DO THE TON

Blood Sweat Tears and Grease => Projects => Cafe Racers => Topic started by: loekm on Dec 03, 2011, 10:59:46

Title: EGLI frame, TR1 engine, build from scratch
Post by: loekm on Dec 03, 2011, 10:59:46
Hi all,

This is my attempt at building a bike from scratch... The project is running for a few months in construction, and for years in my head ;) so first some pictures in from start to where the project is now.

CAD is nice to get going:
(https://lh5.googleusercontent.com/-yFvCaBtO2tw/TojQCUsPZDI/AAAAAAAAAEY/Ftnh5yqtcl8/s1024/motor%252520totaal.JPG)

Start of the frame:
(https://lh6.googleusercontent.com/-lpIiIAjB4Fo/ToR5a8PaQ6I/AAAAAAAAABo/13wRwwaweGc/s912/IMG_0561.JPG)

More preparation on the frame:
(https://lh5.googleusercontent.com/-1ruq159p7go/TpmQU3i4ZjI/AAAAAAAAAFQ/QEeS-LF1nIg/s912/IMG_0602.JPG)

Frontwheel hub (CB750) "before":
(https://lh5.googleusercontent.com/-l4jL0-qlyjQ/TpmW_UXqvyI/AAAAAAAAAFk/rjxBRDjksiQ/s912/voornaaf%252520van%252520FTR%252520classic.JPG)

Rearwheel Hub (CB750) "after":
(https://lh4.googleusercontent.com/-3kM-RAP9EQI/TpmP_Lwe_JI/AAAAAAAAAEw/3E1iA_fX38A/s912/IMG_0595.JPG)

Construction on fork for rear wheel:
(https://lh6.googleusercontent.com/-Ks2JUzxIYIU/Tq1pp7JZ-RI/AAAAAAAAAGY/FOp-2ebzBsM/s912/mallen%252520voor%252520de%252520maatvoering.JPG)

More constructon:
(https://lh3.googleusercontent.com/-sVSR3O7qZhM/Tq1okHvFTzI/AAAAAAAAAF0/UYrPGvi2aG4/s912/Achtervork%2525203.JPG)

Construction on main frame:
(https://lh6.googleusercontent.com/-oC7r9BgBFSk/Ts6vljoJGNI/AAAAAAAAALo/pHMq_kjFzpg/s912/IMG_0710.JPG)

More construction on main frame with tank cover:
(https://lh4.googleusercontent.com/-mcz9XSRiMc8/TtIeNTp4F5I/AAAAAAAAAMU/QBdt8_o2Xlw/s912/IMG_0719.JPG)

Actual situation with jig getting better and better:
(https://lh6.googleusercontent.com/-yYbHghCc3hk/TtoOUYoaCfI/AAAAAAAAANo/UuYB4cs1quY/s912/IMG_0734.JPG)

Hope to get rolling chassis ready this winter. Then of to inspection for chassis number, and if OK build the rest and get a license plate before summer ;D

I'll try and post pictures as often as possible.
Enjoy the weekend!

Best regards,

Loek

Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: JohnGoFast on Dec 03, 2011, 11:15:37
Totally damn awesome, looks like you have some great tools at your disposal and a knowledge of how to use the. These are the type of builds that inspire most of us. Can't wait to see where this leads! Thanks for posting.
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: JohnGoFast on Dec 03, 2011, 11:17:31
Oh and welcome to DTT!
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: GoingsMoto on Dec 03, 2011, 11:34:27
This is awesome, I love seeing engineers/math people build bikes. What kind of steel are you using for the frame? It looks like you are going with rear engine mounts? what kind of suspension are you going to use? a linkage system or a cantilever?

I am surprised you are not going with a Hossack front suspension, or some time of crazy set up.
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: Erskine on Dec 03, 2011, 14:05:50
Bloody brilliant - totally inspiring. 
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: beachcomber on Dec 04, 2011, 08:54:39
hey Loek - awesome work. 8)

I USED to have facilities like yours  ::) - here's my 550 Porsche Spyder [replica ] spaceframe under construction at my pal's workshop in Heyda [ Saxony ].

A distant memory now - here's my current jig bench. 1923 solid [?] Oak desk with REAL leather insert. Oh yes, lock up garage with running water [ from roof ] and no electricity. Ha,ha, Jealous - me? When I was a kid I worked in the street, so I guess I haven't quite come full circle after 50 years !! ;)

(http://i1213.photobucket.com/albums/cc472/manfredvonheyda/550101.jpg)

(http://i1213.photobucket.com/albums/cc472/manfredvonheyda/Picture038-1.jpg)
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: loekm on Dec 04, 2011, 10:05:11
Hey gentlemen,

Thanks for the compliments! The facilities are indeed very nice ;D Nothing to complain there!

@goingsmoto: The steel is just good old S235. I think in English it's called mild steel. The small diameter tubes are seemles though and that's about it. Nothing exotic.
The engine will be mounted at both cilinder heads and at the back, the back part is mostly for attaching the rear swing arm. Although a connection between the main frame and the back of the engine is not needed for strength I'll make it anyway because i like the looks and the frame becomes one piece instead of two. Suspension will look as classic as possible... like this one:

(http://beveltech.net/PA-VernR0511-005.jpg)


This is my first actual build so nothing to exotic suspension wise, maybe the next one ;)

Enjoy your sunday!

Best regards,

Loek
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: loekm on Dec 06, 2011, 12:55:20
Hi there,

Finally took some time to update the drawings a little. Frame starts to get there.... Weight as shown on pictures is a healthy 10,3 Kg which i'm happy with so far.

Picture 1:
(https://lh4.googleusercontent.com/-7r2dTktYiGc/Tt47P5wOv8I/AAAAAAAAAOU/oJqOKsqw-WM/s912/Frame%252520actueel%2525202.jpg)

Picture 2:
(https://lh4.googleusercontent.com/-r21ZXomz69k/Tt47P6giwqI/AAAAAAAAAOQ/anuE30rAuDc/s912/Frame%252520actueel.jpg)

No fabrication this week, maybe some extra CAD... will try yo keep you all informed.

Best regards,

Loek
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: Swagger on Dec 06, 2011, 19:16:47
Looks like a fun build, you're doing what I hope to with mine at some point.
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: 50gary on Dec 06, 2011, 23:13:05
Great start this will be a nice bike for sure.  I'm always a bit jealous of the CAD layouts.
  Cheers, 50gary
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: bluesmoke69 on Dec 07, 2011, 01:04:49
Miss my day's at the machine shop, because you can make anything. looking great.
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: Ringo on Dec 07, 2011, 01:12:13
Very nice.  Can't wait to see more.
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: loekm on Dec 23, 2011, 06:23:47
Goodmorning!

Thanks for the likes folks! I Had some time to start the welds on the frame. I'm not the one who's welding but a nice colleague at work has done a very nice job! the frame is slowly getting there, hope to get it finished early next year.

Preparation:
(https://lh6.googleusercontent.com/-vQ_HsUPTEfg/TvQyQYik8SI/AAAAAAAAAOw/uC7L3U8myhM/s1024/IMG_0010.JPG)

Welding:
(https://lh5.googleusercontent.com/-hxJa6O-kMvA/TvQydq467GI/AAAAAAAAAPI/gPlxsz9ORH0/s1024/IMG_0014.JPG)

More welding:
(https://lh3.googleusercontent.com/-D7qXivl0Pf0/TvQyfRVpK-I/AAAAAAAAAPU/0n7sAIPFq2c/s1024/IMG_0016.JPG)

Result:
(https://lh4.googleusercontent.com/-tSiyVBN-mq0/TvQyuxB0NHI/AAAAAAAAAPs/TG1ppmnus1k/s1024/IMG_0020.JPG)

More results:
(https://lh3.googleusercontent.com/-GR2ilg2sIEE/TvQzAbEVGTI/AAAAAAAAAQM/mwuTUut9FDQ/s1024/IMG_0024.JPG)

I'm pleased with it, off for vacation, more to come next year!

Best regards,

Loek
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: beachcomber on Dec 23, 2011, 08:05:38
Loek,

enjoy your break.

Please keep them coming next year - truly inspirational. 8)
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: JohnGoFast on Dec 23, 2011, 11:10:49
Those Sir, are some nice looking welds.
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: Swagger on Dec 23, 2011, 13:01:17
Very nice indeed!
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: Erskine on Dec 23, 2011, 16:31:59
That welding is pretty impressive!
Looking forward to next year :)
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: loekm on Jan 11, 2012, 15:33:18
Hi all,

The new year is well on his way, so time for some extra pics.... The frame has seen some extra welding. The front cilinder mounting, and the tubes that wil hold the swing arm in place are done.

Back part of frame fully welded:
(https://lh6.googleusercontent.com/-C5ORtB3mykQ/TwmEn4r9DLI/AAAAAAAAAQk/Ei6yNqO3c8Q/s1024/DSC_3648.JPG)

Front part of frame step 1 tack welded:
(https://lh3.googleusercontent.com/-BoNc8JkrSYc/TwmFCZ20BXI/AAAAAAAAAQ8/ks9TxSzdJbg/s1024/DSC_3651.JPG)

Front part of frame complete tack welded:
(https://lh6.googleusercontent.com/-VMe66fyq1gw/TwmFHavnaHI/AAAAAAAAARE/NaMvRIHk_Lo/s1024/DSC_3652.JPG)

Overview:
(https://lh3.googleusercontent.com/-D7syeWV8jYc/TwmFKFd1xWI/AAAAAAAAARM/lMn65ba4uI0/s1024/DSC_3653.JPG)

Tomorrow the lasercut parts arrive (plates for bracing swingarm and plates that "hold" the swingarm, see picture below)

(https://lh4.googleusercontent.com/-7r2dTktYiGc/Tt47P5wOv8I/AAAAAAAAAOU/oJqOKsqw-WM/s912/Frame%252520actueel%2525202.jpg)

So construction of the swingarm is next ad also a mounting point for the back cilinderhead needs to be constructed... but i'm not entirely sure how to do it. So more than enough work remains to get the frame finished....

Best regards,

Loek
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: JustinLonghorn on Jan 11, 2012, 15:38:41
Alright, I am on board.
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: Swagger on Jan 11, 2012, 15:59:38
Whew....something to shoot for! Very nicely done thus far....
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: Cafe Redneck on Jan 11, 2012, 16:37:33
Well, this looks interesting. Do you have plans drawn up on what the completed bike will look like. I'm sure you do, your just going to surprise of us all at the end, I hate surprises. Looking great, keep the photos coming.
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: m357.5 on Jan 11, 2012, 17:07:07
This is wicked, love the build.
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: Rocan on Jan 11, 2012, 23:51:05
extremely jealous of that fab shop!

And those skills! really impressive!


Following this one... I see a future BOTM!
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: ako on Jan 12, 2012, 00:14:38
Nice work so far. Great to see!
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: jimmer on Jan 12, 2012, 00:19:56
Where are your gloves? Nice tigs....
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: Roc City Cafe on Jan 12, 2012, 00:39:04
nice work, would like to see rake and trail numbers, as well as planned f/r loading weights, swingarm angle, sprocket to rear wheel diameter ratio, rear shock velocity ratio and progressive/regressive characteristics :D <- some of us here are truly bike nerds
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: 50gary on Jan 12, 2012, 10:05:07
I would also like to see the chassis numbers?   I've always been interested in chassis more than the engines.  Nice work.  I was wondering about the top tube joint  to the steering head tube.  My question, is this the Proper way to join two tubes of different diameters?  I'm asking because I don't know the answer?  Is this the way the Egli frames were built and that is why you did it that way?  I perhaps would have done it differently?
  Cheers, 50gary
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: joea on Jan 12, 2012, 16:53:03
i feel sorry for you having to deal with all that cheap equipment...ha ha
nice set up and project....
good luck,joe @ vcycle
www.joesvcycle.com
 
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: Swagger on Jan 12, 2012, 18:24:18
hehe....yeah must be hell huh? ;)
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: loekm on Jan 13, 2012, 12:47:24
Gentlemen,

First of all, thanks for the nice words :) of course it's hard to deal with the fab shop! it's hard work... my hands get dirty... I sometimes hurt myself... Can you imagine the horror! ;) .....

Off course it's very nice to be able to use a shop like this, it makes the build possible in the first place. I truely respect the people that build the most awesome bikes in their sheds at home.

Very good to see there are living bikenerds here as well!

My chassis numbers so far:

Rake: 24,5 degrees (adjustable with different inserts in steering head)
Trail: 97mm (depends a bit on tire size)
Wheelbase: 1435 (still open to change a bit, as my swingarm isn't cut to length)
F/R weight distribution: To be discovered
Swingarm angle: Have to check the CAD model after the weekend, swingarm will have some degree of ajustment with offest inserts

@50Gary: In general the steering head tube was welded in this way in EGLI frames, my "extra" reinforcement piece was not in the EGLI frames, but my steering head tube is a bit longer/higher mounted than in most frames i saw pictures of... so I made the decision to weld in some extra sheetmetal. What would have been your solution?

Made some progress yesterday with aligning my swingarm (all fits well, no offset sprockets or spoke paterns needed for the chain). So delivered my hubs to the wheel guy today, he'll lace up some nice 18" excel rims with stainless spokes ;D

Enjoy the weekend people!

Best regards,

Loek



Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: 50gary on Jan 13, 2012, 23:24:44
In reply #12, 5th picture showing the detail of the joining of the two different tubes.  I would have cut a radius (I believe it's 2" 4" diameter?) on the end of the large tube and formed it so the radius would contact the small head tube in a semi-circle.   Probably would have to be heated then weld it to the head tube.  Viewed from overhead the large diameter tube would taper from the 4" dia. to the width of the diameter of the head tube.  This would eliminate the flat end piece made up of the "chord and arc."   Total less inches welded and a simple design?  I'm mean this as shop talk over a pint of beer not in any way critical, as I mentioned I thought your way was the way Egli had done it but I wasn't sure.
  I like your additional head tube brace, I'm doing an Aermacchi 250 replica and will use virtually the same method.  Keep up the good work, excellent and interesting to boot.    This is why this forum is enjoyable for me.
  Cheers, 50gary
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: 1969Honda on Jan 14, 2012, 00:15:27
I'm interested to see how you're going to make your rake and swing arm angles adjustable, are you going to use something similar to an eccentric cam or offset bearing cups? ??? Do tell, I used to work for a small mechanical design firm (I'm no engineer) and enjoyed seeing/assembling the creative ways people would come up with these solutions.  I still try to do a little in SW every now and again but it's definatly a skill you lose with time if not practiced. 

BTW I'm seriously jealous of your facilities and your welder's skills, makes me miss working at the M.E.shop. What was your address again.... I think I have some leave coming up and I know a few guys that are into the whole clandestine thing, just need a truck, a.... oh.... did I say that out loud.... ;D
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: loekm on Jan 17, 2012, 17:03:57
Hey people,

Spent the evening machining some parts for the bike again. Ajustable swingarm is ready (in parts). Just a short picture update :)

Excentric for swingarm:
(https://lh3.googleusercontent.com/-tsDFmt9zOxI/TxXU5O1hM7I/AAAAAAAAATA/aTKPI4wDYyU/s912/IMG_0009.JPG)

Pieces needed to assemble the swingarm:
(https://lh5.googleusercontent.com/-5NFlCNBWhXY/TxXVQFZLPgI/AAAAAAAAAT4/lPi7P95E91A/s912/IMG_0016.JPG)

Swingarm axle partly assembled:
(https://lh5.googleusercontent.com/-tOyYtDmuGxY/TxXVQxYEAHI/AAAAAAAAAUA/fMIks4BHd7o/s912/IMG_0017.JPG)

All the parts in the frame as mockup:
(https://lh6.googleusercontent.com/-tmjkk55HWhY/TxXVaTZPJOI/AAAAAAAAAUU/VYfb3JUxbqQ/s912/IMG_0019.JPG)

Back position:
(https://lh4.googleusercontent.com/-KjfTVoksfwo/TxXViJdGRJI/AAAAAAAAAUo/dj-gqvPsH10/s912/IMG_0023.JPG)

Front position:
(https://lh5.googleusercontent.com/-TEuKupytsj0/TxXViAkPZqI/AAAAAAAAAUs/hqrwRzkm3Hg/s912/IMG_0022.JPG)

The mechanism has 24mm of ajustabillity :) I'm happy ;D and I'll see if it works and is needed in the end...

@50Gary:
I think your solution for the steeringhead will work as well... I didn't think about it your way, it saves some welding wich is good beacause of less heat input, but maybe it brings more "tension" in the large diameter tube because the tube is deformed before welding. My experience tells me that deformed material (heated or not) will release it's tension after welding and maybe that will deform the construction of the steering head during or after welding... who will tell.

It's very nice to have discussions like this for sure! All our bikes get better because of this :)

@1969honda:
I hope this makes clear how the swingarm thingy works. The steering head is somthing different. When it needs changing the angle I have to machine new aluminium inserts... Not a fast job but it is possible and better than grinding and welding the steeringhead again.

Enjoy the evening!

Best regards,

Loek
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: Greg-NWO on Jan 17, 2012, 19:32:27
So cool, these are the types of threads I spend a lot of time scouring the net for :D

Really nice shop and very cool build.  Keep the pics coming :)
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: 1969Honda on Jan 17, 2012, 20:30:41
That's exactly what I had in my head when you mentioned the adjustable angle! Are you going to be welding some type of a clamping mechanism on the back of the swing arm boss around the cut outs to hold the position of the eccentric cam? Or is there more mystery to the puzzle? splines to index off of? maybe a key way?
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: loekm on Jan 18, 2012, 02:56:58
Good morning all,

@honda1969:
Yes... Two pieces of tube, welded at the back will deliver the clamp system, and some sort of indexing is on the way... it'll be a simple stripe I guess. And a tool like the one from an angle grinder (two simple holes in the aluminium part) will do the ajustment. So no special tricks to be expected there :D

@Greg-NWO:
Thanks! i'll keep the pics coming for sure!

Now to work :)

Best regards,

Loek
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: loekm on Jan 20, 2012, 12:47:02
Hey people,

Short update with some pics.

Front sprocket fits! (XS650 sprocket final ratio 18/38):
(https://lh3.googleusercontent.com/-8Lt-d8cAjAE/TxkVMkv7fCI/AAAAAAAAAVE/pu-j0RHARHg/w559-h419-k/IMG_0024.JPG)

Frame back in jig:
(https://lh6.googleusercontent.com/-Oq0Kee5zVRw/TxkVMk-awHI/AAAAAAAAAVI/7YaC7rJnhvQ/w396-h297-k/IMG_0026.JPG)

Start of mountingpoit rear cilinder:
(https://lh5.googleusercontent.com/-zAdwmdBlEXM/TxkVsCh3OzI/AAAAAAAAAWE/NbnMgsKGKMU/w500-h376-k/IMG_0032.JPG)

Mountingpoint of rear cilinder in pieces:
(https://lh3.googleusercontent.com/-8YsBO8AjzkI/TxkV5sqvkZI/AAAAAAAAAWc/jRrFzIV5TOc/w500-h375-k/IMG_0035.JPG)

And it goes together:
(https://lh4.googleusercontent.com/-H9tWh4DhVIc/TxkWITgFnGI/AAAAAAAAAW8/oMnFVGC1iC0/w329-h247-n-k/IMG_0039.JPG)

And last, insert for stearinghead:
(https://lh3.googleusercontent.com/-W_7Nuyg4NAQ/TxkV_W888EI/AAAAAAAAAWk/CWVsRJr9CJg/w500-h376-k/IMG_0036.JPG)

That was last night's progression, to be continued!

Enjoy your weekend!

Best regards,

Loek
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: CrescentSon on Jan 21, 2012, 14:13:14
Can we stick to simple stuff like particle physics and string theory. This beast is making my head hurt. Amazing results so far Loek.
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: dcmspikes on Jan 21, 2012, 14:16:05
yeah im on board for this one.   keep it coming
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: pacomotorstuff on Jan 22, 2012, 15:59:58
Leokm,
I went the same route as you for the sprocket - XS650Direct in Canada is the MikesXS distributor, but I used the optional 520 sprocket.
I don't see any capture method on your countershaft sprocket - are you just going to modify the locking plate like I did (I posted photos on one of the other XV920RH / TR1 threads on the DTT site) or???
I was looking at one of my friend's son's KTM MX bikes and all they use is an external Circlip - simplicity itself!  I went through an industrial supplier's catalogue and found one the correct size to fit the XV / TR countershaft - just haven't gotten around to buying one yet and trying it out.
Let me know about your locking mechanism.
Love your frame - you're building the bike Yamaha should have.
Regards,
Pat Cowan,
Vintage Motorcycle Fiberglass
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: devon on Jan 24, 2012, 13:57:09
Really interesting! I'm definitely tuned in for this one.
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: loekm on Jan 28, 2012, 17:21:14
Hey Guys,

Difficult progress this week.... Some pieces from the last update were welded in place and today I made a small, but difficult, step. At the left side of the frame there has to be a hole through the frame for a very importand mounting point. This is the point that takes the most force when accelerating.

The mounting point:
(http://blogger.xs4all.nl//images/blogger_xs4all_nl/loekm/37505/o_DSC_3682.jpg)

Other side:
(http://blogger.xs4all.nl//images/blogger_xs4all_nl/loekm/37505/o_DSC_3685.jpg)

I knew this mounting point was coming, and today I had enough time to think about it for a bit then measure twice and cut once ;) The plan is to weld a solid piece in the frame and put a bolt through straight into the engine. So accuracy is very importand. And the problem is to clamp the frame... Mill wasn't big enough so drill pres it was... And of course that machine is not as rigid as the mill so clamping was a challenge

Clamping took some fantasy today (and almost 2 hours hours) :) But in the end Mr. holesaw coul do his job, it all worked as planned and they lived happily ever after ;D

Clamping fantasy:
(http://blogger.xs4all.nl//images/blogger_xs4all_nl/loekm/37505/o_DSC_3686.jpg)

And again:
(http://blogger.xs4all.nl//images/blogger_xs4all_nl/loekm/37505/o_DSC_3687.jpg)

The finished hole:
(http://blogger.xs4all.nl//images/blogger_xs4all_nl/loekm/37505/o_DSC_3689.jpg)

And the hole mounting point complete:
(http://blogger.xs4all.nl//images/blogger_xs4all_nl/loekm/37505/o_DSC_3690.jpg)

Next week the wheels are back, and then the swingarm is priority, hope to have it on his wheels within a month or so :D

Enjoy the rest of your weekend!

Best regards,

Loek
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: Staffy on Jan 28, 2012, 19:30:05
The engineering and thought gone into this bike is second to none.  I have to say I'm thouroughly captivated with this build (if not a little jealous of the toys at your disposal).
Keep up the great work and keep the pics coming!
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: 50gary on Jan 28, 2012, 19:35:00
Very nice hold on a rather difficult part.  Frames are always awkward to clamp and the Egli frame takes the prize.  I did a swingarm mounting modification.  Added a boss and second outside plate and a few other things.  We turned the boss O.D. and the I.D. just close but undersized, then bored it on a horizontal boring mill to exact spec.  Holding was easier because of the two bottom frame tubes.   The partial frame is a '73 RT 360 conversion.  Fun to watch your work.
  Cheers, 50gary

Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: loekm on Feb 11, 2012, 07:55:29
Hey Guys,

I've been waiting longer than expected for my wheels.... So in the meantime decided to kill the donorbike...

Bike still complete (sort off):
(http://blogger.xs4all.nl//images/blogger_xs4all_nl/loekm/37520/o_DSC_3693.jpg)

1 hour into the kill:
(http://blogger.xs4all.nl//images/blogger_xs4all_nl/loekm/37520/o_DSC_3695.jpg)

2 hours into the kill:
(http://blogger.xs4all.nl//images/blogger_xs4all_nl/loekm/37520/o_DSC_3697.jpg)

So after almost 3 hours the donor bike is no more and pile of junk is a bit bigger :) The motor stays in the bare frame for easy storage and some measurements. Finally the wheels came back this thursday ;D and I was really happy with that. Today went to the tireshop and got the tires mounted, and now my wheels look like this:
(http://blogger.xs4all.nl//images/blogger_xs4all_nl/loekm/37559/o_DSC_3706.jpg)

instead of this:
(http://blogger.xs4all.nl//images/blogger_xs4all_nl/loekm/37559/o_voornaaf%20van%20FTR%20classic.JPG)

Now there is some more progress to be expected in the next few weeks!!

Best regards,

Loek
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: ProSimex on Feb 11, 2012, 11:36:27
"kill the doner bike"



Yuuuuup, snuffed her but good.
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: 50gary on Feb 11, 2012, 21:43:43
 Loekm  Good call, I have the very same tires on my Honda CX500 conversion. I like them quite a bit.  Good grip and very stable.  Suppose to be good in foul weather but luckily I haven't had to test that facet of them.
 
   Cheers, 50gary

(http://CXon7-5-11forMotus001-1.jpg image by 50gary)
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: VonYinzer on Feb 11, 2012, 21:54:23
This thing sure is puuurdy.
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: loekm on Feb 12, 2012, 15:44:57
Hi 50gary,

Good to hear about the tires, I couldn't find a lot about them so I trusted the tireman in this one. And he has some experience 8).

Next thing on my list is the looks of the bike, I'll try and put everything together for a mockup to check proportions. So wheels, tank, seat, exhaust and of course frame and engine will be put together sort of... We'll see how that works out and the get it going!!

I'll keep you all informed!

Best regards,

Loek
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: 1969Honda on Feb 14, 2012, 07:30:25
Can't wait to see the beast in tins!
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: beachcomber on Feb 14, 2012, 10:39:54
Loek,

I'm posting a pic of MY workshop facilities to make you really jealous ;) ;) ;)

Hopefully all will change in a few weeks when I move into my shared hobby workshop.

truly sensational work my friend ........................ 8) 8)

(http://i1213.photobucket.com/albums/cc472/manfredvonheyda/Picture036.jpg)

Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: loekm on Feb 14, 2012, 16:57:03
Hey Mr. beachcomber,

Thanks for the compliments ;D Hope to make lots of progress soon... There is some sort off classic 4hours endurance demo race in the Netherlands, and it would be a very nice test drive.

Your operation theatre looks awesome  ;) maybe not the space but the parts.....

Best regards,

Loek
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: wfo guy on Feb 14, 2012, 21:00:28
It's obvious to me that you have skills in the machine shop, a friend who can weld, and computer skills. Are you also a painter?  :) I'm enjoying this. I hope you're enjoying the journey.
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: beachcomber on Feb 15, 2012, 05:26:24
Hey Mr. beachcomber,

Thanks for the compliments ;D Hope to make lots of progress soon... There is some sort off classic 4hours endurance demo race in the Netherlands, and it would be a very nice test drive.

Your operation theatre looks awesome  ;) maybe not the space but the parts.....

Best regards,

Loek

In my defence Loek - I'm not normally an untidy person. However, when I had the sudden loss of a second garage [ same size ] that was rammed with my parts and projects - it all had to be condensed into my "working" garage - in 8 hours !

Hopefully, I will be able to post a much better workspace in the next 2-3 weeks after my move.
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: loekm on Feb 15, 2012, 14:39:52
Good afternoon,

@Swivel:
Thanks for the technical comments! I realy like the fact that other people look into the engineering side of my project!

I've seen the construction of the bike you refered to and it is a good option as you explained, but i think that part of the engine is quite strong. It is one of the original mounting points of the engine into the frame, and it takes a big part of the chain force. The smal piece that can be seen in my pictures will be strong, but there will be more mounting points later. We'll see, I keep you informed.

In this gallery: http://www.tr1.de/pages/gallery_sepp.php there are some nice pictures of non standard TR1 engined bikes to compare mounting points.

About the injection on my bike..... it's a plan.... 8) First get this thing safe on the road and then try and see what I can do with the spare engine. Thanks for the camshaft offer! I'll see if they're needed. The injection plan so far is BMW throtlle boddies, and maybe this injection system: http://www.ecotrons.com/ or a megasquirt equivalent.


Thanks again for the comments, please keep them comming!

Best regards,

Loek

Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: Swagger on Feb 15, 2012, 15:01:30
I'm with Loek on this one; EFI is just too good and too easy to implement these days to pass up. I'll be running a microsquirt controller and a couple Buel throttle bodies on mine, I can have it up and running for under $700, tunable via my tablet. I've got those flatslides on the Triumph and as much as I love them (and I do) when it comes time I'll swap it to EFI as well.
It would be difficult to turn away from precise mapping, ignition curve control, elevation compensation, knock sensing etc.....
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: CooperSmithingCo on Feb 16, 2012, 14:03:05
For the swingarm pivot: did you machine a collar to go around the needle bearings? I was trying to figure out the make of the bearing and how it is used, but looking at it I imagine you might have machined the collar so the bearings can't slide inward past the races - which are in turn held apart by the tubular spacer.

Is that what's going on there? If not, what keeps the bearings from sliding inward where the collars would put pressure on the swingarm pivot tube?

For some reason bearings give me the hardest time where they are expected to handle loads in more than one direction - seems it's always necessary to include a small gap in the design. I default to radial contact bearings, but they don't have the contact area of needle bearings.

Wonderful work!
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: 50gary on Feb 16, 2012, 18:10:11
Angular contact bearings will bear load in both radial and axial directions.  Tapered or dual tapered roller bearing will also carry those loads.  Tapered rollers are for heavier loading. 
  Cheers, 50gary
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: loekm on Feb 17, 2012, 03:57:09
Goodmorning gentlemen!

@CoopersmithingCo:
I checked your website a bit.... WOW sheetmetal skills look very nice, frame building as well. About the bearings... The ones I chose are: SKF-NKX-30-Z. They are combined needle / thrust bearins in one piece. Here's the technical sheet I think this makes it a bit more clear. I machined nothing special for the bearings, just some spacers to keep the inner rings in place.

(https://lh3.googleusercontent.com/-ae61xtB_I3Q/Tz4AUJgAKcI/AAAAAAAAAag/hDQqjqPOMQw/s881/SKF.JPG)

@Swagger:
Are you installing EFI at this moment? I would really like to hear your experience in terms of power and torque difference compared to carbs and all the challenges you met ;)

Best regards,

Loek
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: loekm on Feb 17, 2012, 12:06:57
Hi again,

Just checked the pictures from yesterday... did some mockup to see proportions and lines of the bike.

(https://lh4.googleusercontent.com/-yQbBeA5CO38/Tz5BjF7Yu1I/AAAAAAAAAa8/8pkplSM-4Dw/s1055/IMG_0084.jpg)

I'm quite happy with the result, now a week of holliday, and then PROGRESS ;D

Best regards,

Loek
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: JustinLonghorn on Feb 17, 2012, 12:58:02
She looks fantastic, mate.
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: Swagger on Feb 17, 2012, 13:41:17
Loek, that looks great...I hate you! hahaha (joking mate!)

I'm not doing a conversion at the moment but I've done some before using the Megasquirt controller in a couple of cars. As for differences in power delivery, oh my it's a completely different experience.

Before even adjusting the maps (both fuel and ignition) simply the default basic maps I noted that the car started very crisply and the idle was stone steady. Again, before adjusting the maps, the throttle response was notably improved over the previous carburetor system. After a long afternoon on the dyno playing with the mapping we ended up with around 30ft-lb over stock output from a more or less stock 2.4l Toyota 22r.

The Neon on the other hand netted something more like 60ftlb from a 2l with loads of work. It's ported, has a pretty crazy cam, high compression pistons and a very good ignition. I changed from a 49mm throttle body to a 70mm in a fabricated plenum and a merged header with 1.5"x36" primaries.

Basically the more work you do to the engine the more you'll get out of the EFI. In addition to simply better running and more output the 'nature' of the engine changed. I raised the rev limiter to 9000rpm, added traction control in the first 3 gears; 2000lb front wheel drive cars with 200ftlb spin the tires a lot haha. It also allowed me to totally cut fuel on decel which actually netted me a couple mpg improvement too! Other things you can do with the myriad of outputs; multi-stage shift lights, window switching for things like NO2, boost control for turbos and superchargers.

The 'MicroSquirt' unit is more suited to bikes, and like the Mega is totally open source meaning you can tweek the unit to do almost anything you need on a bike. Very cool! I think it's just got less outputs and a few less features due to smaller packaging.

This is the plan for my 920 engine (at the moment)
-Crank, rods, cylinders and heads from a V-star 1100: Lighter than the 920 crank by 6lbs, before any lightening work! The rods have been verified to be stronger than our earlier pieces. The combustion chambers are slightly updated though I'm tempted to weld them up and remachine for a more bathtub shape, the ports are updated and are a great starting point for my port work and the cooling fins are much larger on the V-star parts too.

-11 to 1 compression JE pistons with slip coating on the skirts and ceramic domes. If i can get the combustion chambers and ports clean enough I'll have them ceramic coated too.

-I'm looking at several cam options but haven't settled yet on the grind. Ultimately I'll rework the initial static compression of the pistons (by machining the domes) to suit the cams.

-Since I'll have control of the ignition mapping, the actual ignition driver can simply be a simple powerful system. I'll likely use coil on plug system with the appropriate voltage drivers triggered by the EFI controller.

-50mm throttle bodies from a Buell something or other, though I've also got a set from a TL1000r and a Honda 996.

-2 into 1 exhaust with 45mm x~32" primaries and a 60mm collector. My routing choices all require pipe wrap which I'm fine with as I'll be able to laugh at the plods who will gripe. haha.

So...more than you asked for but I hope it helps...

In short, EFI is really hard to beat.
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: CooperSmithingCo on Feb 17, 2012, 13:54:59
Loekm -

Wonderful, thank you very much for the bearing information, my mind is at ease!

I'm not familiar with the TR1 engine, but it looks remarkably similar to the Virago (xv750) save for the chain drive. What was your motivation for using the engine aside from the low end torque of a v-twin?

Looks great, keep it up!
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: Swagger on Feb 17, 2012, 14:52:27
Maybe you can't port but I can.

I will run whatever throttle bodies suit the end result of my particular engine development, to the point of machining my own if need dictate.
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: Staffy on Feb 17, 2012, 15:52:44
Swivel, the size and makeup of the head doesn't matter.  There are gains to be had with EFI due to it's superior mixing ability.  It gives real time adjustments to the air fuel ratio based on situations happening inside the engine and atmospheric inconsistencies.  Carbys are set and run.
Anything else you throw into the argument is invalid.  Put simply, for efficiency of air fuel mix ratios accross all temperature and atmospheric variables, carbys just cannot compete with EFI.
And for the record, nowhere did Swagger say to use "massive" throttle bodies.  I read from what he said that they should be balanced to whatever engine modifications are performed... or maybe that's just me....
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: Staffy on Feb 17, 2012, 16:13:42

Good day, sir.

/hijack
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: loekm on Feb 17, 2012, 17:17:46
Good evening gentlemen,

Hhmmmm... There is a lot to be discussed about the EFI stuff, that's for sure. My opinion is that it's worth a special thread on this forum 8). But thanks for the info all of you! I'll try and read myself into it and start the thread when ready to go!

Back to buisiness!

@Swagger:
Your plan sounds wicked! I'm not going that far for sure, I'll leave the engine stock and get the EFI running first, maybe XV750 heads (more compression) later on. I'm planning a 40mm exhaust  system on this engine, so carbs need some tweeks for sure. But carbs are all black magic to me so gonna trust the motorcycle shop in this one (the guy runs a classic racing team, and has a dyno ;)). The EFI system is going on the spare engine that I'm using now to build the frame. If the EFI bumps the horses a bit I'm totally happy, a bit better gasresponse is what I'm aiming for.

@Coopersmithingco:
Nice! happy to answer your question. The sheet I posted is from the SKF website, when you register there, you can download all this info and all the bearings directly in CAD. It helped me a lot for sure.

About the TR1 engine. It is the same thing as the XV750 you mentioned. Only chain drive instead of shaft and 981cc instead of 750. I choose thisone becaus I like the character of a twin. I looked into a lot of engine options, and thisone came out on top. It,s quite cheap (spare engine with blown head gasket 35), has reasonable power, chain drive, air cooled and I like the looks. Only disadvantage.... IT WEIGHS A MILLION POUNDS :o

@Swivel:
Thanks for watching this close! The angle of the picture is a bit strange when i look at it again. But the wheelbase is right (+/- 30mm). Good remark about the ride height, the wheels are in this position when the suspension is totally stretched... when the bike is on it's wheels it will be lower en when I'm on even lower. But because i'm quite tall (1,92m) a bit of ride height is OK :)

About the engine position... I planned it this way (but i'ts a bit of a gamble) because the engine weighs roughly the same as I do. So I hope weight distribution will be OK when finished. I'll keep you informed :)

@Staffy:
I'm planning throttle boddies of a BMW GS-something. that kind of engine has sort of the same character. Big displacement, relative low power output, MASSIVE torque. And the goods are for sale everywhere.

Phew... that's it for now, thanks again for all the comments.

Best regards,

Loek
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: Swagger on Feb 17, 2012, 17:35:51
Apologies to Loek for adding to the pointless clutter.
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: CooperSmithingCo on Feb 17, 2012, 18:16:20
Loekm,

Do you know the weight of that engine? I'm looking for a powerplant to go with a superlight spine frame I've been designing for some time now. It has a few similar elements to the Egli in that it gets a majority of the strength from the backbone. Here's a cross-section of the tubing I'm using: http://www.coopersmithingco.com/quick/tubingstraight.jpg

I'm looking at the total weight of the frame to be 18lbs (8.16kg) or less, but I won't know for sure until the prototype is finished (I don't have CAD). By the way, what size of tubing are you using for the backbone and what wall thickness?

Thanks again!

Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: beachcomber on Feb 17, 2012, 18:40:41
Loek - still in awe of your skills and facilities  8) - however................

I've seen ref: to the fitting of 750 heads several times now - the quoted reason "to raise compression".

That I can understand, but why trade off for the significantly smaller valves in the 750 heads ? Especially if you are going to use larger bore pipes. Surely simply skimming the heads 10 thou or so will give you the desired raise in CR whilst retaining larger valves ? The Bob Works bike quoted a CR of 10:1 with a 10thou skim. Convince me !! ;)

I'm afraid I'm a complete Luddite when it comes to anything modern - PC's, mobile phones, ...........fuel injection. And even though I have seen for myself the advantages FI can bring, I don't have the will to set about learning a whole new skill.

You guys who have the ability to simply "plug in a lap top" and play any tune you want is way beyond me. 
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: loekm on Mar 01, 2012, 16:13:33
Hey Gentlemen!

Back from vacation.... so time for the bike again :) Started construction on the swing arm. Made some measurements for dimensions. Grounded the fabricated parts to right dimensions and tacked it all together. Then made som drawings for the sheetmetal reinforcements of the swing arm and send them away to be lasercut. Finally made some new excenter aluminum pieces for ajustment to the swing arm angle, the ones made earlier were a bit to much "off center" wich was bad for bearing construction.... Next thing, finish the swingarm, then front end.

That means making a new steering pin for the triple clamps and aluminium pieces that hold the bearings in place in the steel steering head.

Hopefully the bike is on its wheels within a few weeks ;D

Pictures:

Swing arm in place for tacking the welds:
(https://lh5.googleusercontent.com/-U5QYbip9cbQ/T06iSWKt0ZI/AAAAAAAAAbM/mWWY-iQRFQA/s679/IMG_0103.jpg)

And again:
(https://lh4.googleusercontent.com/-nW38gmxUZ98/T06iSnsodsI/AAAAAAAAAbQ/9E4NVUqwPM8/s679/IMG_0104.jpg)

And check the wheel for the sheetmetal reinforcement:
(https://lh6.googleusercontent.com/-dEAubmG9PhM/T06iSzNt_lI/AAAAAAAAAbU/N0AVAFIFvSE/s679/IMG_0106.jpg)

That's it for now, next construction day this weekend :)

Best regards,

Loek

Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: Rattlecan on Mar 01, 2012, 17:18:19
Very nice work Loek! I'm not sure how I missed it but I'm hear to watch and maybe learn something.
 
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: johnu on Mar 01, 2012, 23:52:07
Probably my favorite build on here right now, excellent work.  Envious of the equipment you have available!
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: Fix on Mar 06, 2012, 09:49:46
Missed this before, but I'm following now for sure.  Can't wait to see how it all shakes out.
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: 50gary on Mar 06, 2012, 15:07:29
loekm, I keep asking Egli questions my ignorance of the marque is showing.  Your swinger is looking every bit as precision built as the rest, my question, is that the same style of design as the Egli chassis uses or your original?  Top drawer alright.
  Cheers, 50gary
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: Swagger on Mar 06, 2012, 18:51:54
Such nice looking work! I have yet to track down a decent local source for oval tubing.....
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: loekm on Mar 08, 2012, 16:07:21
Gentlemen,

Thanks for the compliments... Very cool you guys keep watching the build and comment!

@50Gary: I watched a few other build around the internet very close the last 2 years... and what i'm building now is somehow a combination off the different builds. So I don't know if the flat oval tubing is EGLI original or not. I just like the looks of it... good combination between rectangular and round.... 8)

@Swagger: I think sourcing parts is sometimes quite difficult. I find myself in the absolute luxury that i'm allowed to use the workshop at work and given that, I can source all the materials with the big "industrial" suppliers.... and I can tell you, it makes a hell of a difference. All my luxury situation brings more respect for the builds people finish in their sheds or garage!!

The weekend will be construction time again ;D so updates will be coming sunday.

Best regards,

Loek
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: loekm on Mar 12, 2012, 06:32:02
Gentlemen,

Just a speedy picture update.... because it's worktime ;D

Swing arm with paper reinforcements:
(https://lh4.googleusercontent.com/-KrTo2mXLwDc/T1RibNoVABI/AAAAAAAAAb4/RYPWkjUss28/s1255/IMG_0113.JPG)

First steering head insert:
(https://lh3.googleusercontent.com/-nDIh36KvcQM/T1RiijMtLWI/AAAAAAAAAcU/sXybErS57L0/s1255/IMG_0118.JPG)

Milling the other side of steering head level to top:
(https://lh6.googleusercontent.com/-wKuV-6dRFN0/T1RikFjLdEI/AAAAAAAAAcc/ycmfkSyzzbA/s1255/IMG_0119.JPG)

Swing arm now with lasercut steel reinforcements ;D:
(https://lh3.googleusercontent.com/-VbGbWmiXhe8/T1vZHBoZACI/AAAAAAAAAc0/kf0As04LEtM/s1406/DSC_3803.JPG)

Finished steering head with fork:
(https://lh3.googleusercontent.com/-ibnFMm01rNk/T1vZFfbtBZI/AAAAAAAAAco/in3llkpW7NI/s1406/DSC_3801.JPG)

Frame with front side and back side "complete":
(https://lh5.googleusercontent.com/-5Pu70INbhC0/T1vZKpDYghI/AAAAAAAAAdQ/6UPvLHMRdxE/s1406/DSC_3806.JPG)

Explanation will soon follow, because not everything went perfectly smooth...

Best regards,

Loek
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: 1969Honda on Mar 12, 2012, 09:17:56
Lovin' those gorgeous welds
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: 50gary on Mar 12, 2012, 10:24:27
Very nice indeed.  It will be interesting to hear your explanation, looks good from here? 
  Cheers, 50gary
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: Swagger on Mar 12, 2012, 17:55:08
Very cool, can't wait to see more.....
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: loekm on Mar 18, 2012, 13:43:39
Good afternoon,

Next small steps in the process :) wheels are in and engine is almost in... It took some time to do... lots of measuring (wheel allignment) and not realy much work. Only some spacers on the lathe. But the result looks nice.

Wheels are in:
(https://lh6.googleusercontent.com/-5pqztAfECcQ/T2Jlt7y4l8I/AAAAAAAAAeQ/Jl2fHzhTbEY/s1055/IMG_0133.JPG)

Engine in place but not mounted:
(https://lh5.googleusercontent.com/-WUqNgruKvUw/T2NS7A29BjI/AAAAAAAAAew/HO8em9UbXXQ/s1055/IMG_0141.JPG)

Thought about rear suspension a bit and found these bitubo shocks. They look good and can be ajusted if needed.

(http://www.motofun.eu/compte/yy-motofun-creezvotreboutique-com/images/WME.jpg?osCsid=c3394372fa24c4e7f7d3c19793501389)

Next importand thing is enginemounts and subframe for rear suspension and seat!

@50gary:
The story wasn't that interesting after all. I had a small discussion (good discussion) with a dutch guy about how to be sure the bearings are exactly level and centric.  The method i used is not the standard way to machine your steering head so I took a bit of a gamble and it worked out quite well. So all is fine after all and my steering head works great ;)

Best regards,

Loek
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: 50gary on Mar 18, 2012, 23:01:26
Thanks for the reply.  I like your method of mounting the bearings.  It could be used to change the caster with different inserts.  I've been using heavy wall tubing and machining the bearing seats and then turning off the excess weight on the lathe.  It's a nice finished product but a lot of machine work.  I think I'll try your method next, thanks.
  Cheers, 50gary
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: loekm on Mar 31, 2012, 19:30:11
Hey gentlemen,

It's bin a while... but some things happend in the meantime ;) basicly worked on the frame a lot.

Started the front (and most important) engine mount:
(https://lh3.googleusercontent.com/-4fUgAP_L59A/T2pI3eCdA2I/AAAAAAAAAf8/aNFRKM7zkYs/s1182/DSC_3813.JPG)

made some extra engine mounts on the back side of the engine:
(https://lh4.googleusercontent.com/-9F72cP9e5sk/T2pI45kKxbI/AAAAAAAAAgE/EiguFIti054/s1182/DSC_3815.JPG)

Now the engine in "on its own":
(https://lh3.googleusercontent.com/-kKcZYOPWVhs/T2pI9f39sSI/AAAAAAAAAgc/RPGrOf9YK_c/s1182/DSC_3817.JPG)

Thought about the mufflers for a bit:
(https://lh3.googleusercontent.com/-NyJvPB0Lf8E/T2pI951FqqI/AAAAAAAAAgg/wc4vnlB1MLU/s1182/DSC_3818.JPG)
Got these ducati monster S4R ones for 90,-- brand new from ebay. I need some good mufflers to be road legal at the test... But after the test... ::)

Test fitted the tank cover and seat:
(https://lh4.googleusercontent.com/-VdBvSTQ53uM/T3P5yxf4HiI/AAAAAAAAAhA/zOnaqXciAn0/s1055/IMG_0150.JPG)
shortened the seat to my taste and took some measurements for the subframe. Found fiberglass a pain to work with... :( I prefer steel very much;D Respect to the people who make something nice with fiberglass...

Built the subframe (at least tack welded it in place):
(https://lh6.googleusercontent.com/-kbVNMl7W06E/T3W_wNQrhYI/AAAAAAAAAho/J-xc8-11dTk/s1055/IMG_0158.JPG)

Built the subframe a bit more so the builder himself 8) could have the first "test fit" to get some idea of riding position. First, "pits in/out" riding position:
(https://lh6.googleusercontent.com/-Glk3LzDv2Ig/T3cgt7zjgOI/AAAAAAAAAic/1pt571PSejU/s1182/DSC_3833.JPG)

And then the "Radillon-Kemmel-Les Combes" position:
(https://lh4.googleusercontent.com/-E_Y5IlLEt6s/T3cguJQe1CI/AAAAAAAAAiU/wE0hjdYEm9U/s1182/DSC_3834.JPG)

Finally talked to the suspension guy and weighed the bike to order the right springrate suspension. at this moment the bike is 165 Kg :) and I'm happy with that. Hope to keep it close to 200 Kg when finished. In that situation the bike is almost 45 Kg lighter than a standard Yamaha TR1 wich I started with.

That's it for now, suspension should be here within 2 weeks. Than the frame can be finished ;D

Best regards,

Loek
 
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: miltola on Mar 31, 2012, 20:01:10
Hat's of to you... Very, Very jealous of your work shop man... what wouldn't i give to have such a build environment... anyways great build  ! ! ! ! ! !

If i can make a constructive suggestion... i would opt for a bigger front end like a hayabusa.... but even without it is a dream project ! ! ! ! ! !

Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: Greg-NWO on Mar 31, 2012, 21:06:29
Very  cool!  Are you going to find a smaller brake disc for the rear?
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: Von Kirk 75 dt250 on Apr 01, 2012, 02:35:14
yup, im on board!
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: VonYinzer on Apr 01, 2012, 10:41:17
Absolutly amazing. Can I vote for this as bike of the month as is? ;)
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: loekm on Apr 22, 2012, 10:06:45
Good afternoon gentlemen!

Thanks again for the compliments, it really helps :) and keeps the pace going. Some constructionwork has been done over the last weeks. I got my rear suspension parts and mounted them on the frame... all in all it took quite some time to figure out what the right position and way of mounting them right was. But in the end it worked out quite well. On the dutch forum there were some good comments about riding height of the bike and mounting the suspension.

In the pictures on this forum I was using a glassfiber dummy tank to mockup the bike. I pretty much hated working on the glassfiber seat a few weeks back so an aluminium tank is on the way :D  I could order only the tank "shape" and will be making my own tunnel for it, to fit the bike. That of course because a standard imola tank will never fit onto an egli styled frame.

At this moment the bike is on it's wheels and the frame needs only a bit of work to call it "finished" ;D  Than the engine comes out, the frame gets fully welded and really building the bike to a riding state can start, that includes tons of work of course, but it'll be a different type of work and i'm looking forward a LOT.

Pictures in random order:
(https://lh4.googleusercontent.com/-JAwETk3Qg1w/T5D9UtRSZyI/AAAAAAAAAjw/ksoU_pIuQVM/s1055/IMG_0182.JPG)

(https://lh5.googleusercontent.com/-vZPyo0MkWdQ/T4Xn9IKg_dI/AAAAAAAAAio/nk8N0fCGxHA/s1055/IMG_0167.JPG)

first attempt on mounting the suspension:
(https://lh6.googleusercontent.com/-Kx1VmyrqDqw/T4XoFQWutxI/AAAAAAAAAjU/LgsA9WH5eZg/s1055/IMG_0172.JPG)

Second attempt after the comments of the dutch forum:
(https://lh6.googleusercontent.com/-oIRR8bR1fcM/T5LcWCGFXHI/AAAAAAAAAkc/W6F3KMJwMIo/s1182/DSC_3836.JPG)
the upper mounting plates are smaller and the lower ones are different. it makes the ride height a bit lower. And looks better.

That's it for now!

Best regards,

Loek
 
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: loekm on Apr 29, 2012, 18:33:27
Good evening gentlemen,

Had a nice day to work on the bike. Sort of "finished" the frame. I had one piece left to make and did that and a bunch of other stuff.

Last piece of frame to mount the engine comes here:
(https://lh6.googleusercontent.com/-CBEt7C4l_UA/T5jon9GoTbI/AAAAAAAAAlE/NQfp-NZQgMw/s1182/DSC_3843.JPG)

The piece needs to be bolted to the rest of the frame, otherwise the engine can't come out of the frame.....:
(https://lh3.googleusercontent.com/-S0eT68ydpQ8/T5jpKkMs2GI/AAAAAAAAAlU/5x-5C7RhAU8/s1182/DSC_3847.JPG)

Bolted piece in place:
(https://lh6.googleusercontent.com/-Whuv5Tv4AgM/T51bbw7FFoI/AAAAAAAAAmM/2nIYb19NmOs/s1182/DSC_3853.JPG)

After this piece, the bike is ready to be disassembled, so the final welding can be done:
(https://lh3.googleusercontent.com/-E1nHHZsi-L8/T51bdB1pNbI/AAAAAAAAAmU/6Hl1ZAmWwiE/s1182/DSC_3854.JPG)

(https://lh5.googleusercontent.com/-ni1p-ySERzo/T51bdv7bE7I/AAAAAAAAAmY/NNmGsARF5o8/s1182/DSC_3855.JPG)

And the "finished" frame:
(https://lh6.googleusercontent.com/-pWN98GPbM2o/T51becPhUKI/AAAAAAAAAmg/UHtl9DaxZf8/s1182/DSC_3856.JPG)

The the big tube is closed:
(https://lh3.googleusercontent.com/-bLLCcfVSWC8/T51bgUP4jHI/AAAAAAAAAmw/GJdjPUYeTiU/s1182/DSC_3858.JPG)

I welded the swingarm (almost done):
(https://lh6.googleusercontent.com/-2e6JOO0mAYY/T51bfmiickI/AAAAAAAAAms/8XGjuPYDVf8/s1182/DSC_3857.JPG)

And finally tack welded the mounting for the second cilinder head. It's gonna be a flexible mounting (steel tubes with rubber in between):
(https://lh3.googleusercontent.com/-tHsNOG3Pm-c/T51bhaDi1ZI/AAAAAAAAAm8/wQnhW7i8DW4/s1182/DSC_3859.JPG)

From now on It's building the frame and bike to a state for the first test run(s) :D then diassemble again and have the frame checked for licence plate. When the frame passes the test (it's not that hard I heard) the bike will be build up for real (colors and lights etc....)  and the the tested again for safety, noise, lights and road holding capabillities. When that's passed (more difficult than the first test) it gets a licence plate and registration number. I'm even allowed to give the bike it's own brand name ;D

But all that's still quite some time away....

Best regards,

Loek
 
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: dcmspikes on Apr 29, 2012, 20:05:32
cussing awesome.
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: Sunflash on Apr 29, 2012, 21:04:30
Looking great.  Oh and if your experiance is anything like mine you will love the tires.
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: loekm on Apr 30, 2012, 04:00:03
@sunflash:
Hey that's good to hear, the tires were a bit of a gamble to be honest. The guy at the motorcycle shop is a continental fan. So that's what he got me.

Best regards,

Loek
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: 1969Honda on Apr 30, 2012, 12:43:20
Looks great Loek! Keep up the updates, I think it's safe to say we're all addicted to this thread like crack.
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: Caf'd Out on Apr 30, 2012, 13:11:12
WOW. Reading this build thread is like reading a synopsis of everything I have learned thus far in the 4 years I have been going to school to be a Mechanical Engineer! You have some serious fabrication skills my friend. You are the type of builder that I am most inspired by. The kind of builder that designs things with CAD and then builds them to perfection using high end machinery. I've got my notebook and pencil ready to take notes.. ;)
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: Swagger on Apr 30, 2012, 23:18:48
Loek, the frame looks fantastic! Are you planning this as a street bike or vintage racing? I'm not sure what the year cutoff is but I want to say it's '83 for US classes but don't quote me on it...

Regardless of all that, your project is very inspiring.
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: loekm on May 01, 2012, 03:23:40
Goodmorning all (at least in Europe),

Thanks all for the compliments! The progress was good last weekend, it's always nice to get some things done and keep the pace going and the compliments realy help!.

@Swagger:
It's main goal is to be a road bike, but it will definitely get track time some day ;D About the race classes I'm not sure yet... they will allow me to take part in "demo" races  and trackdays for sure because the bike will look like some sort of classic. And alle the parts are from the early 80's But entering a REAL race is something different i guess. There is a fantastic 4h endurance race for classic bikes in spa francorchamps every year... but my bike was not an existing bike in the early eighties so that won'be possible. Maybe I find some class to race in... first see if it's race worthy ;)

Best regards,

Loek
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: 50gary on May 01, 2012, 10:06:51
The Egli (what is the proper pronunciation?) chassis is interesting in that it's a tube frame that can be made without a tubing bender.  All straight tubes.
  Wow, four hours at Spa.  that would be an exciting way to spend a day.  That would also be a good follow up track test as a review of final product.
  As always..keep up the good work, it's great fun to follow along.
  Cheers, 50gary
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: loekm on May 02, 2012, 05:14:19
Morning,

@50Gary:
All straight tubes indeed, good remark! That's one of the most important reasons for me to build an EGLI ;) And on top of that, in theory, straight tubes are the strongest tubes, triangles the strongest form and big diameter tubes are the best for stiffness. All together the EGLI design isnt that bad ;D

I know that a trellis type frame looks great, but it's much more difficult to "understand" and design.... so that's for the next frame ;)

Thanks for still reading my topic!

Best regards,

Loek

PS. 4h at spa is indeed a great way to spend the day, the whole weekend is great. I'm watching this year, who knows what's the plan for next year ;)
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: Erskine on May 02, 2012, 08:07:19
The inspiration coming out from your build is not just the craftmanship but the humbleness of the creator as well.
ATB
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: biker_reject on May 13, 2012, 12:00:11
Wow... speechless.
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: loekm on May 25, 2012, 09:26:01
Gentlemen,

It's a while ago since the last update... had a small brake on the EGLI project to help out on another fine project!

CB400f:
(https://lh3.googleusercontent.com/-IoGeLD2uor4/T2NXB2CFaCI/AAAAAAAAAfk/w2aQALIPRM4/s1255/IMG_0144.JPG)
Picture is old, we finished electrics, brakes and exhaust and now it runs and it's LOUD.

On with the game!
The frame is FINISHED ;D :
(https://lh3.googleusercontent.com/-8fIXpmqRmi0/T73N5K3aYdI/AAAAAAAAApc/ln2xMdi-Pzc/s1255/IMG_0209.JPG)

And I started to take the mockup engine apart... the plan is to make it fuel injected... this engine had a blown head gastket so I tried to take of the cilinder head to see what the damage was. Damn it was difficult :( All went perfect until one of the pins that places the head on the cilinder decided NOT to come out....

Penetrating fluid.... not working
Small plastic hammer.... not working
BIG plastic hammer.... not working
Puller.... not working

In the end, after a good tip on the dutch forum, I took the cilinder/head assembly off and hammered it off from the inside out.

Hammering from the inside:
(https://lh3.googleusercontent.com/-npvZM6wtKzk/T7zDzzdEjkI/AAAAAAAAAow/YYj0XW6hCIc/s1260/2012-05-23_12-40-47_595.jpg)

And finally a blown head gasket:
(https://lh6.googleusercontent.com/-pbMqlYqE8ok/T7zDlI2I1YI/AAAAAAAAAoY/Uz2yt-cgko4/s1260/2012-05-23_12-48-06_938.jpg)
It appears to be a '81 engine, later years head a slightly different cilinder to prevent this damage. Not sure how to prepair this engine for the "uprated" power of fuel injection. But that's something for the next winter.

The pin that dicided NOT to come (bottom side) out lost his battle in the end ;)
(https://lh3.googleusercontent.com/-FRKZE3WkAz8/T7zDk93MXvI/AAAAAAAAAoU/hljkome4bnA/s1260/2012-05-23_12-48-13_48.jpg)

I also found a aluminium tank shell to complete into a imola fueltank that fits the EGLI frame ::) The standard tunnel does not fit the EGLI frame at all, so i got myself something to do over the next few weeks. it took some time to find a company that would only deliver the shell. And now it worked out quite nice :)

Alu tank shell:
(https://lh3.googleusercontent.com/-M2qzkGS1l7k/T73NypPOk9I/AAAAAAAAApE/NBsBFi3d2BU/s1255/IMG_0206.JPG)

alu tank shell:
(https://lh3.googleusercontent.com/-T4QAowLSgnQ/T73NzjV2X9I/AAAAAAAAApM/UGqomesLC-w/s1255/IMG_0208.JPG)

Finally the frame is built into a rolling chassis again with some new spacers inside the swingarm and the right spacers on the front brakes. Rear brake caliper is also in but i'm not sure about the rear disk... it's big. We'll see.

It's a roller again:
(https://lh5.googleusercontent.com/-H6fk042CQhI/T73N8C02NgI/AAAAAAAAApo/Bpo6scAlwNE/s1255/IMG_0211.JPG)

Next week engine into frame, start with the tank, exhaust and so on... lots to be done!

Best regards,

Loek


 
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: Bozz on May 25, 2012, 09:44:01
breathtaking.
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: JustinLonghorn on May 25, 2012, 10:03:34
Damn, that is fantastic!
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: 50gary on May 25, 2012, 14:26:41
I have a Flat Track racing friend that builds his own engine based on XS650
castings.  He had stud stretch due to the very high comp ratios and 750cc.
 His solution was to add two more studs, which he made his own.  That's a
 laborious task but do-able. ..and yes the rear rotor is big, bigger than the
 front(s).  Exciting to watch this build.
   Cheers, 50gary

Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: VonYinzer on May 25, 2012, 16:36:26
I ike the big rear rotor... If you drilled it out, that would take some "visual weight" off.
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: Von Kirk 75 dt250 on May 26, 2012, 03:15:41
THIS IS KILLER! I don't think i've ever seen a guy build a frame by scratch. You're a magnificent welder.
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: loekm on Aug 18, 2012, 06:33:58
Hey gentlemen,

It's been a long time since the last update.... So here we go again.

In terms of fabrication the progress is not as good as I hoped for. But some things happened since last time. The frame is pretty much finished, I put the motor in and all fits great. Since then I started working on the EFI system....  it takes a LOT of time to choose wich one and why... so reading, reading, reading.
Finally bought the ecotrons small EFI kit. The guy was really helping me out in terms of what should be in the kit and how it all works, perfect service. Go ecotrons! Time for pictures!


Current state:
(https://lh3.googleusercontent.com/-o2zyGOlt9G8/T8faIzwp-JI/AAAAAAAAAqU/0Dw5kXJvcuE/s1055/IMG_0219.JPG)
The tank is not ready yet, and I dont like the glassfiber seat, thinking of building my own aluminium one... But I'm happy with the overall looks.

Since then, EFI ;D and it really slows down progress in terms of fabrication but really cool to work on.

The kit:
(https://lh3.googleusercontent.com/-nHA9gXtnzjs/UCLCYCfPAII/AAAAAAAAArw/imKGZD78K0A/s1055/IMG_0232.JPG)

One of the challenges is to get a good RPM signal out of my engine. And the old system that's on the bike isn't capable of doing that, it only has signal for ignition. So ALL the old systems have to go, carbs, ignition and electrical system. Best place for a triggerwheel / RPM sensor combination is the cilinder head in this engine. But the problem is that a camshaft only makes half the revs of a crankshaft.... and that's the problem Mr. Ecotrons solved with some software :D Great!

Paper version for design check and testfitting:
(https://lh4.googleusercontent.com/-DkQkV3hM7gQ/T_Sm0PPE87I/AAAAAAAAAq0/qt80_dFLyfQ/s1059/2012-07-04_18-15-06_305.jpg)

And the steel one in the spare motor:
(https://lh4.googleusercontent.com/-TabiSLiRRh4/UCLCYiymAqI/AAAAAAAAAr4/eCcM5k8Xf6c/s1055/IMG_0233.JPG)

Next is software / ECU communication, works first time:
(https://lh5.googleusercontent.com/-kntHSHItbJI/UCLCTNLrHVI/AAAAAAAAArQ/FTONr7S9VnY/s1055/IMG_0228.JPG)

Hardware test for RPM signal and triggerwheel:
(https://lh6.googleusercontent.com/-RSiqM-0ywvc/UCLCSFdYD4I/AAAAAAAAArM/meOVZBXs7k0/s1055/IMG_0227.JPG)

Houston we have a signal :)
(https://lh5.googleusercontent.com/-vqwjIsQGOGE/UCLCXlMJLbI/AAAAAAAAArs/KYefyEJPLHA/s1055/IMG_0231.JPG)

Cover for RPM sensor:
(https://lh3.googleusercontent.com/-4K4lscuN4Ec/UCyLj-i0xqI/AAAAAAAAAto/Pvs6bNGVrug/s1055/IMG_0268.JPG)

Ajustment to the cilinder head:
(https://lh6.googleusercontent.com/-eYJHd1xJ6S8/UCyLZw47hkI/AAAAAAAAAtI/vXd6Gq4rmCA/s1055/IMG_0265.JPG)

And it all fits:
(https://lh6.googleusercontent.com/-hwhylxCKJ6Y/UCyLjydTG7I/AAAAAAAAAts/CPvsdJRi7N8/s1055/IMG_0269.JPG)

This is only a cilinderhead of the spare motor, but it's nice to be able to test fit some parts not damaging the original engine! Next is some more sensor integration (2 temp sensors, MAP sensor TPS sensor....) and mounting the throttle bodies on the real engine.

After the sensor integration the exhaust is next and when that is finished the engine should start or at least I can start trying to start the engine.... or so. I'm very curious how difficult it'll be to dial in such a EFI system.... we'll see. Ecotrons will support in tuning the ECU / software in combination with this motor. So I'm looking forward to it!

That's all for now. Will update faster next time.

Bet regards,

Loek



 
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: Caf'd Out on Aug 18, 2012, 09:30:54
Top notch! Are we witnessing this from the Yamaha R&D factory or something?! haha Professional.
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: VonYinzer on Aug 18, 2012, 09:57:50
Is if possible to name a Bike Of The Year, because if so...

Amazing work thus far man. Please keep the updates coming.
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: ProSimex on Aug 18, 2012, 16:02:15
HERESY! WITCHCRAFT! AN ABOMINATION BEFORE GOD!!!


Nah I guess EFI is acceptable in this case. ;D
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: stroker crazy on Aug 18, 2012, 20:52:28
An update like this is worth waiting for!

A methodical, meticulous build.

Crazy


(http://blg.mypicturetown.com/cache/ie2riIOI.B7l1q%25bKqJLdXQLQ4d%26WuGqJasayOlrA.RN8ZN88V2XYolwTbIja5F/item.JPG?rot)(http://blg.mypicturetown.com/cache/RI5RQ8GNnFdZbmJtj3I0G%25P4MzEhs8xAFEONJO7Um4.3VHCT0myqIhJbX*DjEMB/item.JPG?rot)
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: TwinPlug on Aug 19, 2012, 04:38:45
Amazing work!

The ECU looks tiny compared to a Microsquirt, if the software is anything like the Micro-S setup you'll have it running in no time.

A few years ago I EFi'd a Chinese C90 knockoff engine using a Micro-S setup, just for fun, do you have any plans to go forced induction??
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: joea on Aug 19, 2012, 05:01:25
looks like you have made some big progress since i last ck'd , and everything looks beautiful...
  all the equipment is nice but your talent is what makes the big difference ....keep up the great work.
joe@vcycle
 
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: ducatiboy on Aug 19, 2012, 06:50:22
I love this build! First start up will be very exciting :) :)
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: loekm on Aug 20, 2012, 15:33:56
Hey gents,

Thanks for the commpliments! they're to much.... I'm just lucky to have acces to all the equipment.... That opportunity started the project in the first place.

@ducatiboy:
The first start will be exciting for sure ;D starting on fabrication of the exhaust system this week (with ducati monster S2R silencers :) ) so the first try to start should not take months from now.

@TwinPlug:
No plans for "forcing" mor air into the engine. I'll keep it normally aspirated. First see what EFI will do.

Best regards,

Loek

Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: loekm on Aug 27, 2012, 10:12:47
Hi,

Here we are again. Started the exhaust fabrication and it worked out quite well ;D or at least I'm happy with it. Two headers are exactly same length and to get that right was at least " a challenge".
Exhaust is a 2 into 1 into 2 system.

Front header:
(https://lh4.googleusercontent.com/-G3jGABMmbxk/UDphO9nzEZI/AAAAAAAAAuI/GSv-uxw6jtk/s1255/IMG_0273.JPG)

And again:
(https://lh5.googleusercontent.com/-Uf-wWPMXLJQ/UDphPWTaFVI/AAAAAAAAAuQ/5sBrlTfDO5I/s1255/IMG_0274.JPG)

Back header part 1:
(https://lh5.googleusercontent.com/-O4rexT9YPtA/UDphPW-cNZI/AAAAAAAAAuM/DT6caBypGEU/s1255/IMG_0275.JPG)

And on the bike:
(https://lh5.googleusercontent.com/-FFBF4xWGPt8/UDphSCETH_I/AAAAAAAAAug/xVXsSllThCc/s1255/IMG_0276.JPG)

And again on the bike:
(https://lh4.googleusercontent.com/-DeFusU43mNA/UDphSnZ4nqI/AAAAAAAAAuk/UiLfyBEsx3Y/s1255/IMG_0277.JPG)

Clearance is tight but it just fits ;D.... The back header is a two piece otherwise mounting is almost impossible. And there is almost no straight piece 8) in the back header.
There will be some sort of silencer between the two headers and the pipes to the silencers. that's the goal for this week. Then welding and mounting.

Best regards,

Loek
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: JustinLonghorn on Aug 27, 2012, 11:37:23
Fantastic work on the exhaust, sir. Keep it up.
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: DuckHunterJon on Aug 27, 2012, 12:00:19
Beautiful work as usual.  Can you share more on the mufflers?  I love the look - were these custom fabbed?  Also, you wouldn't be interested in making a second set of headers for sale, would you?  Loving this build!

Jon



Hi,

Here we are again. Started the exhaust fabrication and it worked out quite well ;D or at least I'm happy with it. Two headers are exactly same length and to get that right was at least " a challenge".
Exhaust is a 2 into 1 into 2 system.
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: biker_reject on Aug 27, 2012, 12:46:41
Exhaust looks wonderful.  Can't wait for the finished product!
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: 50gary on Aug 27, 2012, 13:45:20
Excellent.  I enjoy the exhaust part of a build.  I lathe turn a 2" heavy wall piece directly off the exhaust port and match the port and eliminate the gasket.  The heavy wall also helps to pull heat out of the head.
  I enjoy the workmanship but your designs are even better, again excellent job, this is an online tutorial.
  Cheers, 50gary
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: loekm on Aug 27, 2012, 15:17:16
Hi all,

Thanks again for the compliments! exhaust building is cool indeed :) It's my first one as with the whole project. In the summer there was a bit of a halt on the project, but now it's really going again, and all the stuff seems to work so far. After the exhaust the throttle bodies are next. The cable assembly is going to be a challenge... But after that, it will be time to start the EFI up and i'm looking forward!

@DuckHunterJon:
I'm afraid that's not going to happen... I live in the netherlands and this exhaust won't fit any other bike I guess... but thanks for the interest anyway. The mufflers are standard ducati monster S4R. I got them cheap as chips from eBay.... ($90 brand new) all the ducati boys change them for termi's and I need something standard to get it trough inspection.
(http://www.hybridlava.com/wp-content/uploads/ducati_monster_s4r.jpg)

@50gary:
Good tip! I didn't think about the last connection piece to the cilinder-head yet. Is it OK to bolt a header pipe rigid to the cilinder head? I thought the gasket was needed to give "some" play to the header.

Best regards,

Loek
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: ducatiboy on Aug 27, 2012, 18:04:54
The work on those header pipes is fantastic. I think when Loekm says something has been "a challenge" you can be guaranteed that it has actually been an epic nightmare...
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: 50gary on Aug 28, 2012, 09:03:42
Humm?  I never considered that possibility.  I got that Idea  from a friend that  races flat track Yamaha 750 and used it on my Yamaha XS650 project years ago.  I haven't had any problems yet and the 650 is quite a shaker.  I also used it on my CX500 Honda  cafe headers that I made (both sets are two into one) The other trick I do to my headers is to Ceramic coat them it works well and looks good too (there is a titianium color that looks upscale).  I have a friend that has a coatings shop and we try  to do in inside as well, really holds the heat in the pipes.
  Cheers, 50gary
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: loekm on Aug 28, 2012, 17:14:21
@ducatiboy:
Oooohhh. The back header pipe took two tries and a good deal of the weekend.... so almost 10 hours for a piece of pipe 60cm in length.... but it's good fun and the reward is big when you get there ;D
I'm expecting a challenge assembling the cables for the throttle bodies as well ;) The mechanism that opened them both at the same time won't fit anymore so I have to make something Tha does exactly the same. I haven't looked into this really but maybe there is something standard that works fairly easy ;D.

@50Gary:
That's good to hear.... if even the XS650 shaker :) and your racing mate's 750 have no problems then it will be goed enough for me for sure. Thanks for the tip again.

Best regards,

Loek
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: john83 on Aug 28, 2012, 20:16:03
Wow, I can't believe I just now found this thread. I read the whole thing. I am definitely tuned in.
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: TwinPlug on Aug 29, 2012, 03:25:18
I'm expecting a challenge assembling the cables for the throttle bodies as well ;) The mechanism that opened them both at the same time won't fit anymore so I have to make something Tha does exactly the same. I haven't looked into this really but maybe there is something standard that works fairly easy ;D.

Take a look at the throttle splitter used on later air cooled DT125's - the one I have is the perfect throttle splitter for running twin carbs (instead of a single carb and oil pump)

It has a single cable entry and two cable outlet, the cables are thicker than most small bikes - I ran one on my BMW engine fitted with a pair of VM32 carbs and it self centres the two cables perfectly.
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: kieferocks on Sep 06, 2012, 15:55:06
Update! Please!
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: loekm on Sep 22, 2012, 15:27:55
Alrighty then...

A small update on the exhaust. I finally got some time to tack the whole system together... It's far from finished, but so far I'm very happy with the result ;D. Decided to get rid of one silencer. It saves weight, looks better and is easier to fabricate... Hope it will not be to loud because I don't like "to loud" streetbikes... Whatever....

Pitures!

(https://lh4.googleusercontent.com/-RUme_xroegA/UF3jTohKx2I/AAAAAAAAAvs/IMqaUOcVAbY/s1144/2012-09-22_17-51-00_304.jpg)

(https://lh4.googleusercontent.com/-9QZ7757Arao/UF3jY6D3YYI/AAAAAAAAAv0/469evwjmACc/s855/2012-09-22_17-51-23_113.jpg)

(https://lh3.googleusercontent.com/-9JesJjH6RVU/UF3jjhkleuI/AAAAAAAAAwE/_lIldcT7DWE/s1144/2012-09-22_17-52-06_570.jpg)

Tomorrow back on the exhaust, fabricate the pieces that connect it to the engine and make a piece to seperate it into two pieces for mounting (that piece comes where the tape is on the pictures).

So more pics to come in the next few days!

Best regards,

Loek
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: 50gary on Sep 22, 2012, 15:49:29
Super job, good design, it get's my seal of approval.  I prefer the two into one exhaust it's lighter looks like a race bike and has a different tone with a single point sound source.  Your bike is going to look like a factory job.
  Cheers, 50gary
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: MoToBoX-VintageSpeed on Sep 22, 2012, 16:18:08
shit....14 pages....now i am blind. 8)
perfect work...
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: john83 on Sep 22, 2012, 21:37:56
Keep the updates coming man!
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: loekm on Sep 25, 2012, 16:23:02
Good day all!

Here's the exhaust on the bike. I had a bit of time to mount it to check the looks, first try.... not perfect, bit of tweeking and a nice result ;)

Result:
(https://lh5.googleusercontent.com/-8WEVxbSr9xM/UGHzLnMmk6I/AAAAAAAAAxo/UNo9KI5VRNQ/s1112/2012-09-25_18-40-06_835.jpg)

And again:
(https://lh6.googleusercontent.com/-w6BqmNzCZqo/UGICUVHd-uI/AAAAAAAAAx8/ELanUNT29XE/s1112/2012-09-25_18-40-20_499.jpg)

@50gary:
Thanks, your approval is always good to have. The few people that see the bike in real always ask did 50gary approve this? ;) ;D Now serious. I'm happy with the result myself. There's a lot to do before the exhaust can be called "finished" but it definitely has potential.

Best regards,

Loek 

Best regards
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: misteroddjob on Sep 25, 2012, 16:45:05
I've been following this build for a while.
People following my build thread posted they wish they had my skills and my tools.
But, I wish I had your skills and your tools.
That's some meticulous craftsmanship.
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: 50gary on Sep 25, 2012, 19:07:43
loekm,  HAHAHA, that's funny!  Thanks for having a sense of humor as well as great design/build skills.  Not that it will ever happen but I'd like to have a drink with you some day.
  Cheers, 50gary
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: VonYinzer on Sep 25, 2012, 19:14:58
Beautiful work as always.
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: danejurrous on Oct 18, 2012, 11:06:47
Any updates?
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: loekm on Oct 26, 2012, 03:11:12
Hi all :)

Amonth ago since the last update..... Shame on me... so it's time for a "big-one". This weekend I've got a spare day as wel so i'll keep to the pictures for this round. And tell the storie this weekend.

Aluminium pieces to mount the throttle bodies including copper gaskets:
(https://lh3.googleusercontent.com/-1y_4lmazkhE/UG3v4gJYSjI/AAAAAAAAAzI/Y6BrRR9a12g/s1260/2012-10-04_18-14-49_695.jpg)

Simple aluminium strip to hold the exhaust in place:
(https://lh4.googleusercontent.com/-ri3DB0A-d5g/UG3v4vk6URI/AAAAAAAAAzE/YX83qZX1RP0/s941/2012-10-04_18-15-03_554.jpg)

Test fit of throttle bodies:
 (https://lh6.googleusercontent.com/-agFL2rN5p6M/UG3v7ZNuCiI/AAAAAAAAAzc/kMQge8FuNG8/s1260/2012-10-04_19-12-06_194.jpg)

I needed to make some sort of bracket to hold the injector in place:
(https://lh5.googleusercontent.com/-pwj9k4V_a1s/UHFIhBFabTI/AAAAAAAAA0E/Xk5mVOaGioI/s1260/2012-10-07_11-07-09_632.jpg)

Bracket in CAD:
(https://lh4.googleusercontent.com/-MSswL9can_g/UHFyz4F-IyI/AAAAAAAAA04/Tdu7k-2FBwk/s1024/Beugeltje+voor+injector.jpg)

Paper test:
(https://lh4.googleusercontent.com/-s4uDaQ_WOys/UHFyZZ3wY1I/AAAAAAAAA0s/W-sBnYTxTxI/s1260/2012-10-07_14-06-16_451.jpg)

Fitting the TB's with heat resistant silicone hose:
(https://lh6.googleusercontent.com/-sL_LBj0Py68/UImaIfXm5EI/AAAAAAAAA1U/IP1CEAHMKnk/s1255/IMG_0311.JPG)

Fitment with bracket in place:
(https://lh4.googleusercontent.com/-1idcnhx1CYs/UImaPBzPbbI/AAAAAAAAA1o/nx1L9dl7TL4/s1255/IMG_0314.JPG)

And again because it works so well ;)
(https://lh4.googleusercontent.com/-ktT4xw_dVwA/UImaPkRLQRI/AAAAAAAAA1w/_1kHDDWgFqE/s1255/IMG_0315.JPG)

Plate for rear brake:
(https://lh5.googleusercontent.com/-5pEs_XqZKqM/UImaPN_ckxI/AAAAAAAAA1s/GhNjOb67ulY/s1255/IMG_0313.JPG)

Rear set and master brake cilinder installed:
(https://lh3.googleusercontent.com/-PkqKTSdMUFA/UImaWT1N0hI/AAAAAAAAA2I/FqZbKatG6OM/s1255/IMG_0317.JPG)

The other side for shifting the gears:
(https://lh5.googleusercontent.com/-3LgUvCuR4rA/UImaVNHWmyI/AAAAAAAAA2A/V4gZhgPCBY8/s1255/IMG_0316.JPG)

And to finsh it, a picture of the whole thing:
(https://lh6.googleusercontent.com/-2hZb9-aLXGo/UImaW5emE8I/AAAAAAAAA2M/pB1WueEKo34/s1255/IMG_0318.JPG)

Best regards,

Loek

PS: I'll be back this weekend with exhaust things.... ;D
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: JustinLonghorn on Oct 26, 2012, 09:17:28
Wow!
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: john83 on Oct 26, 2012, 19:06:52
Damn! Glad to see another update. This thing is looking amazing!
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: 1969Honda on Oct 26, 2012, 21:17:51
Looking Good!!!!!!!!
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: ducatiboy on Oct 28, 2012, 03:24:32
Love big v-twins. Love home-made bikes. Put the two together and you get...my very favourite build of all time, EVER!

Well done Loek!
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: Swagger on Oct 28, 2012, 04:05:31
Thought, after looking at the final picture I note that there's a lot of space between the heads and the backbone. If you raised the motor within the frame you'd gain some clearance under the sump which seems low to my eye. Just a thought, I recognize the amount of rework it would require.
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: cyclhed on Oct 28, 2012, 04:23:28
Signed up! Very nice.
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: beachcomber on Oct 28, 2012, 08:28:49
fantastic work as we've come to expect - a true inspiration. 8)

I'm in awe of your skills and envious of your facilities ...........  ;D
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: Worst cb650 ever on Oct 28, 2012, 11:30:01
Wow, this is amazing, I can't believe I just found this one!  Signing up!  :D
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: Swagger on Oct 28, 2012, 17:45:52
Ya think? I'm constantly amazed at the talent that's amassed here at DTT.
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: Worst cb650 ever on Oct 28, 2012, 22:09:13
Ya think? I'm constantly amazed at the talent that's amassed here at DTT.

No kidding!  Constant inspiration!
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: Tim on Oct 28, 2012, 22:39:24
Incredible work - really awesome to see what can be done with the right tools and more importantly, the right skills and a ton of brain power.

Just a quick note on your footpegs - have you thought about using the folding Tarozzi pegs?  Hate to see anyone loose a foot :P
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: joeyputt on Oct 28, 2012, 23:41:42
I do not know how I missed this build either, very nice design and craftsmanship Brother!
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: IndieSol on Oct 29, 2012, 18:29:10
Holy crap.  Incredible work.
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: rays650cafe on Nov 15, 2012, 18:38:02
How have I messed this? Incredible work man!
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: YogiBear on Nov 15, 2012, 18:52:48
This is going to be awesome! Never seen this done on anything but a chopper.
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: Bert Jan on Nov 16, 2012, 07:10:49
Loek, serious shit man! WOW!

Zag dat je in Nederland zit (kenteken van een auto..)
Waar zit je ergens?
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: manolon6 on Nov 16, 2012, 07:31:31
AWESOME WORK!!!!
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: loekm on Nov 17, 2012, 09:02:52
Thanks all for the compliments ;D Work and other things have been busy lately which is a good thing, but tomorrow the bike is in the picture again! so pictures to come.

best regards,

Loek
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: loekm on Nov 28, 2012, 16:26:19
Hi all,

Time for pictures :) Throttle bodies were mounted, but throttle assembly still had to be done. Not very easy, but fun to work on and very rewarding when finished ;)

Almost finished assembly on TB's:
(https://lh5.googleusercontent.com/-ngTiBB1wLJA/ULPfybhAo3I/AAAAAAAAA3E/73c6AEDoD_s/s1108/IMAG0060.jpg)
Only cables have to be mounted properly

TB on bike without cable:
(https://lh6.googleusercontent.com/-hOT6uS28tQU/ULPfw5-HiyI/AAAAAAAAA2s/5fdaalj29m0/s1108/IMAG0058.jpg)

Soldering the cables:
(https://lh5.googleusercontent.com/-qFsv6EzmRho/ULPfwzcq_5I/AAAAAAAAA2w/LUbTkZGMXWo/s1108/IMAG0057.jpg)

Lasercut parts for wheels (2 pieces of 1mm stainles 1 part of 2mm stainles makes one wheel ;) ):
(https://lh3.googleusercontent.com/-mvCYdmN-gZ0/ULPfw-mOFgI/AAAAAAAAA20/ZNzdVkz6tn8/s1108/IMAG0056.jpg)

And a small video of the working assembly (finally my phone can make movies worth showing):

http://www.youtube.com/watch?feature=player_detailpage&v=Rht5EEVaoTU

More pictures on the exhaust to follow soon.

Best regards,

Loek
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: danejurrous on Nov 28, 2012, 16:38:08
By far one of my favorite builds here on DTT! Amazing work and attention to detail. One quick question for ya though. Where your cable goes through the aluminum bracket at the throttle body are you going to have some bracing to hold it in place and keep from fraying in the slit you have?
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: loekm on Nov 28, 2012, 16:50:08
@danejurrous:
Yes you're absolutely right about that one. Like this the throttle cable will fly of on every twist of the throttle ;D. Thanks for the compliments by the way :)

Best regards,

Loek
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: loekm on Dec 17, 2012, 16:16:40
Hi all,

Things are not going as fast as planned.... but hey, there's still progress and winter is coming to, so time to get it going again!

I'm still tinkering  with the exhaust. It has been welded perfectly, but after that of course it does not fit the same way before welding.... To be expected, and not a real problem.

But mounting it is more difficult than thought of before, so the question is: Split it in two? or keep it in one piece with the difficult mounting? Decisions...

I had a bad luck day as well a week ago. I dropped a small ring into the engine while mounting the RPM sensor wheel.... >:( >:(  Problem could be solved by removing a side cover and use a magnet :) Only a day and a new gasket lost... phew. But shit wasn't over yet
While opening the side cover the magnet that is mounted inside the engine was full of metal:

(https://lh5.googleusercontent.com/-uSriP74Rbt8/UMS8-OM4M9I/AAAAAAAAA7I/Y6ZG-wRZfKk/s912/IMAG0094.jpg)

(https://lh4.googleusercontent.com/-RLwvtjAx3pw/UMS8-QKKPvI/AAAAAAAAA7E/jG5GRYvTbVA/s912/IMAG0097.jpg)

So I thought my engine was history... Luckily some people at the dutch forum told me that it was OK, the magnet is exactly there to catch all the metal from the starterclutch (and the starter clutches are not known for quality ;) on the Yamaha XV's)

All in all a bad day but that was it. After that things were going a bit better at least.

I (or actually my colleagues) made me a small oil-tank like box to house the electrical parts of the bike, it goes between the triangle at the back of the frame:

(https://lh3.googleusercontent.com/-vvPRDeYKM4M/UMS83unIr0I/AAAAAAAAA6U/OpGzxMHsYlc/s912/IMAG0088.jpg)

(https://lh5.googleusercontent.com/-dGIajqyjtLo/UMS84bPrGsI/AAAAAAAAA6c/REj3bor15-w/s912/IMAG0090.jpg)

(https://lh4.googleusercontent.com/-W3tzUUe2eS0/UMtQCx0J5GI/AAAAAAAAA8M/u82CYcm7M5Q/s912/IMAG0120.jpg)

(https://lh6.googleusercontent.com/-VYN8N9c2YqU/UMtQEuO092I/AAAAAAAAA8g/YBHEw1oYmO0/s912/IMAG0122.jpg)

(https://lh6.googleusercontent.com/-iIvMpicpExE/UM33hrMWt9I/AAAAAAAAA9A/uagseLRHDGc/s912/IMAG0123.jpg)

And in general some smaller details were taken care of. The engine mount at the rear cilinder is mounted (was ready a long time ago), the steering head was re mounted with an extra nut to make the tightening a bit easier and ajustment more precise. And finally all the connectors for EFI are in and the fuel hose is cut to length and needs to be mounted between the pump, injectors and pressure regulator. All these things need a final place know :)

So that was progress on my bike, but i'm not the only person working on bikes in this workshop my colleague has finished his CB400f:

(https://lh5.googleusercontent.com/-BjMpnzldHR0/UMdHXlOHj8I/AAAAAAAAA7g/9KIknv-yMZ0/s912/IMAG0100.jpg)

Rides great and looks as a cafe racer should in my opinion ;) only a seat and a front fender...

Best regards,

Loek
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: JustinLonghorn on Dec 17, 2012, 16:23:01
Wow, nice progress mate.

And tell your colleague that the 400F is absolutely beautiful!
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: spyra78 on Dec 17, 2012, 17:16:59
Very impressive build indeed sir!
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: john83 on Dec 17, 2012, 18:03:42
Looking good, looking good!
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: loekm on Dec 22, 2012, 17:57:27
Hi all,

had some extra time on the project last week and with some result :D The exhaust is FINALLY finished and on the bike.... what a nightmare to get the thing on the bike.

First made the clamps that hold the exhaust, then tacked the exhaust flanges on (only one point so that they can still move a bit), then mount the thing with the gaskets (and brute force), then tacked the flanges better in their real position on the engine. Get the thing of without bending or moving the flanges, then final welding and mount the damn thing for real ;D Pheeeew.

Started "wiring" the engine engine with all the sensors, electric harness and fuel system. Only thing that's not on the bike is the triggerwheel and RPM sensor. I'm waiting on some answers from ecotrons (really helpful so far) on how to mount them best and in which position.

Pictures:

Finished exhaust :)
(https://lh5.googleusercontent.com/-zwrqIpRYcbg/UNQPfn7uDFI/AAAAAAAAA9g/ZNh6wQLNSs8/s1108/IMAG0136.jpg)

with "panigale" swirl in the back:
(https://lh4.googleusercontent.com/-bxcJ31l0Xc0/UNQPekq5pBI/AAAAAAAAA9c/NlS6TA0fpJI/s1108/IMAG0133.jpg)

And started the mess of putting all the electrics and fuel system on the bike ;)
(https://lh3.googleusercontent.com/-qNIN8sK0IHY/UNSy8b2xYzI/AAAAAAAAA98/MZsK2M09rzs/s1108/IMAG0138.jpg)

(https://lh4.googleusercontent.com/-uNAmBdmJzxg/UNSy8fBm5MI/AAAAAAAAA94/MzGB5vR_Jlc/s1108/IMAG0140.jpg)

(https://lh5.googleusercontent.com/-LaFJLnlqKF4/UNSzBTyLoyI/AAAAAAAAA-Q/XuuriM1thCE/s1108/IMAG0141.jpg)

I also started to dig a bit deeper into the ProCall software that comes with the ECU. It reads all the sensor signals as it should and as a bonus it was way easier than expected. Below a smal clip of the software reading the Throttle Position Sensor. Works like a dream ;)

http://www.youtube.com/watch?feature=player_detailpage&v=hZ9nog_M2_4

Not a real exciting video, but I'm happy that it works :D

Starting the engine will be early next year after the christmas holliday, looking forward for sure!

Best regards,

Loek
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: 50gary on Dec 22, 2012, 23:10:38
Loekm, Stellar work as we've become accustomed to, really good.  From the pictures only I wonder if on the front cylinder I might have extended the tube (first off the head) about an inch or so before any bend then an angled straight run (eliminating the dogleg) down to the bottom horizontal tube.  If this would clear the starter it could be a freer flow without the dogleg, and  bit more simple with 5 fewer weld joints.  I may also have made it easier to match length with the rear cylinder being that it may be about two inches shorter?  Thanks for build this project, I always enjoy reading and watching.  Will you cross drill the rotors? 
 I was the 21st viewer of your video, you've got a way to go to catch PSY and Gangnam Style.
  Cheers, 50gary
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: stroker crazy on Dec 23, 2012, 02:30:51
It's looking really tidy Loek!  (Ignoring the wiring for now)

It may have been more difficult to build the exhaust with that dogleg in the header, but I think it gives a better line design-wise than a straighter run.

Crazy
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: loekm on Dec 23, 2012, 04:36:15
@50gary:
The exhaust is like this to have maximum clearance for the front wheel to do it's suspension travel, and handle the fork bending.... What you described would've been a bit easier bot not better flowing according to what I remember from education... Hot gasses flow very well through bends.
This is the exhaust you mentioned, isn't it?

(http://image.streetchopperweb.com/f/features/1008_stcp_1981_yamaha_sr500/30817438+pheader_460x1000/1008_stcp_01_z+1981_yamaha_sr500+cover_spread.jpg)

I really like the looks, but I tried to keep it all as compact and close together as possible, so that took some extra bends. But thanks for the comments again! By the way Gangnam style will be difficult to catch ;) but that's not the goal anyhow, first get this thing started.

Best regards,

Loek 
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: 50gary on Dec 23, 2012, 09:13:23
Loekm, yes, that's what I was thinking, a bit more direct routing. You mentioned how difficult the final fitting was so my reasoning was it may have been easier with less weld joints and fewer bends.  Regardless you have done a superlative job.
I think everyone following this build is as eager as you are to see and hear the bike finished all the best.
  Cheers, 50gary
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: loekm on Dec 23, 2012, 11:09:52
@50gary:

Ahaaa... mounting the exhaust with less bends and a less tight package would've been easier for sure. I never thought about it that way. I'll write it down in my "improvements for the next project" book ;) and it's getting quite a book for sure.
Abut the cross-drilled rotors.... I'm not sure yet. I know everybody did it back then. But I actually like the look of solid rotors, i'll think about it after painting them, we'll see how it looks then.

In the end some other brake system will be mounted for sure

Best regards, 

Loek
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: 50gary on Dec 23, 2012, 11:35:10
Thank-you for reading my comments, and Merry Christmas!
  Cheers, 50gary
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: 50gary on Feb 21, 2013, 10:28:52
Loekm, just a check in to see if the bike build is still on track or possibly on hold due to work etc?  Hope all is well, missing your updates on your very interesting project.
  Cheers, 50gary
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: MOTO ARTS COLLECTIVE on Feb 21, 2013, 11:28:31
Would love to see some updates as well. amazing stuff!
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: Cuba Libre on May 02, 2013, 09:29:44
Any update?


Suscribed!
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: 1969Honda on Aug 10, 2013, 12:20:37
Any updates on this one Loek? This has been one of my favorite threads to read and look over in the past, hope everything is going well and that you're just out enjoying putting the bike thru her paces instead of playing on the internet.
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: cruisingram on Aug 10, 2013, 18:09:53
Really long time since update!
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: loekm on Aug 13, 2013, 11:30:33
Hi all,

Updates..... long time ago. I almost forgot this topic :(

I saw my last update was november 2012... I should be ashamed. Only text for now, pictures will follow later.

The project had some setbacks last winter and spring. In general the ECU was giving problems. First with the settings in the tuning software, then the hardware. The first ECU went up in smoke for no reason.... Got a new "upgraded" one with bleutooth for communication. Problem again, it had different firmware than the old one (mine had custom firmware because of different method for RPM signal). Solved again and when I finally tried to start the engine it gave up again! send back again. Investigation by manufacturer.... got it back fixed. That's how far I got from the point of my last update.

Summary:
The bike hasn't started yet... and is almost in the same state as my last update. Only difference are working brakes. which is nice to have when it starts ;D

In the meantime I have been doing a small "side-project" for this build. I had a spare motor (with a blown head-gasket) lying around and decided to change that one into a slightly modified motor :) I got the cranck, barrels and pistons from an XV1100 motor, and now I'm building the best parts of the two motors together to end up with a well built, nice and shiny, high compression 1063 cc TR1 motor that can replace the stock one after the bike got it's license plate. You have to entertain yourself from time to time... isnt it? The heads will be ported, the cams reground, the compression upgraded and so on, we'll see how far we get.

Besides that I've been a supporter/mechanic with a local amateur classic endurance racing team on two races. It's this series: http://www.europeanclassicseries.eu/en  Realy cool to see how serious the game is and the pace of the top teams is mindblowing. The  top bikes develop almost double the horsepower they were meant to have back in the early eighties. And are raced for four hours!

And of course I drove my daily bike (CBR1000F) a lot through summer. So in the end the project is still alive and kicking and I hope to make bigger progress (worth posting here) soon

I'll trie and put some pictures on the forum asap!

Thanks for all your interest guys!

Best regards,

Loek
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: beachcomber on Aug 14, 2013, 05:09:15
Loek,

good to hear the old gal is still on the boil.

Like yourself, my Vindicator Cafe Racer [ 60's style ] has been simply bubbling away on the back burner - although in my case due to a combo of a health scare [ again ! ] and lack of funds.

However, I often dip into yours and the other TR1 / XV build threads to give myself encouragement !

Can't wait to hear more on the 1063 !!
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: loekm on Oct 18, 2013, 03:52:17
Hi all,

the spare engine is still being thought about :) dicisions, decisions.... So I picked up the EFI story again. The standard engine is in a seperate frame just for testing, and yesterday evening it would finaly "run" for the first time. Way to much fuel so it stopped, but it's close ;D

http://www.youtube.com/watch?feature=player_detailpage&v=T6vaVLk-rHo

Try to keep you updated a bit more....

Best regards,

Loek
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: stroker crazy on Oct 18, 2013, 04:37:56
Good to see the start!

Now you might be able to get the ECU sorted.

Good luck -

Crazy
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: 50gary on Oct 18, 2013, 10:52:42
Phew, I can exhale, I've  been holding my breath (figuratively) for nearly a year.  Back on track, and the second engine will be a big upgrade.  I've wondered if you would use the larger 1100 cylinders, good move, (there' no replacement for displacement)  Plus I'd call it "1063" it's Ducati-esq. Your's and Johnu's (T-500 build) are my favorites on DTT. Thanks for the update.
  Cheers, 50gary
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: Erskine on Oct 20, 2013, 13:13:10
Sweet.
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: loekm on Oct 21, 2013, 05:47:26
Thanks all for the compliments ;D

There has been some progress as well, the engine keeps running by itself which is a good thing of course! It leaks a bit of oil through a "sensor mounting hole" so that's next and I think the silencer is not flowing enough... the exhaust is extremely hot in 30 seconds, so for testing I'll mount a more OPEN exhaust  ;D In the end it has to silence again because of the "road test" by authorities.

Best regards,

Loek

Proof of running engine ;)
http://www.youtube.com/watch?v=Jq-4dSKVLI4
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: spyra78 on Jan 28, 2014, 01:40:02
Any updates please?

Sent from my GT-I9100 using Tapatalk

Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: 50gary on Jan 28, 2014, 08:48:55
This was a true build project, not merely an assembly of parts.  Always my "go to" read.  It would nice to see the final edition.  I'm sure the bike will have been completed it was too close not to. The other interesting item it was to be put to the test on the track, Spa no less.
  Cheers, 50gary
Title: EGLI frame, TR1 engine, build from scratch
Post by: ABCanuck on Jan 30, 2014, 02:35:00
Funny how life so often seems to catch up to us isn't it. I remember  a near promise of a trellis frame for the next project so here's hoping this one is being sorted.
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: rundown on Jan 30, 2014, 11:56:49
Yes, lets hope it is completed soon; has to be top ten all time builds on DTT!!  Incredibly ambitious build with so many departures form the safe path.
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: loekm on Feb 03, 2014, 18:14:19
Sorry guys.....

I forget to update this topic as regular as the dutch one i'm writing as well...... But a very big thanks to the people who are still reading it!

Lots of things happened in the meantime. Some not very possitive, others as planned.
First of all the project is still very much alive ;D although not exactly as planned. Decided to ditch the EFI for a while.... it's not working as good as I hoped for and the ECU keeps "burning" itself up.

So different ignition from ignitech (it works with the standard pick-ups of the TR1 and is tunable via laptop) and back to standard carbs (rebuilt).

The engine has run on it's stand and works like a dream :) At this moment I'm working towards a first test "drive" of the rolling chassis. It should go on the dyno soon to set up carbs and see where we stand in terms of POWER ;)

Short previews of motor running:
http://www.youtube.com/watch?v=9BRMlhlQPH8
http://www.youtube.com/watch?v=2m-fsGrsX3o
http://www.youtube.com/watch?v=atiRQPUhS1o
http://www.youtube.com/watch?v=LdudHZLlFbk

By the way, it's not me in the movies. That's the carburetor wizzard!
I'll post pictures very soon!

Best regards,

Loek

Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: loekm on Feb 04, 2014, 16:09:52
Hellothere!

It's picture time! A lot has happened since the stupid EFI thing blew up again. It's not a bad system but for now it doesn't work or I can't get it working the right way.... so big decision was made... back to carbs and a different ignition system from ignitech. otherwise the project had not nearly enough progress.

So enjoy the pictures and feel free to ask the questions if needed ;)

Back to standard carbs....
(https://lh3.googleusercontent.com/-qhdviZM_ubE/UsLr1QhkCoI/AAAAAAAABps/T5IAafyOvyE/w913-h685-no/IMAG1012.jpg)

Better breathing exhaust silencer:
(https://lh4.googleusercontent.com/-eC9K16tpAFA/UriyfROvQGI/AAAAAAAABko/lLFe-LKLbmU/w913-h685-no/IMAG1024_BURST001-ERASER.jpg)

Split the exhaust for easier mounting:
(https://lh5.googleusercontent.com/-1zm30o8dQdo/UrixzbcApiI/AAAAAAAABkA/zhBHtdj0EmA/w913-h685-no/IMAG1023_BURST001.jpg)

Standard rebuilt carbs and a start for the wiring of the ignitech system:
(https://lh5.googleusercontent.com/-VMGSEx7QYfw/UrixqMqxHaI/AAAAAAAABjs/5w2Q9PWCp4k/w913-h685-no/IMAG1022_BURST002_COVER.jpg)

Ignitech system, wich is BRILLIANT so far ;D easy install, works withe the standard pick-ups and is fully programmable
(https://lh5.googleusercontent.com/-IYNKGs1JsZs/UrixXvU3y_I/AAAAAAAABi8/uLNXkA7O_rc/w913-h685-no/IMAG1020.jpg)

System fully wired for first try:
(https://lh5.googleusercontent.com/-mVzCiHO-qNM/UrixYdWU_rI/AAAAAAAABjE/ASd4Y3M570M/w913-h685-no/IMAG1019_BURST004.jpg)

First start.... mixture is a bit wrong :o see the videos for setting the carbs right.
(https://lh3.googleusercontent.com/-LE-VqcQmurY/Usg0THAryXI/AAAAAAAABwo/uDn7Z8AJF0o/w913-h685-no/IMAG1036.jpg)

Engine back in frame after succesfully setting the carbs. I'm buiilding it to rolling chassis for dyno and "street" testing:
(https://lh4.googleusercontent.com/-n9kQAAJkdxg/Usg0gUp_8aI/AAAAAAAABxM/gPIBIAUHpME/w913-h685-no/IMAG1039.jpg)

Mounting of a new 530 front sprocket.... no standard solution so you make something for it....
(https://lh4.googleusercontent.com/-EggoN1z3t3E/UtjyOk2imuI/AAAAAAAAB80/KDFhp2ea9B4/w913-h685-no/IMAG1093.jpg)

Sprocket in place:
(https://lh6.googleusercontent.com/-WnVizy_yeaE/UvCb-sf8N7I/AAAAAAAACBY/hRm6ZYkOzcQ/w913-h685-no/IMAG1138.jpg)

Rear brake assembly finished:
(https://lh3.googleusercontent.com/-eVtoUrTzJmY/UvCb72yI8rI/AAAAAAAACBM/Fuo6shkfxYg/w913-h685-no/IMAG1139.jpg)

Wiring almost finished, big red for starter motor, small yellow for starter clutch mechanism:
(https://lh4.googleusercontent.com/-dCqhEj1WU00/UvCcWNNkYGI/AAAAAAAACB0/7zGV0y4bGc0/w913-h685-no/IMAG1142.jpg)

And finally some spark makers in place ;)
(https://lh6.googleusercontent.com/-b9o1b1OW7AA/UvE6lBOhbsI/AAAAAAAACKA/hW6HRkIAtvk/w913-h685-no/IMAG1145.jpg)

Phew a lot of pictures.... what needs to be done for dyno and "road testing":
- some nuts and bolts
- chain tensioners and chain
- some engine ventilation hoses, or how do you call them?
- a bit of wiring, the least bit of buttons I want on the handlebars is ignition on/off and starter
- shorten silencer and refill for the right sound
- temporary small gas tank
- CHECK, CHECK and DUBBELCHECK

And then go for it!

Best regards,

Loek
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: Sav0r on Feb 04, 2014, 17:03:25
That rear brake isn't actually finished is it? I mean, you've come so far, but now you're going to rely on a brake push rod that has a bend it?
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: SONIC. on Feb 04, 2014, 17:07:26
That rear brake isn't actually finished is it? I mean, you've come so far, but now you're going to rely on a brake push rod that has a bend it?

Agreed  ;)
Make a longer pivot

This thing is all sorts of badass. I can't wait to see it finished
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: loekm on Feb 04, 2014, 17:31:38
That rear brake isn't actually finished is it? I mean, you've come so far, but now you're going to rely on a brake push rod that has a bend it?

Hi Savor,

Uuhhhh.... yes I'm sorry.... It's actually quite strong. It won't bend under force of braking I promise ;D. It's not even an inch long. And above that, the shift link rod has two bends in it and is much longer. They both feel rock solid. The applied forces are just not that big.

A lot of "cool" things actually have bends in them don't they ;) I'm sure you can find some.

And now serious.... Thanks for the comment. Ik like it when people look at it from a "critical" point of view. But in this situation I'll try it as is and keep your comment in mind when it needs improvement.

Best regards,

Loek
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: Sav0r on Feb 04, 2014, 17:42:24
Shift linkage is one thing, your brakes are something completely different. But hey, it's your funeral not mine.
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: johnu on Feb 04, 2014, 18:25:53
Shift linkage is one thing, your brakes are something completely different. But hey, it's your funeral not mine.

I agree it doesn't look great with the bend on the threaded part of the rod but why would it be his funeral.  Do you realise how much force is required to bend that rod?  The only issue I see is that it doesn't get a straight push from the arm on the pedal, but considering the small distance that it moves anyway it would not really have much negative effect.
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: Swagger on Feb 04, 2014, 18:42:21
Agreed, as well the rear brake plays only a marginal part of over all braking performance. More for settling the chassis in prep for a corner. At least in my case I rarely use the rear for actual stopping. If it was a drilled out machined link nobody woulda said anything.
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: Roc City Cafe on Feb 04, 2014, 18:52:49
this is really cool, as far as the brake, I'd say put some more time into it and align the axis of the m.c. with the tangent of the arm, with so much quality work on the rest of the bike it seems rushed
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: loekm on Feb 05, 2014, 03:26:33
allright, allright.... before the bike enters it's first race ;) I'll look into it. Although function and strength wise there's nothing wrong with it. The looks are not unimportant, I have to admit. A bit strange that someone spots this small "defect" while there's a TON of work and details that need to be sorted or improved on the bike.... this detail was not on my list of improvements to be made for sure! I'll put it on.

I'll keep you all informed in the near future :)

Best regards,

Loek
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: stroker crazy on Feb 05, 2014, 05:38:12
A bit strange that someone spots this small "defect"

It's only because you are building a bike where anything less than perfection really stands out!

Crazy
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: loekm on Feb 06, 2014, 17:53:46
Hi all,

Had some time left to "finish" the electrics. Goal is to get it on the dyno as a rolling chassis to do some carb tuning  ;D
Sound is a bit to much without muffler, the mic of the camera can't keep up.... Stationary running is ok, but on the throttle it sure needs work!

http://www.youtube.com/watch?v=nabMDKj1O3w

http://www.youtube.com/watch?v=gDESYIPaDek

To be continued ;)

Best regards,

Loek
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: beachcomber on Mar 18, 2014, 07:45:25
Hi all,

Had some time left to "finish" the electrics. Goal is to get it on the dyno as a rolling chassis to do some carb tuning  ;D
Sound is a bit to much without muffler, the mic of the camera can't keep up.... Stationary running is ok, but on the throttle it sure needs work!

http://www.youtube.com/watch?v=nabMDKj1O3w

http://www.youtube.com/watch?v=gDESYIPaDek

To be continued ;)

Best regards,

Loek

Hey Loek - know you're busy, but any more updates ?

I check your build out every so often to spur me on with my own humble efforts !!
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: loekm on Jun 04, 2016, 16:35:32
Hey guys,

More than two years since my last post... I thought to let you now how it "finished" or at least how it looks today.

(https://lh3.googleusercontent.com/Nzf6Qc2owjKh48MxhaH5ZfXIqB2YurBHFDKaBRAf3E0EegU8B0fYobf2y24QJw7i5hcxngHvZew-tXKyGq1o8M4nBWBX5ZVJqPrUdMrZQamr_OdYNgz6JGkB8m-YPpbeqMgLXvMtS7f8TKCUota8LI7Wjdd4-6MUE98kJFK8pDYZfniqXSGkkDfyKQ-DFBTNfZXgTvWm7G7OrGPghL5Yq49Gf8pymBfMQ63mDQ3KBOg85K9m5zMV6wpZGHDlIdG0Vss5b8fDyFrPFxxcmv8leRqOQBI9j9fVVMKjCnV5pLEhZTd9XGlopaOGSxSg73Ni_KsiApTdzBVafer9q95wd_2dTF23j_E_hc2s0DYnq8LlQMfdOk9qfc4k-yvm26eE7eUwdS3i7aiAonPNl2tP8Y2MpKRVTK3xM8WBhn1wZbKEOl-nYFUYddEX4l1vtBaT86SP2o6Qhmp4v9jChzWzmbaMCDSpFmKbjYDeucq-PLgwoXyw-UbPLtUDf63mt4laz3f65TGA32ijiNpGFHUO02TTz1FmeLC2Yb2KhjpIXj2GPquRQl_XcIr7_sxsGrMMFyX1pR8aZrnEck8BiZtPikQH1d9nw-4=w1392-h783-no)

Still no paint but a lot happened in two years! The bike had it's first track outing last month and I drove with a big smile all day long, it performed better than expected in terms of handling. I learnt a lot that day and really enjoyed driving it amongst all the modern japanese supersports. Almost all the other bikes were out accelerating me by quite a margin. But while braking, turning in and carrying speed trough a corner the difference was a lot less than I expected.

All in all very satisfied after all these years ;-)

(https://lh3.googleusercontent.com/RRw4YI9_FV3arnxw0qyHaCy_6Y3Ddxx6OWwGmmD2wZgEw-61rHYuahO66FwvSEycldp13w4lMNTYr1lmq4D6Sso3l3rqvcFuFAvdbpuI4NavL5GHaKk5WMvkDzIWY6xHMQE5mazHfkLPLXwnXiOUDrvpkBXDXdaKRoNKecX6rmCtA8iVwB_SBbC1h33qnsvZkR_nVyDSRo10ZEbT94xfNxYT9Wo6yeQwOFJhogKpX-vkmYybLQdCWYOF8iwMlRTgZvkahzk_0_r69OUO5rpA_oZxXRES9_iFyDkmQNQOYq7xq__XJ_z8FAW3V7CmL8zTvHgkdizlsy8CucdLNQGfCATrVdhV2pGPtQ9QLdCSY2yCxQdeexzmivphkiMSSlNUn0I5OraWnSFnMMdz02HAG8Y3ejnsHEAG0GdH_9Zk_Ag7-w9EW7qCgiG14BMDZZCEl-bXvn2iFF-zcFKV5mlJgrXp4YIsduTUtBou-zm01m8G1mMwX8IL7SOoj9hS6yGNwBokqQeidpK6oVOEsOG9r5aiMfqazaHh15FJoY0HdKK0ZwGsSv49YGnaHSP7_1QDhY5_c-Zqemjn44QcCjVZ2db8eQ=w1044-h783-no)

(https://lh3.googleusercontent.com/f6-vJWQDkrSlHo3x2BYcnS94ocO-BUSUkzopO0r4Dy5bXqUStjjsCmzWwThaNldNbm7mv8b3nZdFLM3oqRmq2J9-o-8t0HkpgeOwn36b4_u4RFCxdm-Ctp85ijaE-y4h8MYk3YuVYiNV3lDuaWode-D28-BWHnsGC0JCP9G1oW9FVT-IuKYEpmPzCoWdyuln3yNVMPWJkgr6R5XOv2G7ugvINbB7rHvXPvL7VRghzHSNM2CBw0Es2hEQ71MKAdx22f83zAS1tVEaeyqrXn9BLjOz96f7v-uJ3KpsviTpEugzAOyMw3hgP4t_A4r--y8q7rYKIwbKAnx6fMdO1a9JBsDg0mWCLCA_Tptou4V9K2rmInZrpfA3zbbeXM8K-aMZL7MFkKlmAD8dycDY-V0CDBJv9z4y6DvDHKngSGrzcJIUFFCsw3PVP4wLaDkfej1isTT_oYvkiis9GHbk7nlF2W9w8vmRI0KGyWLH69xt9hugU_WhhAhAYtYBs8Lz3J4C9cS5asrhttvpd3DH1EujIGaVpy5AjiV4P06r34F1OY202yhFvRf37cWegjUYZPtXiK-09DToFh4MjJ0oqrHlETs34Q=w1392-h783-no)

(https://lh3.googleusercontent.com/KxNYYLJFDwK1XfnmXshj5-3QpDW0EW2nsWf0Fg26ShjvPNHOdTnD89tu67cHxZrO7G6hzFu_oxF98_V9oVWkBO3iZ5UuyTgJ8Af568bA5OBpWC-aiA-lHY85nkKsY_tPddcQeRIffrVlOGMRzN16sMreFBYY3udtK-OkD0qmBsTJn3zjGLBoQW1fIeWtTFVuEB3aaaL6mF8zf19Avp2YJ3OaqMNWwDWfe0wVJMRbl_vPFfLUYn26ERMxMiNkTrjrxL_egSF3o6xPvwzxvFF9N8G0rQGKdTH9lFl1efz7aqcHicA0Tu459hGWAggLTGRvuXXTIsiFa6HzJ8064uoxp4l9OZJnRtok_eqL7dhQbWTkfKEDL8eaCCI2HhDzGmfUD2gJaiRKu4v-tqzb61Oz_PwihdTYwUSb4FYMKtAVdj4rhaUbtTh99Tv37-aKGUkttxu0ajdbjkJ9U9ebFggg-GXm2PNKJoRuUcyeZ1_bazuAIPJEQLTyAFKcIjoBXEP7Uo24Lrrp6WAmm5pZpmQjNCr5rQbuRmGNjy0U-HREXgkd2pU6Bnyi0hRTG7R_xcVq5DCcuXfOKja-Q_-FAg14Zs3rlw=w1392-h783-no)

(https://lh3.googleusercontent.com/d2ZpFkzz2aEm89ejAUOK_Z8d6KnOlgbou8beUuAxOnV8YA-NiwvpSwQPFU8ckFM8LgZ9hB9AWrTx8a2XxeY9NsKbs_maTu_C3Cw7m67IIXJ0HltnGeGpijsaGpzM1zonRJwyofCoHYl5FodbbPB-hwAzKjZFlbBaqcbkao4rRhGrggblYA2p-OdIYQyurhnljJ8tnTq-X_EflA1mNbWDifQjHLrjk3TWCjA7qpX_ifGABr_c8tkB7UY6jjHqCUoLLsN202d_5GE2MJ4ZBa3OGwhaNwBzzjogc22RWF9AG8BcIQ9wEL4KZn70fvCYfMKzRjLY_vXw3dMvB62EbX0loVsxAFS8N53-VkPPsvw_poiHnZGbUX60qiFaXYnlxvruU5m3Q3_mMeOs1N6SVC-h0mPsfDWtLD6O8OJyUwWbZrM7jAhjQlYZULzVTVLlyQK1E0uAEPlqpAhd0ZgAr_cMiwnRR-UOo3VSbpvSrn1sHK8LfxhYo6bwN4gurRruXbin4otPtn5S0fub76V6aoEpHa5S2kpMEDDGAJHZj0kDzEaWl2B6TO5G1ZRF_6K3yzkx_yhF-jXijn3YbBQo6EZIpkaqug=w1392-h783-no)

(https://lh3.googleusercontent.com/gR1rAF8EAelDEak1Rf7LMy14dP8k-cmXx_OAhL-juUHVI1fY-EP4i6L0kYsGQhkai8amL21Zj_-pv-ANzqZ1HVDD7y7YSTZTnUVL0qUqBuoqcoglKvDkWF0afPCXjrjc6_xC8SC4Z6TeBuT9MXHHCxbpwUYw6HicXVC8U3RuMSqQqDpUS21NcZgGoFzygKKEbyyX90iiJNSHTtNyqn1f3wWg6apLFMFoT8J9pyXo6hQgZTNlVw4aRlZ4jideeams84Pc4bAfujj1oewheWLrGl3OrWwODhsl3HG7vrdVVaaX3Isv6zIONUB0GnvjQXX5EgP0dZ9YgQOji270tQiRKQzVHk68Oi5kDuNtwX-qrm0t2biBZij9Q9-eN73cPjhmJjLOmB5NFce2em8WyfV-savil13F8ARpJXXHJawrsnuCuBoKB7148_r6nYDVzZdO2IzfTmoW6mNjg3zuq4x23ew-EOb8BgavxpXEJZKk6Bu_8CLznNmM2Fl6ZT02dA9Zb0HkNK8Fc5juBtExk8ljGX4Va3PN5HRoH6ALmuxoDrLZu39SkuJNjcjO0yTQX3Fkq0vo83wUNF5ZuKIuSKSq_7CEfg=w1392-h783-no)

(https://lh3.googleusercontent.com/DDQvyHcFPY4KuzjfBKZ4qS9Vjt8Rl3FLp_mRuhutS0NLq3mX4PV4IFdoD3_xpksdco_nnpxMsnXb4BVyyYNSGHW6FGuQAqSJAJnJLWnArmQB6v3WmT3Xoz_ChB3NN4OiXqV6zRGbVvtmelCCvDtpZUXhFUclPf311bmFIAKoQHGReNp5JdjQSmSdOU859Wl4W1_kMdWj9qKn0XfqfgDz42dbESzN9Eme7SBRSLjso-VMliWwRoWRXJr8dbNaJvxSei45Nta4JEfpeaAkbqPz9jw76mJgK-1gUp31XE4TBILeiUvmdvwZ0NxSGvioMABiC3jpWUxO6RIHxn02a08WevJKaAW4lJkhkjeBPQ2w4sXg9KfGc9hhrOp7g-KyT_7Xm9ivrEbuxUu_E0bXkfqvTvw3RLhv2dzSZza4QUPt_e9nVmi3h2dOzOlYAzudAYxscsnA7w4n7107za4mOdebzpbYk1MxdlV6EBsMflheRmmEJVZP8FGzkOtKP7X9QPxXxSehmWjrWt_WmuyV-3Qgbn8LVKQUDgfefZBEg4vEOZ1cB3CZkR_s9-7U2jOtEtN-946eH_Srq0zfafEj-uMSKDrJDQ=w1392-h783-no)

(https://lh3.googleusercontent.com/XuNO4yJWrmUnwPg3NrBi921HmU57oMc4xw8Pw43CkOjTNNMXK6P6xXx-uT3ky2nEKQPhwLN0eMoHGAN-Vech_FXoVhVgXF5Akx28bZ2RZTrfdfQOQJVbShTRXat7rzoM6z8mABk-Ip-maZ0IABglretRAia2VqG1B6cuJHFxZ-QCC3iLQj8PKrA72qYZ8TL4KflAY0lEJzayzQocilwJpYGdbReNRFmw1sJzYb-19NYUL5i1lvrUJgddB1ba-0lVcSL-YQuE2GcQv59ffC4ADzESvDSOc88SkmWonWPO_k9T4TQw5RuAvxfVfAqY-asijNntx4nWi9idbn7_5PRAnB0IbJMLqTFWk4-iHADvA6VL9tM0KP-8_YBnEWrpqT0feSHbcEmC7ItTPta2BgLVqMNzLJbNXUEmCE1EnyThG_MQJc_PZp34EqzahERQjC-Gq8cpKvAF807_E5uyOVliXacWjtyPeEXka8cUnxPA1_rjt3f4RVgwv5UsbQPQR68P1tiaXnxg0TM2kkoSTRrJwISAs8r8N2wPnObxCScLubbw9akFczbi-9twHX5W9FhYwloH-7Qg2qYKaQ3AoSB76uV_Aw=w1392-h783-no)

(https://lh3.googleusercontent.com/Y6m7BpZBxr7ZVLmRMdNE5Dbdgj_rfRLf4zAGvASsugHNaV6XLM_4EYgKtXQXXmZVeXAuoUSrfE42fKflq93P3qn3XvM9Uwm-M8aZzAujIrZT_-sxIohC1CWTf8gzCnvjNIwVW2scB3v4MR5YYufCTchVp4YEedERG2xu5jCsMpgeT8a6OyR1gMeePsJpNDp-mcA4UHIhZO4wobv1L5_6dPCbFxqFEtjSqrb4S5QZuXM5haf3tqSYJezkkAhc_csti0FEp_rYdZPH7I6TtAx71eGpyKWan2JgZI7ngkusMrdPwd4l5zATPBwQPB9BhYaYtnK2GObyoeZUJ9xPEZp15mTHuFym25_N0uzOG7KY1gJjc0xuU97RHjTJo54s7hQxZrinc3knRdaA97jFvqE7e8I0ptPp6JhxE25YE-y-ciwUvuZnb0ohO7I8GsXM8qOhBpss71NYAz6_AI6bdpNnyJ1hQiN58fCdOixVjBIsxZsUKi4_syi_UjIJblASa8cVNHccmDWUHqu9wiXVkca6kFeItgkOOV4Wm-nbt0EyiugODtnriB6yUrOVmZFhQI5H5Pj1phEONr7quzW9CRO8krB-xw=w1392-h783-no)

(https://lh3.googleusercontent.com/TnS-cP020hbMMtu6eLoc1_Yw-e1iNylbvBR9Wf5Mqq57M3aBivQyQKotlf6iMAS0khAPeHK5BnojYJ1cqt4rlL6kdeUx1mMWzZHHNzDle-pIGZ83_iJV4QFQFuyt2468GmCprgg9EPHpDuc0u-nM58etQOPlG3Vz0-cl-gzlseKF9Uid9v5QW7i7rYqpi0QlxBkqqC1ODV2QEdnB0SMU1gxW770r0jp97OXw9NXyZKAq8ucbrvvhXnnUhnlc2Cr8WjJOEmleKaSlNOFBbDFkz2vSHzbBYuPjix1oUkpbD3pw4d-_0vGjXptJlEfK4IUDYNu8M5a9H1qOdMdN2QqjHKXGEOXB1gJX57Y6bd3MG_YfFH2W2ODWnlJsyWs5SX3lXpSrz35PF_6PLGyKKI19BguAvzVoDCdIRI7ihRK1KfohTLFnaH45ZgjrvkF_0FLK8j2Y3XtWXsH6JM2W3Y9nh_zZDftVApHdhrgp19FaB_0dAzpUmtfXSkpbGIueQ8zIrFnUWsG136umVm75dyBccyupoqxaeAYdA2zOeDOnNAhYJVXQmI_ElDvKhtaGof5_p53Qp3N6zirl6GGdFLTpGR39bw=w1392-h783-no)

(https://lh3.googleusercontent.com/0pJ7kvTKq_fYLkRKOMAPNfuuBGByTTicuQ6nmfS7BqTMTSvjk9WVIvcltX7VV7SUtaXGiFkDQsxd2btmzuIOu2hEM_Uzf5vGYnNPeHNzr_gZI-XUXZ4Abm4ybNURAfKIT_XJU1mPQsLjorFRMigBQjCInp5z4zm97bs03J_Ttpq-HoLFDBw6PY89uQE888UOGs6ZhwaQAPPMlkdqW4NQx7aDHM-dJ8Jm9FDptbeOKbA_3-UwPhr-1cOB308zRasKvLcSd5XNdhJRxCC_WbnjtBSgzfFgPda1vvseAqhEaDOdyQk5AJuctKyyGQ5qpe4YP_2IwyQY9t2VIhJaGjyOGa47nYu8c8blXBVrwJdtKC4A8hexe-N5_dERWz_gVJkoMoEb46FIk3te5NZKcRF0Yw5a_3ieryOy_VFruJtfzoDlY5Ztk4hZMXzkw2qwwVovMl2HxjxmbBIm8XCH2xT6pN9mJoxAKPLGz--GGBHodXm5VyssXqdanPxFlQ0nk7c5KRmAJzN4bkbWWE1oe9WhWXLGtWEut1eaRMZ_AA_yTmqefWdlbdchXyVplZEHso17zNyQdEYqbr0foJfiWus-fp0OJQ=w1392-h783-no)

Well that's it....

Construction is more or less finished.... now the development proces starts! plans are endless als always. Maybe i'll start a new thread in the race ready section to write about that a bit.....

Best regards,

Loek
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: 50gary on Jun 04, 2016, 17:26:38
Wow, one of my DTT favorites comes back!  Great job all around.  It's encouraging to hear how well it handles and brakes.  Well done vintage style bikes still have a chance.  You said you'd run it a Spa in the vintage enduro  races.  Did that happen?  A video would be fun to see and hear the bike.
  Cheers, 50gary
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: loekm on Jun 05, 2016, 04:52:18
Hey Gary,

Spa didn't happen... The event became an official FIM championship and is WAY more expensive than it was.... You can not take part without a racing licence... So it will not happen in the near future. I'm going to the event to assist a team in pitstops, good fun!

I hope to participate in Oschersleben this fall. Also a 3 hour race for amateurs. www.classicendurance.com

I shot a video of a small testdrive long ago, it's not running as good as it is now, and the clutch wasn't working ok..... but you get the point. No actual footage of tracktime as the gopro didn't work.... stupid thing.

https://youtu.be/C6EEDRZ5JeQ

Best regards,

Loek

B
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: themotoworks on May 18, 2017, 15:44:10
what is the thickness on that large diameter tubing and is the material chromoly?  I'm trying to design a similar frame but can't find chromoly tubing like that
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: YamahaTR1 on Jun 05, 2017, 13:05:14
This is not what yamaha had in mind when building the virago. Great work!
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: loekm on Jun 06, 2017, 05:30:34
Well maybe Yamaha had something like it in mind when disigning the TR1 :D It has some "race pedigree" It was sure against the mainstream of that era...

Whatever! I like the engine and it works quite good for me :)

And as we're replying ;) hereby a small update:

The bike has seen quite some track time last season. Had a lot of fun and the bike performed better than expected:
(http://i68.tinypic.com/2dt3c52.jpg)

Time for some serious upgrades over winter! A pair of dellorto PHM40's were installed and a set of custom rotors

CAD of rotor:
(http://i67.tinypic.com/f41d6o.jpg)

Rotor in real life:
(http://i66.tinypic.com/10yjkm9.jpg)

Rotor and bracket on wheel:
(https://s6.postimg.org/gjy9n4uz5/20170407_181052.jpg)

(https://s6.postimg.org/9urq749n5/20170407_181101.jpg)

Dellorto's:
(https://s6.postimg.org/9w1o0jbgx/20170227_110657.jpg)

(https://s6.postimg.org/tfaunmzm9/20170227_131426.jpg)

So I was ready and psyched for a new season of trackdays :) Power went up from 55Hp or so to 65Hp at the wheel and torque was almost 80Nm at the wheel as well!

And then all went wrong on the first trackday of the season...... :-[ Bad wheather, wet track, rider mistake at the end of straight, to much rear brake, whoop, crash......





Not to much damage, at least no structural damage. new parts needed:
- fairing
- master brake cylinder + handle
- throttle
- brake line

and some small stuf

Also the aluminium tank got punctured... and a footstep needed some serious repair. So the bike was disassembled, new stuff ordered and old stuf and I'm putting it together... hope to be ready for a trackday in the near future.

Best regards,

Loek
Title: Re: EGLI frame, TR1 engine, build from scratch
Post by: 50gary on Jun 06, 2017, 09:58:03
Loek, so good to hear from you with the update.  Every step of the way your work is professional, the brake rotor is outstanding.  10bhp wow a 15% increase!  One of my favorite builds ever on DTT, plus it's a track bike, well done.
  Cheers, 50gary