DR800 Big single thumper

lchris21

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Hello fellow builders, lurkers, tinkerers and garden shed engineers.

its been a few months since the completion of my Yamaha TR1 cafe make over and its time to get on with something else....

Was going to build another Yam TR1, but soon got on thinking about something else. With mind wandering and google image overload I decided I wanted a single to mess around with. First thoughts were an old aircooled British lump but the prices they command these days are eye-watering :eek: :eek:

So I stumbled across this beast of a thing!! Single cylinder.....check, and a mahoosive 800cc of it....Nice !!! Aircooled'ish looking..............need to find somewhere to hide the cooler......eventually.

Compared to my last starting point on the TR1 build, this is nearly finished ;)

Plenty of stuff to be getting on with, and lots of researching of bits to do.

Excuse the non fabrication build pics at the moment, just want to get the thread started to remind myself to get in the garage this winter............I'm in the "amass a pile of parts" stage, before i find the stuff I need and want?

Like the last one, this aint going to be an overnight build..........The other bike took the best part of 3 Winters in a nice cold wet British garage.......... ;D ;D

On with the pics........

Haven't quite decide on which tank to use at the moment, I'm favouring the CB50 tank as its got a narrower profile. The CB500 tank sits better on the neck tube as its bigger, but the CB50 needs a few tunnel mods to get it to sit right ( I wont be mounting at that angle !!!)......... Just throwing some bits together for inspiration.
 

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Never mind all that. What's that Jenn You wine Dunstall tank doing hiding in there and trying to escape? :)
 
Here comes another one !!! 8) Watching with bated breath. I did start on a big Japanese single myself a few years back - but it joined the cull !
 
So, it's an 800cc single with dual carbs? I'm curious to know more about the engine!
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Ah, a Dr Big. At the time the largest production single pot motor in the World.

Watching with interest.
 
beachcomber said:
Can I vote for the Dunlop tank please ??? 8)
Yeah I'm 50/50 at the mo.....want to get the tunnel out of the smaller tank and see how it sits in its correct position? Might go with Dunlop if I can smash some decent knee indents into it

Sent from my SM-G388F using DO THE TON mobile app
 
Smaller tank looks better imho ;) As you say though needs some surgery to get it to sit right. Love the 800 thumper :)
 
lchris21 said:
Yeah I'm 50/50 at the mo.....want to get the tunnel out of the smaller tank and see how it sits in its correct position? Might go with Dunlop if I can smash some decent knee indents into it

Sent from my SM-G388F using DO THE TON mobile app

If anyone can - it's you my man ..........................
 
Happy New Year fellow builders, lurkers and observers.....

Managed to get some garage time in during the Xmas period, not a lot, but anything is progress? Seemed to spend most of my time trawling the internet, ebay, breakers yards etc looking for bits I need, buying bits I think I need then selling the same bits I wont need !!!

Have been concentrating on the front end, trying to decide on what I want to do. I originally decided and bought a set of Aprilia forks, but then had a change of plan and decided to use some GSXR 600 forks with radial calipers as they came up at the right price, might be easier to fit into the headstock and bit less of a headache. Always liked the look of a radial front end with spoked wheels, but as we know they tend to use custom hubs which can get a bit £££'s

Anyway few visits to the local breakers secured some wheels I thought I could use.............At one point I think I had more wheels than him.......... Fast forward a few weeks and I spot a set of discs which I like the look of, from a Ducati something.....they will look nice as well.

Cut a long story short I'm now back on the Aprilia forks, with the Ducati discs and some calipers I've used before, which are common on many Honda's. Bit of jiggery pokery with some spacers for the calipers and all should be fine. So I made a start cutting stuff and machining some bits.
 

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Plan is to remove the rim from the rear original DR800 wheel and use that on the front. Then re-lace the the hub from one of the scrap wheels into that rim. Use the DR800 rear hub, and the new wider rim I've picked up......following me

During my quest to find a hub, I managed to locate a wheel off some random Japanese bike that had the right PCD for the disc along with correct register bore, but unfortunately the spoke count was wrong. The various wheels I tried had some key missing qualities I was looking for, so I eventually plumped for the "Japanese" wheel which looked meaty enough and could be modified to to the discs I want to use.

Some of the wheels in the breakers are so old, the model labels have long since dropped off, and trying to find a rare XS650 hub was like trying to find a needle in stack of haystacks. The XS650 hubs, as we know are commonly used for spoked front conversions, but since the invention of the phrase "barn find" they now sell for the same price as a small family hatchback.

Need to modify the discs by elongating the mounting holes a mm, to pick up the PCD off the, I think Suzuki GT hub???............Didn't want to re-drill 6 more holes in the hub or disc, and I also have to make spacers to register the discs for concentricty on the hub.
 

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