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Blood Sweat Tears and Grease => Projects => Trackers => Topic started by: Pinky23 on Sep 11, 2017, 17:07:12

Title: Honda XL600R - DTRA race bike build
Post by: Pinky23 on Sep 11, 2017, 17:07:12
Hey everyone! I've been wanting to build a flat tracker for a while now. Then these XL's came up on eBay.(https://uploads.tapatalk-cdn.com/20170911/0f3840c485ddb3a505f288af50e22116.png)

I checked all the parts and although I'm not familiar with XL's I thought I've got pretty much everything I need to build at least one bike, maybe even 2. To be honest I won't actually be using that much of the original bike. (https://uploads.tapatalk-cdn.com/20170911/659530b7dd5fe5320a0004b2dd10ef8b.jpg)

I've had them in my garage now for a few weeks. I'm not rushing this build. I started with the carbs, ordered full rebuild kits and set to stripping the carbs down. They where pretty manky inside. I borrowed an ultrasonic cleaner and stripped them down completely. (https://uploads.tapatalk-cdn.com/20170911/38891792aae28b5398c25364ddf847bc.jpg)(https://uploads.tapatalk-cdn.com/20170911/253643972516d28044eba11d87733841.jpg)

After reassembling the carbs I put them back on. Next I dropped the oil, put some fresh oil in, new filter, plug and plug cap. I managed to cobble together enough of a wiring loom to get a spark so I rigged up a fuel source and gave it a kick... it started on literally the first kick

Now that I know it runs I can concentrate on the chassis mods. However it was a little smokey so I might take the head off when I strip engine from the frame and re lap the valves and put some new stem seals in. Hopefully that will cure it.

Next up I managed to buy a full set of 19" wheels. Excel rims, Talon hubs and stainless spokes and they had the regulation maxxis DTR1 tyres on.
(https://uploads.tapatalk-cdn.com/20170911/b2515779059f0c522c19dc938b9baab1.png)

That's enough for now, but I hope to start getting a rolling chassis together this week so I'll post a few more updates then.

If anyone has any info or any sources about setting up a tracker frame geometry wise, heights etc. Please chip in!!


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Title: Re: Honda XL600R - DTRA race bike build
Post by: 1fasgsxr on Sep 11, 2017, 21:53:33
That's a good start, following along.
Title: Re: Honda XL600R - DTRA race bike build
Post by: Pinky23 on Sep 14, 2017, 18:49:01
I had some time in the garage the past few days, cleared a few jobs up with the Vmax, new forks, rebuilt fresh from the powder coaters. Rebuilt carbs. All back on and ready to get rebalanced.

My garage is a little stuffy at the moment
(https://uploads.tapatalk-cdn.com/20170914/2a11f1b1bbd3a9155aa6a9b926e637a7.jpg)

I had some old Vmax forks lying around so I put them in the frame because the XL forks weren't wide enough to take the new wheels with tyres.

I cleaned some spare parts up in a parts washer and then I started fitting the swingarm to the spare frame.
(https://uploads.tapatalk-cdn.com/20170914/b3bcd2ae46ee64b2b1b03575e4e2bcf3.jpg)
(https://uploads.tapatalk-cdn.com/20170914/21540ce5b49b0409489564832232433b.jpg)

Once the swingarm was in the frame. I put the wheels in just to have a look at whereabouts we where. It's looking good so far though...
(https://uploads.tapatalk-cdn.com/20170914/6ac3853815ad14b9d928ee0f59798972.jpg)

I can't decide whether to use the Vmax yokes, bore them out from 40 to 41 mm for the forks I want to use or go down the root of making my own yokes... I've already drawn some up, might even make some adjustable ones.

I'll keep posting updates as I go


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Title: Re: Honda XL600R - DTRA race bike build
Post by: Pinky23 on Sep 17, 2017, 15:05:17
I haven't done much on the bike for the last few days but I have managed to get some adjustable triple clamps drawn up:
(https://uploads.tapatalk-cdn.com/20170917/1d2285f7e1acbf2289663e5331e0249b.jpg)(https://uploads.tapatalk-cdn.com/20170917/d88c16c4d12d842e6529626b09627a50.jpg)
I also won some forks off eBay the other day from a thunder cat. I'm pretty sure they are exactly the same as the R6 5EB forks but they where only 77 delivered and the R6 ones are 250+ Happy with that. I'm hoping to get all the yokes machines asap so I can push on with the frame mods.



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Title: Re: Honda XL600R - DTRA race bike build
Post by: NoRiders on Sep 17, 2017, 16:56:54
Bloody good start fella. Looking in as I'm building a street tracker for the road :)

Carry on
Title: Re: Honda XL600R - DTRA race bike build
Post by: Pinky23 on Sep 24, 2017, 12:59:57
Haven't been getting much done last week but plenty in the pipe line. I've finalised the design for the clamps and I'm just waiting on a quote back to get them ordered.

I have made a new steerer tube though, got on the lathe in work and took a couple of hours.
(https://uploads.tapatalk-cdn.com/20170924/263d8868cf83da04b8446a3bbca780db.jpg)
I turned it up out of stainless. One of my friends thinks I should have used high tensile steel but I think 24mm OD stainless should cope. Any thoughts?
Managed to get this far on my own...
(https://uploads.tapatalk-cdn.com/20170924/047016132b91e35df75000ebe15245e0.jpg)
Then I had to take it to a friend who's a machinist to get the thread put on. And that's it done!(https://uploads.tapatalk-cdn.com/20170924/ff9b0bb7a521dab9803efb27fa7d696f.jpg)
I've had my forks now too so I've taken a few measurements and should be able to work out the size of the spindle, and wheel spacers I need to make so more lathe time this week hopefully.


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Title: Re: Honda XL600R - DTRA race bike build
Post by: Rat_ranger on Sep 24, 2017, 13:56:03
I made my stem out of 7075 aluminum.  Stainless should be more than strong enough
Title: Re: Honda XL600R - DTRA race bike build
Post by: Pinky23 on Sep 24, 2017, 15:50:27
Ye I'm pretty sure it will be fine. It's probably heavier than standard and definitely heavier than aluminium but it's what I was able to get hold of free


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Title: Re: Honda XL600R - DTRA race bike build
Post by: Rat_ranger on Sep 24, 2017, 15:59:34
Lol, I understand that.  Everything machined for my bike was pulled out of a scrap bin. 
Title: Re: Honda XL600R - DTRA race bike build
Post by: Pinky23 on Sep 25, 2017, 16:44:05
A small amount of progress tonight. My bearings arrived so I had a go at trial fitting the steerer tube. Pretty happy to say that it fits like a glove!
(https://uploads.tapatalk-cdn.com/20170925/1dd3b299987878c463a977a9482bf9a3.jpg)
I've never done this type of swap before so I'm really happy it fits so well.
I've also had a little sketch on solidworks to see how it will look because I was a little concerned I'd made the yokes too wide.
(https://uploads.tapatalk-cdn.com/20170925/f912e254f7630e5bc68770d0673aec92.jpg)
I'm happy with the way they look so I got them ordered today and hopefully they'll be here by the end of next week.
To say I'm excited is a little bit of an understatement

I've also been looking at inspiration online and came across this...
(https://uploads.tapatalk-cdn.com/20170925/2efcc31d3587362ac7c041150f47811d.jpg)
If mine looks anything like that when it's done I'll be pretty happy


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Title: Re: Honda XL600R - DTRA race bike build
Post by: Rat_ranger on Sep 25, 2017, 17:06:29
That almost looks like a bike from mule.  I love the look of the champion seat, its a bit more work to uae but looks good.
Title: Re: Honda XL600R - DTRA race bike build
Post by: Pinky23 on Oct 05, 2017, 18:50:51
Not much been happening over the last week because I'm still waiting on my yokes to be machined out which is holing me up on building the other parts I want to start working on because without the forks in the frame I can't really work out the geometry I want for the rest of the bike. So I've been playing on solidworks working out a rough idea for a new swingarm. I struggled to find any geometry set up advice anywhere and ended up messaging Survivor customs on instagram and fair play to him, he gave me some advice so hopefully I can use that as basic dimensions and then I can work from there.

Here's a couple of screenshots of the swingarm I'd like to build so hopefully I can get this moving in the next week. I'm going to convert the bike to twin shock because I like the old school look more and also it will let me run pod filters, which is a pain on XL's otherwise because the mono shock is so close to the carbs!​
(https://uploads.tapatalk-cdn.com/20171005/db20ff982d0c12d0fc66e671402f0ff4.jpg)(https://uploads.tapatalk-cdn.com/20171005/6962a302baaa9e7f64b68b71a68da350.jpg)(https://uploads.tapatalk-cdn.com/20171005/9f5f79dabdd1ea61a840ddf8b7bc073f.jpg)

Let me know what you think


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Title: Re: Honda XL600R - DTRA race bike build
Post by: Pinky23 on Oct 16, 2017, 17:52:47
Finally got my yokes back from the machine shop. I'm really happy the way they turned out
(https://uploads.tapatalk-cdn.com/20171016/bea4d9a1c6c240425b05ec0e8501c597.jpg)
They will be cleaned up eventually but right now while I mock everything up I'll leave them and clean everything at the end. I got the yokes fitted and trialled the forks and I'm liking the way they look. I think when it's got the number board on it's gonna look awesome.
(https://uploads.tapatalk-cdn.com/20171016/0c8f999099cc9ea72eacbb85aed821c7.jpg)
Fitted the wheel, used a standard spindle but it's not long enough now because the forks are wider than standard so it'll have to make a new spindle. I've ordered some high tensile EN19T bar.
(https://uploads.tapatalk-cdn.com/20171016/560d99a66b71b612c59f61d8ddb561a9.jpg)
I went to the national motorcycle mechanics show in Stafford this weekend and bought a tank it's of a K500 Kawasaki. I trialled it on the roller chassis, but I think it's too long and a little bit too big so I'm gonna look around for another one, at least I've got an idea and size to go off (https://uploads.tapatalk-cdn.com/20171016/7e80aadb7f53499785a5a8163ce25833.jpg)
I just couldn't help myself really to see where I was going.
I also checked the geometry of the frame while it was set up an the moment I'm pretty happy. I think it's pretty close to where I want to be. Hopefully soon I'll be able to start the real fabrication!(https://uploads.tapatalk-cdn.com/20171016/cd8f3ce093297800b709de7bd1ead825.jpg)



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Title: Re: Honda XL600R - DTRA race bike build
Post by: Pinky23 on Nov 03, 2017, 12:21:38
I've had a quiet few weeks in the shed with not much going on since I've fitted the front forks but it's been time that I've spent trying to figure out a few things. Anyway got going this week with the exhaust. I have wanted to make a sectionalised exhaust for a while now so I already knew which direction I was headed. I have a standard exhaust already and I measured the pipes on that, 32mm OD out of the ports in to 42 OD from then on. Ports measure around 38 mm OD so I figured 38 mm tube would be spot on for what I wanted to do and would give them a chunkier look.

(https://uploads.tapatalk-cdn.com/20171103/dc3caca2a0e8cee3e1739b9b746bfad6.jpg)

Started off by cutting a handful of pipe sections some with 10 degree cuts, some with 5 degree cuts, I hadn't pre drawn or calculated anything beforehand I just cut what I thought would work, I have done pipe fabrication in the past so I had an idea on what would work and what wouldn't. After cutting all the sections I deburred the edges inside and out.

(https://uploads.tapatalk-cdn.com/20171103/5e0c0969b168d178642eeb5d01a7c61f.jpg)

Then I set to starting the mock up, I basically had 2 pieces of pipe roughly the same size with square cuts one side and 10 degree the other and I put them in to the ports as a starting point. Then I just held some tapered sections together and tried to gauge where I wanted them to go.

(https://uploads.tapatalk-cdn.com/20171103/23ad371f37e300ed12699136088eccde.jpg)

Once I was happy with that I just tacked a few pieces together, checked them and worked from there, one or two pieces at a time.

(https://uploads.tapatalk-cdn.com/20171103/f9c30e8c1dffb26d9a1ab6f888e96321.jpg)

I repeated that for both ports and tried to get them to come close enough together that I could then join them together with a Y section. I tried to keep them the same length but without making them completely symmetrical which would have caused issues with the drain plug for the frame I couldn't so I used one more section on the left port than the right. I'm no exhaust guru but I cant see 15-20 mm making a massive difference and to be honest I'm not chasing all out power either.

I then set to making a Y piece, which I'd never made before! So basically I cut 2 pieces of tube the same length had a guess as to where to cut them and attacked with the grinder! Apart from a quick clean up with the flap disc they literally fitted together as you see in the pic. I don't know if it would happen like that again but it worked out perfect.

(https://uploads.tapatalk-cdn.com/20171103/d7b4f1df504846fe508ec4e8f14a4cc0.jpg)




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Title: Re: Honda XL600R - DTRA race bike build
Post by: Pinky23 on Nov 03, 2017, 12:23:25
I did all this in about an hour and a half one night then came in the next night and decided it could be better so I took some of it apart and re-worked it. I was happier the second time around so I set to the welding! I've still got a few things to add but this is where I'm up to on the pipes. I'm not 100% happy with the welding but this is a race bike after all, and I am probably just being picky.



If anyone wants to keep more up to date on the build or other things I am building/working on the have a look at my instagram @pinkyscustomfabrication(https://uploads.tapatalk-cdn.com/20171103/55a1332744ff5928ddb74e61692ddad3.jpg)(https://uploads.tapatalk-cdn.com/20171103/fb7f72378ce3311dcaa394a353edb78b.jpg)(https://uploads.tapatalk-cdn.com/20171103/db9aef10c5d9b8c77bb8c8942339a64f.jpg)


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