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Author Topic: EGLI frame, TR1 engine, build from scratch  (Read 60188 times)

Offline 50gary

  • Posts: 585
  • Under the Limelight
Re: EGLI frame, TR1 engine, build from scratch
« Reply #30 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
« Last Edit: Jan 13, 2012, 23:38:44 by 50gary »
Short track speedskating, cycling, guitars, motorcycles, juggling dynamite. I was born to laugh at Tornadoes.

Offline 1969Honda

  • Posts: 296
Re: EGLI frame, TR1 engine, build from scratch
« Reply #31 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
"Life happens, you'll either get over it or die from it"

Offline loekm

  • Posts: 62
  • TR1 racer is starting to look like a bike!
Re: EGLI frame, TR1 engine, build from scratch
« Reply #32 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:


Pieces needed to assemble the swingarm:


Swingarm axle partly assembled:


All the parts in the frame as mockup:


Back position:


Front position:


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

Offline Greg-NWO

  • Posts: 53
Re: EGLI frame, TR1 engine, build from scratch
« Reply #33 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 :)

Offline 1969Honda

  • Posts: 296
Re: EGLI frame, TR1 engine, build from scratch
« Reply #34 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?
"Life happens, you'll either get over it or die from it"

Offline loekm

  • Posts: 62
  • TR1 racer is starting to look like a bike!
Re: EGLI frame, TR1 engine, build from scratch
« Reply #35 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

Offline loekm

  • Posts: 62
  • TR1 racer is starting to look like a bike!
Re: EGLI frame, TR1 engine, build from scratch
« Reply #36 on: Jan 20, 2012, 12:47:02 »
Hey people,

Short update with some pics.

Front sprocket fits! (XS650 sprocket final ratio 18/38):


Frame back in jig:


Start of mountingpoit rear cilinder:


Mountingpoint of rear cilinder in pieces:


And it goes together:


And last, insert for stearinghead:


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

Enjoy your weekend!

Best regards,

Loek

Offline CrescentSon

  • Posts: 2423
Re: EGLI frame, TR1 engine, build from scratch
« Reply #37 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.
"I hated hipsters before it was cool." -Sonreier

"Lifes a bitch when your trying to sell gold bars to beggars" -VonYinzer

"To say that ALL cafe racers are the same degree of ho hum is like saying that finger banging a fisher price piano is on par with listening to Beethoven." -Kanticoy

Offline dcmspikes

  • Posts: 1001
Re: EGLI frame, TR1 engine, build from scratch
« Reply #38 on: Jan 21, 2012, 14:16:05 »
yeah im on board for this one.   keep it coming

Offline pacomotorstuff

  • DTT SUPPORTER
  • *
  • Posts: 829
Re: EGLI frame, TR1 engine, build from scratch
« Reply #39 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

Offline devon

  • Posts: 150
Re: EGLI frame, TR1 engine, build from scratch
« Reply #40 on: Jan 24, 2012, 13:57:09 »
Really interesting! I'm definitely tuned in for this one.

Offline loekm

  • Posts: 62
  • TR1 racer is starting to look like a bike!
Re: EGLI frame, TR1 engine, build from scratch
« Reply #41 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:


Other side:


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:


And again:


The finished hole:


And the hole mounting point complete:


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

Offline Staffy

  • Posts: 1500
  • It's not yours 'til you cut it up.
Re: EGLI frame, TR1 engine, build from scratch
« Reply #42 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!

Offline 50gary

  • Posts: 585
  • Under the Limelight
Re: EGLI frame, TR1 engine, build from scratch
« Reply #43 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

« Last Edit: Jan 28, 2012, 19:45:52 by 50gary »
Short track speedskating, cycling, guitars, motorcycles, juggling dynamite. I was born to laugh at Tornadoes.

Offline loekm

  • Posts: 62
  • TR1 racer is starting to look like a bike!
Re: EGLI frame, TR1 engine, build from scratch
« Reply #44 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):


1 hour into the kill:


2 hours into the kill:


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:


instead of this:


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

Best regards,

Loek