My first build - Schwinn Del Mar

[Gungatim]

Well, My son and I just started our first build project. We are using the Schwinn Del Mar cruiser style bike from Walmart. When we saw it in the rack it was literally begging for a motor! We are using the powerking 80cc kit and so far have made a few modifications: cross drilled the chain idler and installed a grease zerk (pic 1). This should make it easy to grease between rides. The fitting clears the spokes but I didn't realize the nylon actually faced inward toward the tire, so the clearance is a little tighter than I thought. We then tried to install the engine but ran into a couple of mounting snags. First, the rear mount was too small for the upright tube. we used our OSS from the woodshop to widen the curve of the aluminum block. Course sandpaper on a 1 1/4" drum worked perfectly and it now matches the tube exactly. For the front mount, the studs would not even clear the main tube. I have seen some who drill, and others who bend the tube to make it fit. Instead, we decided to make a plate mount using two 1 1/4" pipe clamps, some flat stock, and washers (although I am looking for some spacers to replace the washers with for better looks) See pic 2 for detail.
The rear sprocket went on pretty easily, it did need the ID enlarged .020 to clear the hub, but a minute or so with the Dremel fixed that up. It slipped on with a little friction and is centered perfectly.
The mufler will need to be bent, of course, and we still have a few things to hook up. I ordered locknuts and M6 allthread from Mcmaster Carr and will replace fasteners this week. I did try using capscrews on the magneto cover but the head diameter does not fit the holes...bummer...it would have looked cool. I am also toying with the idea of using brass compression fittings and soft copper tubing for the fuel line to get more of an old fashioned look.

Let me know what you think.

http://i105.photobucket.com/albums/m238/tschubeck/motorbike3.jpg
http://i105.photobucket.com/albums/m238/tschubeck/motorbike2.jpg
http://i105.photobucket.com/albums/m238/tschubeck/motorbike4.jpg
http://i105.photobucket.com/albums/m238/tschubeck/motorbike1.jpg
http://i105.photobucket.com/albums/m238/tschubeck/motorbike.jpg

 

[Whirlwind]

Hi Gungatim
I was also looking for a bike (1st build) to hang my 47cc 2-stroke on, and I would have bought the exact same bike as you if the bikes hadn't been parked outside of Walmart rusting from exposure. I settled on a Schwinn Legacy Cruiser for $98 from Target.

As to mechanicals......I took a similar approach to mounting the engine. See pic. I'll tackle the exhaust this weekend. I struggled with how I would handle the exhaust and settled on welding an extension similar to another that I found on this forum. See pic. I'm interested in how you mounted your sprocket. Mine fit nicely over the hub. Both of the gaskets or thick rubber dampers are located on the inside of the spokes with the sprocket resting against the spokes. I don't like the spokes up against the sprocket, but I saw no other way. Is this what you did? Stay posted. We may be able to help each other avoid the other's pitfalls.

 

[Gungatim]

sprocket mounting

For my rear sprocket, we initially mounted it up against the spokes with one rubber inside the wheel. After reading more and seeing some misalignment with the front sprocket, I took it apart last night and put in the 2nd rubber between the gear and spokes. I think this is the way to go. The only issue is that the bearing cap on the coaster brake side is sized to go over the hub, but with the gear on there, it takes up the space where the bearing cap would be. Seems to be only a minor issue, as when I tighten down the axle, the bearing cap pulls in tightly and only the edges are slightly bent.
I had to cut away a fair chunk of fender to keep the chain aligned, but I am very uncomfortable with how close the chain rides to the tire. Does yours run close? I will try and post some more pics next week after we are back from camping. The bike is about ready for the road, just need to wire tie the cables and fillerup with gas!

 

[Hot Dog Piggy Tails]

Front Mount

Heres a pic of my Delmar Front Mount

 

[bluegoatwoods]

Nice work, guys. Gungatim's grease fitting is a good idea. And I liked the green motor mount a lot.

Chain/tire clearance seems to be a bit of an issue on coaster brake type bikes. I mounted an HT on a Kulana and it was real close. Chewed up the first tire pretty bad. With some pushing and pulling I got it out far enough, though.

 

[biken stins]

Had trouble with chain tire clearance also. Schwinn cruiser, coaster brake. Used 1/16" flat stock between sprocket and fiber sprocket. Used the metal retainer for a pattern.Went with shorter round allen head bolts.Seems to work ok.

 

[Egor]

I like the cruiser frames but the distance from the engine to the frame is long and I have to make up the distance. I am building this now, I will let you know how it turns out. I am hoping that it will also help in the vibration also (IE isolate some) if this works out I will use it on my Schwinn. Have fun, Dave

 

[Hot Dog Piggy Tails]

man you need saddles on them Clamps the area you are using is nill.

 

[Egor]

Hot Dog I like the fins on that head, what kit is that? I wish all the manufactures knew the need for good fins. Have fun, Dave

PS: I abandon that mount for a rear one out front.

 

[Irish John]

Heres a pic of my Delmar Front Mount

That's a picture of your rear mount.