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Author Topic: EGLI frame, TR1 engine, build from scratch  (Read 66576 times)

Offline biker_reject

  • Posts: 2147
Re: EGLI frame, TR1 engine, build from scratch
« Reply #100 on: May 13, 2012, 12:00:11 »
Wow... speechless.

Offline loekm

  • Posts: 62
  • TR1 racer is starting to look like a bike!
Re: EGLI frame, TR1 engine, build from scratch
« Reply #101 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:

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 :


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:


And finally a blown head gasket:

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 ;)


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:


alu tank shell:


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:


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

Best regards,

Loek


 

Offline Bozz

  • Posts: 696
    • not nearly cool enough website
Re: EGLI frame, TR1 engine, build from scratch
« Reply #102 on: May 25, 2012, 09:44:01 »
breathtaking.
Cheers!
-Bozz

(All opinions worth less than you paid for them!)

Offline JustinLonghorn

  • DTT SUPPORTER
  • *
  • Posts: 6340
  • No Purple Hearts, No Blue Ribbons
Re: EGLI frame, TR1 engine, build from scratch
« Reply #103 on: May 25, 2012, 10:03:34 »
Damn, that is fantastic!
I'm going to eat your brains and gain your knowledge.

Into The Sunset, CB750 build

TT500 the Animal

Offline 50gary

  • Posts: 585
  • Under the Limelight
Re: EGLI frame, TR1 engine, build from scratch
« Reply #104 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

Short track speedskating, cycling, guitars, motorcycles, juggling dynamite. I was born to laugh at Tornadoes.

Offline VonYinzer

  • DTT SUPPORTER
  • *
  • Posts: 18322
Re: EGLI frame, TR1 engine, build from scratch
« Reply #105 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.
Like a river that don't know where it's flowin'
I took a wrong turn and just kept goin'

Offline Von Kirk 75 dt250

  • Posts: 429
  • DT250 project in the works!
Re: EGLI frame, TR1 engine, build from scratch
« Reply #106 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.
Four wheels move the body,
But two wheels move the soul.

I don't need special paint and chrome
for my bike, i know how big my cock is.
http://www.dotheton.com/forum/index.php?topic=35089.0

Offline loekm

  • Posts: 62
  • TR1 racer is starting to look like a bike!
Re: EGLI frame, TR1 engine, build from scratch
« Reply #107 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:

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:


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:


And the steel one in the spare motor:


Next is software / ECU communication, works first time:


Hardware test for RPM signal and triggerwheel:


Houston we have a signal :)


Cover for RPM sensor:


Ajustment to the cilinder head:


And it all fits:


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



 

Offline Caf'd Out

  • Posts: 317
Re: EGLI frame, TR1 engine, build from scratch
« Reply #108 on: Aug 18, 2012, 09:30:54 »
Top notch! Are we witnessing this from the Yamaha R&D factory or something?! haha Professional.

Offline VonYinzer

  • DTT SUPPORTER
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  • Posts: 18322
Re: EGLI frame, TR1 engine, build from scratch
« Reply #109 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.
Like a river that don't know where it's flowin'
I took a wrong turn and just kept goin'