Honda & Schwinn D7 Build

Discussion in 'Photos & Bicycle Builds' started by Irish John, Dec 14, 2009.

  1. Irish John

    Irish John Guest

    Here is my latest Fosscati Billinudgel Bullet 2010 build. The differences between this and previous Billinudgel Bullets is that I stove enamelled the tank in the kitchen oven and I spray painted the engine cover black to match the bike. I've finally managed to get the engine mount nearly perfect after so many builds but this bike had a few serious problems.
    The chrome literally fell off the handlebars during the build (really bad chroming from Schwinn in China but that's nothing new). The front v-brakes were harder to set so they worked effectively than any previous D7 I've had and I spent 15 hours fiddling around to get them to work (problem caused by poor precision welding of bosses to forks). I used axle spacers to help get over the problem and filed the caliper holes to allow the shoes to go low enough to hit the rims and not the tyre. I split the downpipe on the poo poo exhaust trying to bend it cold using wooden blocks in a vice - I didn't want to use gas and discolour it. The Grubee freewheels have also taken a quality nose dive and I had to dissemle it and rebuild it using grease and loctite on the flange. The sprocket clamp is my own fabrication in stainless steel.
    Have to order a whole new one because they don't sell just downpipes.
    The rear rack is always a nightmare to fit because it isn't very precisely measured and is a brute force job using 2 strong men.
    That's about it but the bike will eventually have it's long exhaust and also a Brooks 119B black leather saddle with a bum area about the size of a cricket pitch and huge coil springs (5 springs in all). The saddle is my Xmas present to myself and I'm hoping it will be supremely comfortable. Incidentally I don't think the HS motor could pull this bike because it is steel and weighs a ton. I wouldn't even consider trying to use one.
    In my view and from my experience I much prefer the alloy Schwinn cruiser frames because they are better crafted but this steel frame comes with springers and the alloy frames don't and can't fit them cos headtubes are too long. The quality at Schwinn has taken a nose dive on next years models and I am seeing all sorts of little corner cutting tricks in the manufacture. Sadly the prices haven't nose-dived to match the quality fade - this bike retails for Aus $975.00 and it isn't worth the price believe me. For an extra $150 you can get an Electra which is about 30% better made.
     

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    Last edited by a moderator: Dec 14, 2009

  2. Irish John

    Irish John Guest

    Finished Fosscati FG4 Billinudgel Bullet

    Here is what the finished Fosscati FG4 Billinudgel Bullet 2010 model looks like.
    She'll be getting a Brooks saddle tomorrow so I'll be taking more pics when I install the saddle. It's a B190, their largest saddle, with room for two enormous buttocks. New features include twin HID headlighs that can fry a snake at a hundred paces and a cigar lighter with Blackberry reception!
     

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    Last edited by a moderator: Dec 21, 2009
  3. cwucat42

    cwucat42 Guest

    Well done. I love it! I'll bet you get a lot of comments.
     
  4. ballermj23

    ballermj23 New Member

    nice bike... liking all the stuff your have done it...
     
  5. Beautiful classic looking bike. How does she run?
     
  6. Irish John

    Irish John Guest

    Thanks guys for the compliments. She runs really well BTW Mike. It is a heavy steel bike and so it isn't quite as responsive as the my alloy Schwinn but it holds its own in the wind and it will cruise at the same speed as the lighter bike - probably uses considerably more fuel though.
    The new Brooks saddle is really comfy and I love sliding about on the smooth leather. The front coil spring is a bonus and I reckon after a couple of years I'll have stopped thinking about the Aus $286.00 I paid for it and the air freight from UK. It really does smell good as well! I'll post a picture of it tomorrow. The added comfort is exquisite but just because the bumps are no longer felt doesn't mean the bike likes going over bumps. The standard Schwinn saddles are very very good too but in intense heat like today the leather is much cooler on the old posterior and the wedding tackle appreciates the big spring at the front of the saddle.
     

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  7. Irish John

    Irish John Guest

    I have come to the conclusion after building ten of the Schwinn Deluxe 7s that the cheaper alloy Schwinns are a better bike overall because they are lighter and consequently less wear and tear on the drive train. The D7 is too heavy and loosens the 11T freewheel drive sprocket all the time even though I threadloc it closed with red threadloc and leave it 2 days to set. The alloy Schwinns haven't got the springer forks and can't take them cos the head tube is too long but the rigid tapered steel forks are twangy enough and the ride is quite adequately comfortable.
    I really don't reckon the D7 is worth the weight and the high maintenance costs even though it is comfy, beautiful and holds its line in a crosswind.
    I think I might try a Felt MP next if I can get one in Australia.
     
  8. Irish John

    Irish John Guest

    Some pics of my bike with the Brooks B19 saddle

    Here are some recent pics of my Schwinn deluxe 7 with the Brooks saddle fitted. The saddle is extremely comfortable. I also respoked the rear wheel with 12g swiss DT spokes (sorry they are only 14g cos the hub won't fit 12g) cos the stock ones were breaking on the rght side hub flange.
    Since posting this I took the bike out and the saddle rails snapped. I think I need a special dual rail clamp to grip all 4 saddle rails but at least Brooks will probably replace the broken rail gratis. Stay tuned. $287 worth of saddle now awaiting a new part. Unknowingly I was wearing my T-shirt inside out which is supposed to bring luck!!! The local bike shop lent me a saddle to ride home with.
    Called Brooks in England & new rail & bolts etc are being sent out to me today. That's the sort of service I expect from the best of British.
    Actually one side of bottom rail was snapped without me knowing it and I only noticed when the other side broke. I will probably have to delete the suspended saddle post so I can fit the twin rail clamp on. If the saddle had come off I could have been rodgered by my own saddle post and if you are to be rodgered by a saddle post then it may as well be a sprung saddle post cos it mightn't be quite so sore! Maybe it was my lucky day after all.
     

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    Last edited by a moderator: Apr 23, 2010
  9. cwucat42

    cwucat42 Guest

    D=7

    I love what you've done with the bike. It is a beautiful ride! My second build is a New Belgium Fat Tire Ale bike (2009) Schwinn. It's pretty heavy, but I love the tank and the springer fork. I've posted pictures in the pic gallery under 'New Belgium'. Keep on motorin'!
     
  10. Not too impressed with the saddle braking like that , takes a lot to distress/fatigue the kind of steel that SHOULD be made from .Do Brooks have a specific clamp ?
     
  11. Irish John

    Irish John Guest

    They supply a special double rail clamp but it is for a rigid saddle post. I just attached it by the bottom rail because I use a suspended saddle post and that is why it broke. I have fabricated a special spacer so the Brooks can fit properly on a suspended saddle post - see picture.
    It broke because I installed it by the incorrect method but, despite that, Brooks are sending out the replacement parts under its lifetime warranty.
    That's what they mean by The Best of British Simon.
    If you are lucky enough to have been born British Simon, you can have been dealt an ace from the pack of life! :jester:
     

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  12. Irish John

    Irish John Guest

    Thanks cwucat, the D7 is a nice bike but it breaks spokes cos it is so heavy. It is made even heavier than your 'New Belgium' because it has a Shmano Nexus 7 spd hub and I install a 5X thicker thornproof tube with slime because I don't ever want a puncture. I think if you used the extra engine spacer at the front of your engine as opposed to the rear it would probably have been easier - I haven't put a 2-stroke into a steel Schwinn but I have done so on the Alloy ones which are similar geometry but thicker tubing.
    http://www.motoredbikes.com/showpost.php?p=262693&postcount=1
    I found respoking with DT Swiss fixed the spoke problem.
    I reckon the New Belgium is the same as the D7 except the D7 has a 7 spd hub and, in Australia, front V-brakes on the springers and they (the brakes) are a total must have because the rear coaster is pretty pathetic as a brake.
    On your thread someone reckons the Electra is similar to the New Belgium but the downtube is different and the geometry between the downtube and seat tube is different and it is necessary to make the engine tray much longer to fit. Fetor 56 built a Honda\Electra and has a thread on it. he used telescopic front forks as well. The Electra springer comes with a single bolt caliper brake that is really insulting on such an expensive bike. They are beautifully made etc but are not as good for motorising as the Schwinns which give you more value for the price I reckon. I like the alloy Schwinns best but they can't fit a springer because the head tube is 7.5" long. Are your fenders stainless and did you have to cut the rear one to let the chain past? Are the tyres wider than 26 x 2.125?
     
  13. cwucat42

    cwucat42 Guest

    D-7

    Hi,

    The fenders are painted an aluminum color. I wish they were chrome. The rims were originally alloy, but I had the rear re-spoked with a heavy duty hub that came with the engine kit. It was a disaster from the start. It was too wide and the free wheel spit out the bearings so I replaced the rims with ones off a Schwinn Cruiser Deluxe-I'm MUCH happier with them and they look better. The tires are 26 X 2.125. We took a 7 mile ride tonight and had a blast! Take care.

    Shawn
     
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