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Author Topic: Custom Racer with Aluminium Frame and Sportster Engine  (Read 5768 times)

Offline DM_Andreas

  • Posts: 25
Re: Custom Racer with Aluminium Frame and Sportster Engine
« Reply #40 on: Jan 19, 2018, 01:30:44 »
Look at the 2004 ZX10R frame...cast head and bottom mounts welded to boxed sheet in between.


Sent from my iPhone using Tapatalk

That's actually pretty common with modern frames...

Our machined head stock is stronger than a comparable cast unit, as our raw material is stronger and it does not loose attributes during the machining.

Offline The Limey

  • Posts: 407
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Re: Custom Racer with Aluminium Frame and Sportster Engine
« Reply #41 on: Jan 19, 2018, 05:27:18 »
Cool, you seem to have done your homework.  If you say billet is up to the job then carry-on.  Wasn't being picky, I just genuinely know little about such metallurgical matters.

Looking good, can't wait to see the progress.
I was born a rocker.  I'll die a rocker.  And I'm proud of it.

Offline SONIC.

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Re: Custom Racer with Aluminium Frame and Sportster Engine
« Reply #42 on: Jan 19, 2018, 09:31:26 »
This is very cool!

Take the criticisms with a grain of salt and a smile. A lot of bright folks around here, but in the end it's your project do what you want to do, but don't exclude good advice if you can avoid doing so.

I like it, the hard mount engine is slightly concerning but the mounts look nice and beefy and I don't think you'll have a problem, or at least not a catastrophic failure.

Agreed on the powder, this things going to be too cool looking to cover up. Go clear on the powder.

Offline DM_Andreas

  • Posts: 25
Re: Custom Racer with Aluminium Frame and Sportster Engine
« Reply #43 on: Jan 19, 2018, 09:34:33 »
Then let's do an update again.

First we made some spacers to mock up the swingarm mounts in their final place.







We mainly wanted to check at this point if the frame tubes clear the engine nicely.
As we don't have a proper 3D model of the engine, that clearance/fitment really need to be checked on the actual engine.

So we proceeded and mocked up the tubes for the rear section of the frame.

Note that the top tube has also already been shortened.

That looks then like this.
Everything is roughly in place and a few tack welds hold the parts together...











The the frame went to our welders.

They made a small jig out of some steel tubes which we still had laying around and then TIG welded the complete assembly.

After they did their magic, I put the frame back on the engine to check the distorsion.

That's the result...





While there's of course some distorsion, it's actuall all better then expected.
We don't need to mechanically straighten the frame, it can be used as it.

But that's also due to a small trick!

The swingarm mounts are so far not bored to size, they're still 4mm smaller in diameter.

Once the frame is completly finished and all the small parts are welded on, we'll put the frame on one of our machines and drill out both axle mounts to size, all in one go.

In this way we can make sure they're straight and that the position and angle are correct.

The top tube will also be the oil tank for the engine.

So we had to add a filler neck as well as flanges for the hoses.

The oil feed is down at the left, lower frame rail. It has been internally broken through to the main tube.

The oil return is the long tube, which we weld into the bottom of the main tube.

It's long enough to end over the oil level, when the tank is filled.

At last there's still the cam-cover vent hose.

We used an 8mm tube which goes into the tank on the bottom end and then inside the tank to the filler.

I asked my welder to take some pictures this time...













And that's the current state of affairs...


Offline canyoncarver

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Re: Custom Racer with Aluminium Frame and Sportster Engine
« Reply #44 on: Jan 19, 2018, 12:25:53 »
I'm starting to see it now.  Looks great.    I keep thinking Egli Vincent when I look at it.
--

YZF750/1000R The Fly
KZ 750 Twin
ZRX 1100
KZ400 The Rabbit
65 Norton, My damn Shovelhead chop, and an 86' FXR
more YZF750R's, the KZ's, a Zephyr750...and the unfinished 75' CB550 cafe.
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Offline teazer

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Re: Custom Racer with Aluminium Frame and Sportster Engine
« Reply #45 on: Jan 20, 2018, 18:55:16 »
Check out the Irving Vincent with a similar frame made from 4130 steel.  Looks like a stock Vincent or an Egli but much stiffer. Admittedly they had a different use for their bikes in mind when they designed them.

Offline MiniatureNinja

  • Posts: 431
Re: Custom Racer with Aluminium Frame and Sportster Engine
« Reply #46 on: Jan 20, 2018, 19:10:13 »
this thing is turning out AWESOME! the billet stuff is absolutely gorgeous
'75 Honda CB360 - thread

Offline killerx

  • Posts: 51
Re: Custom Racer with Aluminium Frame and Sportster Engine
« Reply #47 on: Jan 22, 2018, 11:15:01 »
This is looking too cool.
Can't wait to see it finished.
05 Victory Hammer(110hp 115tq @ the wheel)

73 Honda Cl350(Haven't decided what to do with it) SOLD

75 Suzuki GT380

Too much of everything is just enough.

Offline DM_Andreas

  • Posts: 25
Re: Custom Racer with Aluminium Frame and Sportster Engine
« Reply #48 on: Jan 29, 2018, 22:40:08 »
We've been busy again and made a swingarm.

The adjusters on the end and the shock mount are CNC cut billet, the rest is the same tubing we used for the rear of the frame.























Also we've done some more work to the frame.
Added a shock mount and closed the bottom of the main tube.







A first mock up of frame, swingarm and rear shock.









Offline doc_rot

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Re: Custom Racer with Aluminium Frame and Sportster Engine
« Reply #49 on: Jan 30, 2018, 01:49:19 »
nice work. swingarm looks stout.