Build ...phase 1

[echotraveler]

Hello Motoredbike bikers!

the motor kit arrived yesterday, it was well packed, and all the components seem to be there, the hardware looks nice, the muffler is tougher than i thought.


its gonna be time consumming:

first (done today) the upper screws of the motor block are not long enough. after some digging i found a 3ft screw from which i made my 4" long screws.
then i want to have some kind of spacer to re-enforce the screws so i found another 3ft tube that would cover, the 1" gap between the motor and the "gray holding block"

also, the rear sproket is 1"1/4" when it should be 1"3/4" so i put the sproket on a music turn table and blanced it the best i could. marking a couple of cicles around the center. (see pic)
tried to dremmel it but i need a tougher tool..what professional should i ask for this task?

THE TASK FOR TOMORROW:

Alter the carb tubing, a muffler man has to help me!
plz see pics, you can see how the carby gets in the way.

heres the pictures of everything, it seems safe, but plz shime in.

 

[srdavo]

wow.... that's a tight fit!! I have some ideas that should help you out.

In the 4th photo.... rotate the engine counter-clockwise, until the front engine mount sites properly on the bike's downtube.

the space at the rear mount can be filled in easily.

take pics of adjustments.

then try to put your exhaust pipe on....... you don't have to bolt it on .... just make sure it will fit. If not.... note which part of the frame interferes.
take more pics.

The carb can be pointed out to either side, by using a similar sized metal elbow...attached with a short section of rubber hose & hose clamps. there are pics of this method on this site.

there's more..... but let's see what everyone else has to say.

 

[echotraveler]

hey srdavo i didnt get the counter clockwise movement your talking about, but i did unscrew, reposition and screw again.....now the motor is dead center from the top view and solid in the frame...

added the muffler, i would like to bend it close to the frame.

 

[srdavo]

hey srdavo i didnt get the counter clockwise movement your talking about, but i did unscrew, reposition

good... by repositioning.... you accomplished the CCW movement needed.

don't try bending your muffler, just yet. It will need to be REMOVED from the Bike first and probably heated with a torch, to make a smooth bend.

there are two more important things to do 1st:
Solidly, fill in the gap between the rear mounting block & the engine, (Did you get an extra mounting block with your kit?)

and
attach an elbow to your intake manifold so the carb will turn 90 degrees to the left or the right.

The carb can be pointed out to either side, by using a similar sized metal elbow...attached with a short section of rubber hose & hose clamps. there are pics of this method on this site.

I haven't located a pic yet

 

[srdavo]

here's one: http://i15.photobucket.com/albums/a356/bushpig450/Sassy/DSC03621.jpg

this will give you an idea on what can be done to make your carb fit.
note: this can be done without welding

 

[ENO]

hey ECHOooo..ENO (Down Under)..This is why we need Super Moderators and with the info youre getting you start with the right ideas and mechanically know how and then you have no hiccups down the track...I like the exhausts fitted by the "Muffler Man" ($30) and to have them extended so they neatly sit under the motor and clear the pedal nicely..(Pic)..Goo for it you enjoy the build as much as the ride sometimes..Thanks Davo..Good luck ECHOooo...ENO

 

[echotraveler]

SrDavo: there are no other mounting blocks that i can see...now that i think aobut it thers a "U" shaped screw witha metal square with 4 wholes...i thought that was another braket.

about the carby, is the elbow your talking about metal or bendable plastic (like water hose)? im not getting how not to weld ti?

i wont bend the muffler myself, the muffler man's gonna earn his money.
there is a mounting bracket for the muffler, i may need to shorten it.

Eno: will enjoy the build as much as i can, making any problem the adventure for the day. that muffler looks badass. When the muffler is heated, does it loose the "chrome"??

another step is getting that rear sprokets center to fit my hub...1/2" bigger

 

[echotraveler]

by the way i will buy something to fill the gap..in the rear mount, its an easy task beacuase thers a piece of rubber on the frame for protection

 

[cooltoy]

If you put a round file into a drill, it makes making that centre hole easy. Just go in and out and round and round , along with common sense. You would be surprised how well a spinning file can remove metal.
Heating will turn the chrome blue on the muffler but you could always paint it black with B-B-Q paint.

 

[echotraveler]

lol yeah im trying to keep things simple, but muffler guys here dont do anything. and went to a machine shop and they also didnt do it, now im going to a guys house, he does metal work milling torneo.....hes gonna help me for sure, people are thinking im looking for presision cutting and pressision bending...im not sure i want that $$$ but im having fun looking around!