Go Back OFN Forums > Fabrication > Cycle Fabrication

Cycle Fabrication Old School, Choppers, Bobbers, and Customs


Cycle Fabrication Old School, Choppers, Bobbers, and Customs

Reply
 
Thread Tools
  #41  
Old 07-04-2010, 03:37 PM
Yamaha_chop's Avatar
Yamaha_chop Yamaha_chop is offline
Fabricator
 
Join Date: Jan 2010
Posts: 62
So I got to finish up my intercooler piping yesterday, very excited about this step because it finally means the air path system is completely tacked together! from the inlet on the turbo straight out through the exhaust it's all together. Yay!
Let me point out that I realize the sharp bend right off the turbo outlet is not conducive to power, and that's fine. I'm very pleased with how it looks. Also I made a large effort to make sure the piping did not stick out past the framerail, I think it turned out well.

Anyway, check the pics and let me know whatcha think.
thanks
Sky















Can't wait to hear that blow-off valve go off!
Reply With Quote
  #42  
Old 07-13-2010, 02:42 AM
Yamaha_chop's Avatar
Yamaha_chop Yamaha_chop is offline
Fabricator
 
Join Date: Jan 2010
Posts: 62
back to the progress pics:

I've been having a really tough time figuring out how to mount my rearsets. So I decided to take advantage of the factory mounting points that I had left in place (I'm glad i did that) I got a set of factory pegs:



These were a touch too long, so I took about four inches out of them :)





This puts the pegs in a perfect spot. I'm going to cut those pegs off and use them on my chopper redesign this winter. These mounting brackets will become the base for my ZX6R pegs.

I also got to use my lathe for the first time! When I first tried it, the lathe wasn't spinning true, there was a tiny wobble in it, which of course makes a lathe useless. Anyway I started freaking out a bit, but then I tried to tackle the problem logically. Eventually I pulled the chuck off, and found the backing plate where the holes were drilled had some small burrs still in place, so I used the lathe to face it up a bit, put the chuck back on and Voila! works like a champ.

Started making my fuel rail injector bungs. I don't really have a before shot, but just imagine some 7/8" bar stock. I cut down the outside to about 3/4", then drilled the center and bored it to 17/32" Then I chamfered the end to ease the o-ring entry. I still need to polish the inside a bit, and take some of the edge off. Overall though I'm extremely pleased with how they turned out, and I'm having a blast with this new tool.



Tapping 1/4" plate is a pain in the butt:







Still some finishing work needed before I weld it up, but it's one step closer, a million to go.

Thanks for looking
Sky
Reply With Quote
  #43  
Old 07-16-2010, 03:20 PM
mulletcar's Avatar
mulletcar mulletcar is offline
Junior Fabricator
 
Join Date: Dec 2009
Posts: 22
Its coming together nicely, you have a really creative vision and eye for detail man. Nice work indeed!
Reply With Quote
  #44  
Old 07-28-2010, 02:10 AM
Yamaha_chop's Avatar
Yamaha_chop Yamaha_chop is offline
Fabricator
 
Join Date: Jan 2010
Posts: 62
Thanks for the encouragement man, much appreciated

So I've discovered the inherent flaw in using pie cuts for everything. Besides tons of welding that is. All the heat from welding, and all the little gaps added together means a lot more opportunities for the metal to pull. I finally welded up the exhaust and the turbo manifold. The turbo mani pulled almost a quarter of an inch, so I had to cut it apart again and add in a section to get it back where it needed to be. Whew, that was a lot of welding :)







Also I welded up the fuel rail and installed it. I still need to figure out some mounting tabs for it, but it just looks so cool in there I had to take a few pictures!



It's a tight fit for sure.



I'm optimistically about a month and a half away from starting this thing up, got to start checking things off of the list so I can accomplish that.

Welding up the intercooler piping is next.

thanks for looking
Sky
Reply With Quote
  #45  
Old 08-20-2010, 04:13 AM
akuma10408's Avatar
akuma10408 akuma10408 is offline
Junior Fabricator
 
Join Date: Aug 2010
Location: Powers Lake, ND
Posts: 12
Thumbs up

This is my favorite project on the board. Good luck and I hope everything works out!
Reply With Quote
  #46  
Old 10-11-2010, 03:30 AM
COMP's Avatar
COMP COMP is offline
Fabricator
 
Join Date: Jun 2008
Location: So IN.
Posts: 37
looking for updates
Reply With Quote
  #47  
Old 10-11-2010, 10:27 PM
baxter's Avatar
baxter baxter is offline
Master Fabricator
 
Join Date: Nov 2007
Location: Rockford,OH
Posts: 756
Wow first time I cought this.Are you waiting to put tires on it because you have to build them yet?Awsome work and very original!
Reply With Quote
  #48  
Old 10-12-2010, 02:38 AM
Yamaha_chop's Avatar
Yamaha_chop Yamaha_chop is offline
Fabricator
 
Join Date: Jan 2010
Posts: 62
Thanks for the good words man. I'm working hard on this right now, getting a lot of parts together to try and get it started by the end of the month. It's a milestone that I'm really trying hard to achieve.

Stick with me, I'll have some updates soon!
Reply With Quote
  #49  
Old 10-12-2010, 08:23 AM
Wheels4's Avatar
Wheels4 Wheels4 is offline
Master Fabricator
 
Join Date: Mar 2009
Location: Birmingham Area, Alabama
Posts: 238
by looking at the progress so far... it's hard to believe it started life as a xs650. well done so far...
Reply With Quote
  #50  
Old 10-17-2010, 05:28 AM
mulletcar's Avatar
mulletcar mulletcar is offline
Junior Fabricator
 
Join Date: Dec 2009
Posts: 22
ive been following your build, its freaking amazing! dont lose that steam!! im interested in how the megasquirt will work for you, i just ordered a prebuilt ms2 plug and play for my 2.3 turbo mustang
Reply With Quote
  #51  
Old 10-19-2010, 12:41 AM
Yamaha_chop's Avatar
Yamaha_chop Yamaha_chop is offline
Fabricator
 
Join Date: Jan 2010
Posts: 62
Thanks for the kind words guys I do appreciate it. I got the intercooler piping all welded up, working on getting this thing started.

Here's all the stuff I've got:



And it's all gotta go in this:



Quick rundown:
Megasquirt system
Wideband sensor
Wideband gauge
Boost gauge
crank sensor
Coolant temp sensor
Air intake sensor
Fuel pump
Fuel pressure regulator
A bunch of wiring I don't have listed
And a bunch of other work too!

Gah! It's craziness just to get this thing started. Ah well, I'm hoping it comes together pretty soon.

Oh, I also ditched the tail section. Wasn't feeling it anymore. I'm completely redoing the subframe so my wife can ride 2-up with me. And the shock relocation is craziness, I'll get you some updates on that pretty soon.

Thanks
Sky
Reply With Quote
  #52  
Old 10-19-2010, 09:45 PM
akuma10408's Avatar
akuma10408 akuma10408 is offline
Junior Fabricator
 
Join Date: Aug 2010
Location: Powers Lake, ND
Posts: 12
FWIW I didn't like the tail section either. It looked like a cheesy aftermarket piece for an R6. Fighterish, but not quite right. No offense.

Here's some inspiration for a dual seat, if you don't already have a good idea of what you want.



I had a VF700S like this with a bobbed tail section, so the seat was effectively the tail with a small junkyard '87 Honda CBR tail light tucked underneath. The small lip at the back gives it a nice look while being a functional two-up. Its not particularly streetfighter-esque, which seems to be what you're going for, but something shorter than the VF700S' might work.

Last edited by akuma10408; 10-19-2010 at 10:02 PM.
Reply With Quote
  #53  
Old 10-21-2010, 09:36 PM
Yamaha_chop's Avatar
Yamaha_chop Yamaha_chop is offline
Fabricator
 
Join Date: Jan 2010
Posts: 62
It'll definitely be a split seat arrangement. I'll still use the ZX6r front seat, but I'm thinking of mimicing the 1000rr Honda tail section and using that rear seat. Small yes, but functional. Sort of..... :)

Thanks for the comments!
Reply With Quote
  #54  
Old 10-29-2010, 09:23 AM
Wheels4's Avatar
Wheels4 Wheels4 is offline
Master Fabricator
 
Join Date: Mar 2009
Location: Birmingham Area, Alabama
Posts: 238
hey Chop... any updates?
Reply With Quote
  #55  
Old 10-30-2010, 06:52 PM
Yamaha_chop's Avatar
Yamaha_chop Yamaha_chop is offline
Fabricator
 
Join Date: Jan 2010
Posts: 62
Still working on the fuel system and wiring. Might be a couple weeks yet. Hopefully next time I post it'll be with a youtube video of me starting it up!
Reply With Quote
  #56  
Old 11-14-2010, 11:36 PM
mulletcar's Avatar
mulletcar mulletcar is offline
Junior Fabricator
 
Join Date: Dec 2009
Posts: 22
heres to hoping, ill be waiting eagerly! it sucks when a project takes longer than expected.. mine has been in the works for 4 years now, 3 of which the car were in storage and i was stationed in japan.
Reply With Quote
  #57  
Old 12-13-2010, 12:49 AM
Yamaha_chop's Avatar
Yamaha_chop Yamaha_chop is offline
Fabricator
 
Join Date: Jan 2010
Posts: 62
Betcha thought I was dead right?

Haha, man been working a lot on this thing lately, about time to get back to the fabrication side of things, but here's a video to show you what I've been up to!

YouTube - Turbocharged/fuel injected XS650 It runs!

Man, it's been amazing to actually get the engine to start up, it's validation of everything I've done so far. It really gives me the motivation I need to really get back at this thing and get it going. Now that I know I'm not just wasting my time with it I can really put forth some solid effort.

Two things: The sound quality is pretty bad on the video, sorry about that. It sounds better in person. It also sounds like it's idling at 4000 rpm in the vid, in actuality it's somewhere around 1700rpm. Also I was kind of bummed because I figured that with the two into one exhaust and the turbo it'd sound pretty different. Wrong it sounds identical to my chopper! Hah, guess I should have seen that one coming since they're the same engine, but still, maybe it'll sound different once I get it under load and really up into the powerband.

Thanks to everyone who's been writing and asking about this. It's been a labor of love and even though it won't be rideable for some time yet, I really appreciate everyone who gives me feedback on it.

Hope you enjoy the video and if you have any questions at all feel free to ask....
Sky
Reply With Quote
  #58  
Old 12-13-2010, 01:16 AM
entropy's Avatar
entropy entropy is offline
Master Fabricator
 
Join Date: Sep 2007
Location: 95-miles from the center of Oregon.
Posts: 8,379
Congrats on making noise!
__________________
When did empirical knowledge get replaced by a theoretical education?

Reply With Quote
  #59  
Old 12-13-2010, 04:44 PM
MogDogg's Avatar
MogDogg MogDogg is offline
Junior Fabricator
 
Join Date: Feb 2009
Posts: 4
Very cool, good job. I don't envy you with all that wiring concealment!
Reply With Quote
  #60  
Old 12-13-2010, 06:38 PM
DJPyro's Avatar
DJPyro DJPyro is offline
Master Fabricator
 
Join Date: Jul 2009
Posts: 104
The turbo won't make much noise until you start to spool it. Give it some load and you'll hear that baby start to whistle.

You're right, with a project that takes this long, just hearing it make noise again is such validation of all the time it's taken so far.

I'm excited to see this thing on the road. Glad to hear you didn't give up on it.
Reply With Quote
Reply

Bookmarks


Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
 
Thread Tools

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off

Forum Jump


All times are GMT -4. The time now is 01:10 AM.

Powered by vBulletin® Version 3.8.0
Copyright ©2000 - 2018, Jelsoft Enterprises Ltd.
Template-Modifications by TMS
Copyright 2012, Offroad Fabrication Network