Petrol tank install.

So. I bought a tank, which is from Simson moped. Have to do something, so I can mount it into my bike.

Had to fill that hole in front of the tank, so I made plate into it.

Then hammered some curves into the plate

Fits quite fine

Then welded it

Had to put something under the plate, to keep the tank stable. I cut some pipe to half.

There it sits. I like. Have to drill hole into pipe & do threads into frame at the front of the tank.

Last mockup

Back from the countryside. Now have to really focus on this, if I want to drive Him this summer. Here´s The Last Mockup. I found old Simson moped petrol tank and I am going to fit it into this + push handlebars up and there it is. Like this:

Trying to make a sissybar part2

Yesterday I did better & taller one. Not ready yet, but soon. After I have finished it,

I´ll post "making of" pictures.

Trying to make a sissybar

Now I am at that point, that I can start to make a sissybar. I have never done this before, but have readed instructions from web. It is quite straightforwarded. You heat metal bar and then bend it! Of course there is lot of things, which I should learn, but I am pretty satisfied about this testing prototype. Have to buy more steel bar (in this case 13mm axle steel) and try to make taller one tomorrow.

Trying to straighten it at start. Should have done first bend at stable metal table.

In any case, it went quite well. This is not just tall enough.

At this pic I have already made those bends, which go over wheel.

Prototype ready.

Seat "problem"

I have tried many seats on this and tried to avoid "normal" solo seat. Yesterday I thought that I´ll have to do one of my own. Today I thought that I´ll give solo seat a try. Have to admit. This is best I have tried on this. Tomorrow I´ll start to do mountings for it.

Rear fender mounting

Started to do mountings for rear fender. These are maybe best mountings I have ever done. Simple and easy to do.

First I put some pipe under the fender to get measurements somewhat right 

Calculating measurements

Busy cat

Then I grinded another end to shape of fender mount pipe.

Did 8mm threads to other end

Fits quite fine

Now tack welding has to be done

And there they are. Have to shorten them little bit, fender is somewhat too close, weld them properly and then they are ready. Now I can start to do sissy bar. 

TCMC Custom Bike Show, Sweden

Did great trip to TCMC Custom Bike Show. Came back yesterday. Trip went well, Sporster worked and weather was good, except few of shower of rains. This was my 14th time to visit there and now Summer officially started for me. Hangover. Over and out.

Mock up of Royal Enfield Chopper

Have to clean up my garage, so I put Him out to smell the winds of summer (it is going to rain soon...). Lots of things to do, but I am pretty sure that We will drive this summer together.

New improved chain tensioner

I fixed my old chain tensioner, which I made last winter, a little bit. Made one leg from thicker material + did longer roller from nylon. This way I can swap it around, if it wears too much on The Road.

Springer rockers modification.

Since I am rebuilding my springer for Royal Enfield Chopper, I decided to do some modification for rockers too. They looked cool, but were not working properly. You can see the modification (and fault with those) more easily from pictures. I also changed the location where front axle come, so I fixed little bit of trail, which was too big. Now they are more like Sugar Bear style. I maybe do them from scratch at some point, but this is just test now.

That high notch sticks to springer bar.

Here you can see the Sugar Bear style also.

Results of The Plan

Gig went well & parties were good. Have to continue my front end.

The Plan

First I cut nylon bar with axle grinder (not best method, I soon noticed...). I burned my hand because of melting nylon. You can see how the bar has been melted in this picture. With cutting tool of lathe or with normal saw, I would have had better results. Bad thing is, that I don´t have any of those, so axle grinder it was...Then I bored bigger hole into nylon bar, because I only have 10mm drill bit and hole needed to be 13mm.

Now it fits.

Then I faced the nylon bar with lathe. Carbide bits make quite good surface even on nylon.

Here is the old one. It does not have any support for springs. This is made with file last summer.

Here is the final piece.

This way it sits at the bottom of the upper spring.

 Why I did not invent this before? I don´t know, but good that I did it now.

This is so great. I have other piece ready as well and front end feels much more stable in every manner now. I am anxious to see how it works when I drive. But I am really far away from that. Hope that I get this bike ready for this summer.

Lots of nylon waste

Gig & Spacer

We have gig with F.T.W. Boogie Machine today at Viikinki MC. They have wedding party there and they celebrate their 21th anniversary also at same time. I am pretty sure that there will be One Helluva Party!

Gig starts at 22.30, so I have plenty of time to do other stuff before that. Started to do lower spacers for upper springs of springer. 

Here´s The Plan.

Royal Enfield Chopper in progress...Continues

I started to rebuild my springer. It has lots of free play here and there and those springer rods are bend little bit + they have bad threads. What I found from internet, were little bit too short for me also, so I decided to do them by myself. I will do Sugar Bear style rockers to springer too. More about that later.

Old ones

First I did some lathe job to axle steel bar

I read this trick, that you can put thread cutter directly to tailstock, tighten it and then just rotate chuck by had. Did not work for me, thread cutter does not stay at place.

I had to keep cutter still with other hand, add little bit pressure from back and rotate chuck by hand.

Worked! Only 3 more left. This is good method, since you get cutter straight to bar.

One side ready.

Then I did some spacer, so that the upper springs don´t move when tightened. First I cutted away some stuff from bigger nut with lathe.

Then took material out from too narrow spacer

Here they are, ready to be together. 

I am happy with results.

Fits fine. Also modified nut goes inside the spring, so it keeps it straight

There they are. Have to do something for the bottom end of the upper spring also, so it stays in line.

Here is pictures of my new hard tail. It is made from 25*3mm hydraulic tube & TIG welded together.

Yes. We did had a jig...

And here it is, all welded & ready to go with me. We did errors that much, that instead of using about 3 meters of tube, we used at least 5 meters! Errors happened and WILL happen in future also!