Treesus
Probably not sane.
Hello Ton-ers,
This is not a really cafe project. I am really into small-bike long-distance travel, so most of these changes are pointed in that direction. I am putting this up here to glean some of the wonderful wisdom available from you mad-tinkerers. Much thanks to the wizard PJ who has already helped me immensely by putting up with my questions and anyone else who has posted a useful tidbit somewhere in this vast series of magical tubes we call the internet.
Now for a wordy introduction to foster understanding of the project for anyone who cares. Maybe no one.
When I got the bike it looked like any other stock 360. It had a few dents and scrapes, but nothing major and after a good tuning of the engine, pedals and cables it was a great ride. I eventually changed a few minor items like the bars and headlight unit, put on some better tires, and attempted to get better flow out of the stock pipes by cutting out the baffles about 6 inches in from the end.
Before making camp on my second long trip. Burlap bag on the back is a gas can, black side bag is full of tools.
Anyhow, after a few 2-4,000 mile road trips on this tiny champ I decided I wanted longer range for those intimidatingly long stretches of desert without carrying a gas can on the back. I also wanted the pegs moved to a position more comfortable for someone my height but not way back where everyone puts rear-sets on these. Annnddd.... I also wanted to try boring and porting an engine purely because I had never done it. Suddenly I wanted to build my own bike out of this... well, shift. Project time.
General Project Goals:
(there are items here people will warn me about, but most of the controversial stuff is already done)
~Increased capacity tank with elongated trials/cafe mix look that maintains an impression of original tank
Add a crossfeed line for two halves to feed better. (Who hasn't run out of gas to find the right side still has plenty? Second reserve, I guess).
Make the tank higher so that when I stack a sleeping bag and such on top I can use it to lean forward on during long rides (did this before and it helped my back and cut down on wind fatigue)
~Increase Displacement to 383” with GS850 +.5mm pistons
~Make engine more durable for long distance highway riding at 65mph (oil feed and gearing changes)
~New Clutch with stiffer springs (10% I believe, from Dime City). Original was slipping quite a bit.
~Custom foot peg and controls position
~Custom exhaust
~Extend 1.5” and strengthen/stiffen swingarm
~Brace frame for more stiffness
~Generally make it look extra badass
~Have Fun
I actually started working on this project in January 2012. With my comfortable, tool-stocked Utah workshop and consistent paychecks I was cruising along to have it well done and finished by April at the latest. However, it wasn't to be. I got a job opportunity that in terms of advancing my career I couldn't refuse. So, I sold most everything I own and spent that plus my savings to move up to Alaska and be a bush pilot apprentice. I have no regrets because everything is working out very well, but living up here is expensive and the pay is minimal which has left me eating ramen and still lacking any money for motorcycle work. Also, without a good portion of my tools and a solid workspace, I haven't been super motivated.
However, I've decided to get crafty and at least do what I can until I can start putting a bit more money in again.
So.... A sacrificial tank. I procured two beat up and rusy 360 tanks to Frankenstein into one super 383 tank. Aircraft Remover at work.
My highly missed former workspace with the engine pulled.
Here is a mock-up with an upper shell of the tank tack-welded to get an idea for the new profile. The headlight is too low because I just loosely set everything together and it slid down. Please excuse the poor picture quality.
Here is another mock up with the tank a bit further along. I learned MIG welding a thin steel tank is a pain is the arse, but it is possible with loads of patience. It looks rippled and uneven, but that is just a result of grinding off tiny slag and the beads. It is actually pretty smooth and didn't take too much pounding to get the curves right. The new tank is 3" longer, a total of 2" wider at the rear and .5" wider at the front, and on average about 1.25 inches taller. BUT, it still fits on the stock tank mounts with easy access to the rear rubber mount.
The swingwarm is 1.5" longer than the stock and braced with square still tubing for most of the length of each side. The extension plugs (made by Wrench Tech Racing as a custom length kit) are pressed into each side of of the cut arm about an 1.25"
Now for the engine.
I had acquired some GS 850 pistons to add a grand total of 2.5mm to the diameter, and had it bored. I was originally going to do a resleeve for longevity but the motorcycle machinist who I was going to have do both the bore and sleeve talked me out of it (not easily, mind you) after measuring everything up. He said it was well within a durable range. We will see...
Anyhow. The rockers and cam had some pitting, so those will be sent off for resurfacing and hard facing as soon as the money rolls in. Pitting can be seen in these photos:
Also found my tensioner was mildly broken. Thanks to previous advice, I have a post-recall NOS tensioner sitting around already. It would be really nice if someone started making and selling a viable replacement piece for that.
Journals.
The cam journals definitely have some wear, although it wasn't bad enough to allow movement resulting in a leaking points seal. Thus, I'm not sure how serious this is. Any input here? Also, does anyone have a solution for this other than buying a new head? I read somewhere on here about someone putting a thin layer of JB Weld to fill in the grooves. If that was you, did it work?
Also, does anyone know a machinist or someone with a media blaster within 100 miles or so of Anchorage?
Whew that was a lot, but is all for now. Cheers,
Tree
This is not a really cafe project. I am really into small-bike long-distance travel, so most of these changes are pointed in that direction. I am putting this up here to glean some of the wonderful wisdom available from you mad-tinkerers. Much thanks to the wizard PJ who has already helped me immensely by putting up with my questions and anyone else who has posted a useful tidbit somewhere in this vast series of magical tubes we call the internet.
Now for a wordy introduction to foster understanding of the project for anyone who cares. Maybe no one.
When I got the bike it looked like any other stock 360. It had a few dents and scrapes, but nothing major and after a good tuning of the engine, pedals and cables it was a great ride. I eventually changed a few minor items like the bars and headlight unit, put on some better tires, and attempted to get better flow out of the stock pipes by cutting out the baffles about 6 inches in from the end.
Before making camp on my second long trip. Burlap bag on the back is a gas can, black side bag is full of tools.
Anyhow, after a few 2-4,000 mile road trips on this tiny champ I decided I wanted longer range for those intimidatingly long stretches of desert without carrying a gas can on the back. I also wanted the pegs moved to a position more comfortable for someone my height but not way back where everyone puts rear-sets on these. Annnddd.... I also wanted to try boring and porting an engine purely because I had never done it. Suddenly I wanted to build my own bike out of this... well, shift. Project time.
General Project Goals:
(there are items here people will warn me about, but most of the controversial stuff is already done)
~Increased capacity tank with elongated trials/cafe mix look that maintains an impression of original tank
Add a crossfeed line for two halves to feed better. (Who hasn't run out of gas to find the right side still has plenty? Second reserve, I guess).
Make the tank higher so that when I stack a sleeping bag and such on top I can use it to lean forward on during long rides (did this before and it helped my back and cut down on wind fatigue)
~Increase Displacement to 383” with GS850 +.5mm pistons
~Make engine more durable for long distance highway riding at 65mph (oil feed and gearing changes)
~New Clutch with stiffer springs (10% I believe, from Dime City). Original was slipping quite a bit.
~Custom foot peg and controls position
~Custom exhaust
~Extend 1.5” and strengthen/stiffen swingarm
~Brace frame for more stiffness
~Generally make it look extra badass
~Have Fun
I actually started working on this project in January 2012. With my comfortable, tool-stocked Utah workshop and consistent paychecks I was cruising along to have it well done and finished by April at the latest. However, it wasn't to be. I got a job opportunity that in terms of advancing my career I couldn't refuse. So, I sold most everything I own and spent that plus my savings to move up to Alaska and be a bush pilot apprentice. I have no regrets because everything is working out very well, but living up here is expensive and the pay is minimal which has left me eating ramen and still lacking any money for motorcycle work. Also, without a good portion of my tools and a solid workspace, I haven't been super motivated.
However, I've decided to get crafty and at least do what I can until I can start putting a bit more money in again.
So.... A sacrificial tank. I procured two beat up and rusy 360 tanks to Frankenstein into one super 383 tank. Aircraft Remover at work.
My highly missed former workspace with the engine pulled.
Here is a mock-up with an upper shell of the tank tack-welded to get an idea for the new profile. The headlight is too low because I just loosely set everything together and it slid down. Please excuse the poor picture quality.
Here is another mock up with the tank a bit further along. I learned MIG welding a thin steel tank is a pain is the arse, but it is possible with loads of patience. It looks rippled and uneven, but that is just a result of grinding off tiny slag and the beads. It is actually pretty smooth and didn't take too much pounding to get the curves right. The new tank is 3" longer, a total of 2" wider at the rear and .5" wider at the front, and on average about 1.25 inches taller. BUT, it still fits on the stock tank mounts with easy access to the rear rubber mount.
The swingwarm is 1.5" longer than the stock and braced with square still tubing for most of the length of each side. The extension plugs (made by Wrench Tech Racing as a custom length kit) are pressed into each side of of the cut arm about an 1.25"
Now for the engine.
I had acquired some GS 850 pistons to add a grand total of 2.5mm to the diameter, and had it bored. I was originally going to do a resleeve for longevity but the motorcycle machinist who I was going to have do both the bore and sleeve talked me out of it (not easily, mind you) after measuring everything up. He said it was well within a durable range. We will see...
Anyhow. The rockers and cam had some pitting, so those will be sent off for resurfacing and hard facing as soon as the money rolls in. Pitting can be seen in these photos:
Also found my tensioner was mildly broken. Thanks to previous advice, I have a post-recall NOS tensioner sitting around already. It would be really nice if someone started making and selling a viable replacement piece for that.
Journals.
The cam journals definitely have some wear, although it wasn't bad enough to allow movement resulting in a leaking points seal. Thus, I'm not sure how serious this is. Any input here? Also, does anyone have a solution for this other than buying a new head? I read somewhere on here about someone putting a thin layer of JB Weld to fill in the grooves. If that was you, did it work?
Also, does anyone know a machinist or someone with a media blaster within 100 miles or so of Anchorage?
Whew that was a lot, but is all for now. Cheers,
Tree