlop liveried tank? I think it looks very distinctive...
     
  6. lchris21

    lchris21 Member

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    1,182
    Location:
    South Wales
    I don't think its going to make the cut........ :whistle:

    edging towards the CB50 tank if I can get it in the position I want without too much drastic surgery :D

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  7. Wallace

    Wallace Member

    Messages:
    6,462
    Location:
    Staines, Middlesex, England.
    The tank with Dunlop on looks like it's from a CB500/4, couldn't place the CB50 tank until you said!
     
  8. lchris21

    lchris21 Member

    Messages:
    1,182
    Location:
    South Wales
    Bit of jiggery pokery this afternoon and it's nearly there....the Dunlop tank can wait for another day....:whistle: 20171119_180305.jpg
     
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  9. Wallace

    Wallace Member

    Messages:
    6,462
    Location:
    Staines, Middlesex, England.
    Nice, swinging arm looks a bit long, you could put the exhaust in the gap though. :thumbup:
     
  10. lchris21

    lchris21 Member

    Messages:
    1,182
    Location:
    South Wales
    Was going for the drag bike look:o Swing arm is also surplus already decided it was way too long as pointed out. Geometry needs tweaking to compensate for shorter forks Converting it to twin shock....:thumbup:
     
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  11. Wallace

    Wallace Member

    Messages:
    6,462
    Location:
    Staines, Middlesex, England.
    Twin shocks will look cool.
     
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  12. lchris21

    lchris21 Member

    Messages:
    1,182
    Location:
    South Wales
    Have been mostly ordering parts and messing around with bits an bobs to get the wheels sorted so I can get some tyres on, in order to get the shorter swing arm in.

    Also there's a new kid on the block in the tank department. All the way from the far eastern manufacturing universe, 8 days from ordering :o. To be fair it looks decent, not too much remedial work with only a couple of low spots, and a great improvement over the tank I bought from India a few years back.

    And the winner is..........:drunk:

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  13. lchris21

    lchris21 Member

    Messages:
    1,182
    Location:
    South Wales
    The wheels needed a strip down. The plan is/was........

    Remove the hub from the rear rim and put it into the wider replacement rim I've bought so I can get a bigger tyre up back. Then re-lace the front hub into the rear rim........you following me...:D

    The rear hub had become attached to the spokes after a very long relationship, and they did not want to divorce without a fight :welder:......eventually managed to get them all in the right places. Will get some stainless replacements on order but for the time being the old rusty ones will be used during the build.

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  14. lchris21

    lchris21 Member

    Messages:
    1,182
    Location:
    South Wales
    Been mostly working towards getting the front wheel sorted this week. Plan is to try and get it the bike sitting on its wheels and tyres before the end of the year.......:whistle:

    First job up was to shorten the front wheel spindle. I'd forgotten it was too long after the end of the last season. So a quick zip with a parting tool in the lathe and a bit of threading and all is good.

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  15. lchris21

    lchris21 Member

    Messages:
    1,182
    Location:
    South Wales
    As I was truing the wheel up ready to start messing about with it, I realised I had forgotten to machine the hub to even up the bearing housings as one is longer than the other. Want to get it looking symmetrical and it should help with the brake disc adaptors I need to make. Time to strip the wheel down again and build it back up. This time with some spare spokes I found at the bottom of a pile of misc bike parts I've been hoarding for years.....the rusty spokes were making the place look untidy anyhow :D

    I'm getting quite quick at re-spoking wheels these days !!

    She should have a decent amount of stopping power up front compared to the old set up :D

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  16. lchris21

    lchris21 Member

    Messages:
    1,182
    Location:
    South Wales
    Fits quite nice.......
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  17. lchris21

    lchris21 Member

    Messages:
    1,182
    Location:
    South Wales
    Need to get the brake rotor and caliper brackets sorted. So out with the scissors and cardboard............I always watched Blue Peter as a kid :D

    Don't think the cardboard adapter plate will be able to handle the forces of the Nissin 3 Pots, so I made a stronger one out of 1mm aluminium.....................should be fine :o

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  18. darren.a.roberts Member

    Messages:
    113
    Cambridge
    Loving it.....
     
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  19. jpmillermatic

    jpmillermatic Member

    Messages:
    778
    USA-NY
    wow, amazing work...very detailed...


    JP
     
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  20. RichardM Member

    Stepped plates for the calipers?
    Do those Nissins have a separate system for the linked brakes?
     
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