Honda & Schwinn D7 Build

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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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 ?

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! :giggle:
 

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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'!
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?
 
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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