well I got the frame back with all the welding done and have started the paintwork. I've sprayed the bike in a VW yellow but to be honest there are loads out there to choose from in that bright yellow. the idea is to use cellulose and then as things need rewelding you just spray some primer in quick and yellow when you can?
this isn't going to be pretty
first thing the lads found was that my spot welds were off course (of course!) and I would have been 3mm out at the wheels. they corrected this and then welded the headstock on, the downtube neatly into the old one. if you look closely at this first photo you'll see that the downtube from the new headstock slips straight onto the old one just above the splay in the frame. also each of the two tubes running underneath the engine hs 4 tiny welds to 4 tiny cuts, this was easier than bending the frame.
they then re-arranged the radiator points as well. they welded up the air filter holes
and the rubber boot hole but I had done the engine breather and the bottom of the old headstock holes with MIG before letting them have it to save them time and me a little money. this is now only half visible at the back.
the front half is now concealed forever behind the new headstock. they've also welded on the new petrol cap mouth (this photo was taken beforehand obviously!).
I'm not pleased to say this but without having sat down and really worked it out, I decided to just make a double male fixing to go in the bottom of the frame spine for the fuel to come from. this means the fuel will be permanently on. the trouble is: TIME! this way we can see how it works and if it leeks. we should learn a lot from it. the pipe only just misses the auxillary tank and the rear shock.
remember, the idea is slow and steady progress by riding and feeling.....
I have fitted a 2003 set of electrics as well as my old 400 engine. I have swopped the valving and base spindle holes from a set of 2003 forks so I can use the big spindle on the front. I have a relatively new set of shiny wheels to go in but the rear is a 19". what the hell! I have a few 19" enduro tyres here that weren't moving so now they'll find a home!
I used an old swing arm I found with new bushes etc. this was in rough condition and to this i added a new chain guard, C & S, another carb.
the carb has the cone air filter back that i used to race with 2-3 years ago. this stops against the shock.
the exhaust just HAS to be the original Doma that I always used to race. this goes around to the right and then crosses through under the carb to exit on the left side as usual.
the left header though wants to caress the frame downtube here though as the downtube has moved some 10mm forwards. so we fit a steel ring around the port exit and the header goes in through this giving us 2mm of gap.
a set of EX bars finish the job, I hate them, I really do but it is a start. someone more organised would have had something sorted by now!
the sidestand is one I find and is in black and off an SM so I shop out a bit more diagonal tube from the 'old' frame and weld it in. I do it to where I like it and ignore all the EX side stands I can see around me....I know better! new springs and a 'c' clip complete the job. I add a 2004 bolt and drill through the oval holes to round them again.
and so we come to the moment of starting it. the bike fires after three kicks and is back to it's old self. I'm using the fuel can that we hang from the roof....this is easy!
the kickstart arm closes in with a whallop against the diagonal bar but there is nothing I can do about it....
now we get ready to ride it for the first time! firstly though, we must fill the three holes with fuel and work out how the four (yes 4!!!) taps are all going to work!
stuff lined up:
I have ordered a set of triple clamps off racfx. they are 11-14mm offset and I'm having the gold anodise changed to a nnice iceberg blue before I fit them. so they are away at the moment.
the 14mm offset KTM set I've had 7-8 years have been fitted for now though.
nothing else is in the pipeline though.....wait till I start troble shooting though! OH MY WORD!!!!!!
I have a deadline to get all this done and ready for next friday (thursday PM then..) when I ride for two days in Wales again!
regards
Taffy
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