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August 18th, 2014, 09:27 PM   #61
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Originally Posted by bushmechanic View Post


I might get it right one day carl
he's in Oz for gawdsake! The whole world is upside down!

Ok, how do you "machine" a bearing to be narrower without messing up the internals?
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August 19th, 2014, 03:31 AM   #62
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dunno Goose, ive never done it seems like you just put it in a lathe and machine it with carbide or use a surface grinder

is it up the right way yet Carl ?



bit of stuffing around to get the starter to fit, moved holes in the bracket and filed the case down. do you like the black hammertone finish ? its called toasted motul with FCR tint



welded a 7/8" nut over the drainplug





carb adapter specially made with proper carb alignment for the 650 cases, Mopwer and i did the design, he was able to print out a few different ones with STL rapid prototyping







smooth transition and an oring grove, i didn't use the oring just 3bond



Mopwer wanted one in 40mm so made a few of those,



with cnc its dumb not to make more than one



these were out of a 20mm sheet which left the base thinner than I think is proper so ive given them all away bar one 40mm one.

if these are something people want i can do a run of 10 or so from 25mm sheet with a thicker flange, they are for the 650 cases only.
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August 19th, 2014, 04:26 AM   #63
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Hey Bushie,
Youre not only THE Mechanical WIZARD, but also a photo wizard?

Grtz Rens
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August 19th, 2014, 04:39 AM   #64
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i use a Canon powershot G2 bought in 1999, been apart a few times

do you like my hat selfie pic?

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Last edited by bushmechanic; August 19th, 2014 at 04:41 AM.
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August 19th, 2014, 06:18 AM   #65
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Hey Bushie,
Well that hat selfie is brilliant, but to use it for a logo seems me to be difficult, especially the feather
But the portait will be the most challenching thing to cnc machine!!!!
The Canon G2 is indeed a very good camera.
Hope that if i get a good stickerset, that i can place some good photo's to.

Grtz Rens
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August 29th, 2014, 09:46 PM   #66
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couldn't shift through the gears properly with the cover tightened up

the clutch shaft and everything related to that is located closer to the crank in the old cases so when I put the new cover on it pushed the selector shaft backward which in turn pushed the shifting ratchet mechanism into the underside of the shift star.

(One of these bits ran into something else )


measured the location of the crank oil galery seal in the cover and found it out by 0.3mm so drilled out the locating holes for the dowels so at least the crank seal is happy.

the shift mechanism I just bent it out of the way so it doesn't hit the shift star, kickstart shaft doesn't care much about misalignment, we will see how the e start gears like it.

high quality picture



found some old forks laying around, Scotts damper, bike now also has brakes and clutch.

plenty of boring stuff left to do, prolly take a while
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August 30th, 2014, 04:05 AM   #67
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normal bike!

... I don't always have apair of old forks laying around, but when I do, they're Íhlins.
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August 30th, 2014, 04:29 AM   #68
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Hahaha Bush might have woken up one day and said "I might have a berg laying around somewhere" and turns out he actually did!

It starts to look familiar to me now

That doesn't look like the stock seat, is it?
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August 30th, 2014, 04:57 AM   #69
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good to see havn;t given up on ur project ya old shaggs
photo wizard just suit ya nicely dude

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August 30th, 2014, 05:23 PM   #70
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seat is a guts its taller than stock, got it of ebay with a gearbox, rear shock and a stator all for $180 inc shipping from the us
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