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Blood Sweat Tears and Grease => Projects => Cafe Racers => Topic started by: Thetoolman on Mar 06, 2018, 16:53:34

Title: Thetoolman's 197? At1?!? Build
Post by: Thetoolman on Mar 06, 2018, 16:53:34
hey dudes and dudetes! I'm tim, I've had an account here for a few years but can't remember any of my login info so here I am starting over.

Anyways, about my build!
I picked this bike up a few weeks ago, while I'm not really sure what it is, it's gonna be a fun build! I was told it's a 1973 dt175 when I picked it up, after doing some research I've found out dt's didn't start till 1974. The first three on the frame is at1 which makes me believe it's a 69-71 at1 but... at1's have a 125cc 2 stroke and this does have the 175cc 66mm bore so I'm kind of at a loss on what it actually is.

So... I'll just start with what I have planned for this so far.


I've got the bike stripped to the frame right now.
(Front end)
2007 Yz85 front end, upper fork tubes powdercoated copper, triples powdercoated gloss black.
Forks lowered internally 3 inches.
Custom .52 weight fork springs from cannon racecraft made 3" shorter than stock.
3" spacers from racetech to make up for the shorter springs.
Ttr125l front hub (for disk front brake) powdercoated copper.
Yz85 front caliper powdercoated black.
Yz85 big rotor kit.
DNA 17x3.5" hoop in gloss black.
I have to have custom spokes made.
Woodcraft 46mm clip ons.
I'm gonna use the old bar mounts on the upper triple to make a speedo/tach mount.

(Rear end setup)
Custom made swingarm which will be made out of double stacked 1" chromoly.
Swingarm stretched 2 inches.
2001 yz125 rear hub, powdercoated copper.
Yz125 rear brake setup.
Yz125 axle.
Have to have custom spokes made.
DNA 17x3.5" rear hoop in gloss black.

(Frame)
Rear hoop has been cut off and am having a new one bent up.
The tail cowl will be a bit different, it will have a chromoly skeleton and fiberglassed inside are.
I will make a electrical wiring tray under the seat.
Powdercoated gloss black.
De tabbed.
Other than that the frame will mostly stay the way it is.

(Engine)
I don't know what I have planned for this yet, as for right now I've cleaned it up and painted it gloss black.
I'm thinking banshee reed cage, boyesen reeds.
Maybe mill the head to reduce the squish.
Maybe have the cylinder ported.

(Exhaust)
For now I have picked up a expansion chamber/silencer from a 01 yz125.
The expansion chamber took a little bending to get it to fit around the frame but it fits like a glove now.
I'm gonna have to cut the inlet tube off the silencer and make up a new one to get the silencer to sit where I want it.
I don't know how well this exhaust is going to work on the 175 so if it's not what I want power wise I'm gonna have a custom one made up.

(Seat)
I've made up a new seat pan, I'm gonna weld the bolts for the mounting points tonight.
Then I'll paint it black and it will go to the upholsterer.
We are gonna do black leather, white diamond stitch seating area, white piping.

(Paint)
As for right now I have in my head a really dark blue, this may change by the time I'm to that point.
The tank, rear cowl and fenders will all be the same color.

(Electrical)
For the electrical I'm gonna use most of the stock wiring harness and get rid of what I don't need.
One of the previous owners swapped it over to a total loss battery setup which really sucks!! I spent 2 hours trying to figure out why I didn't have spark after I picked the bike up, pulled the magneto cover and there's no magneto/flywheel. I'm thinking I'll just keep 3 small anti gravity batteries under the rear cowl so I can swap over to the next one when one dies.

That's pretty much it, I'll post up progress pics over the rest of the evening and try to explain everything I've done. That was a really long read so if you had enough interest to make it all the way thru, thank you!!
Here's some pics from the day I picked it up.
Title: Re: Thetoolman's 197? At1?!? Build
Post by: Thetoolman on Mar 06, 2018, 18:22:37
If any one has some advice on how to get a 175cc two stroke to do the ton I'm all ears.
Title: Re: Thetoolman's 197? At1?!? Build
Post by: Thetoolman on Mar 06, 2018, 18:26:33
This is where I started to tear down, I was trying to figure out what I wanted to do with the rear cowl and that wasn't it lol.
Title: Re: Thetoolman's 197? At1?!? Build
Post by: Thetoolman on Mar 06, 2018, 18:29:05
And where I got the yz125 expansion chamber to fit, It fits pretty well.
Title: Re: Thetoolman's 197? At1?!? Build
Post by: Thetoolman on Mar 06, 2018, 18:30:00
I guess this will only let me post 1 pic at a time.
Title: Re: Thetoolman's 197? At1?!? Build
Post by: Thetoolman on Mar 06, 2018, 18:31:17
Seat pan
Title: Re: Thetoolman's 197? At1?!? Build
Post by: Thetoolman on Mar 06, 2018, 18:32:26
Seat pan part 2. I don't know why it keeps rotating my pictures.
Title: Re: Thetoolman's 197? At1?!? Build
Post by: Thetoolman on Mar 06, 2018, 18:34:36
The expansion chamber had quite a few dents in it. I tried to freeze them out which worked on the bigger ones, but the small ones are still there. It also split my pipe which sucks but I'll weld it up and when I know the engine runs well with it I'll buy a brand new one.
Title: Re: Thetoolman's 197? At1?!? Build
Post by: Thetoolman on Mar 06, 2018, 18:35:29
Bringing home the donor bike for the yz85 front end.
Title: Re: Thetoolman's 197? At1?!? Build
Post by: Thetoolman on Mar 06, 2018, 18:37:38
The yz85 steering stem was 1/2" to short as you can see here.
Title: Re: Thetoolman's 197? At1?!? Build
Post by: Thetoolman on Mar 06, 2018, 18:42:30
And here
Title: Re: Thetoolman's 197? At1?!? Build
Post by: Thetoolman on Mar 06, 2018, 18:45:07
My solution was to turn down a spacer on the lathe, the middle diameter the od of my steering stem, the ends 1.5" long and .005 bigger than the id of my steering stem, this way I could cut the stem in half, press the 2 parts of stem on the spacer to keep everything strong and concentric and then weld the spacer to the stem and grind it down.
Title: Re: Thetoolman's 197? At1?!? Build
Post by: Thetoolman on Mar 06, 2018, 18:45:39
Stem part 2
Title: Re: Thetoolman's 197? At1?!? Build
Post by: Thetoolman on Mar 06, 2018, 18:46:12
Stem part 3
Title: Re: Thetoolman's 197? At1?!? Build
Post by: Thetoolman on Mar 06, 2018, 18:46:49
Stem part 4
Title: Re: Thetoolman's 197? At1?!? Build
Post by: Thetoolman on Mar 06, 2018, 18:48:07
Stem part 5, done!! I'm waiting on my triples to come back from powdercoat and then I'll reinstall the stem with the allballs bearings needed for the dt175 frame.
Title: Re: Thetoolman's 197? At1?!? Build
Post by: Thetoolman on Mar 06, 2018, 18:49:07
Engine cleaned and painted
Title: Re: Thetoolman's 197? At1?!? Build
Post by: Thetoolman on Mar 06, 2018, 18:49:57
Engine paint part 2! And that is where I'm at, at the moment. More updates soon!
Title: Re: Thetoolman's 197? At1?!? Build
Post by: Thetoolman on Mar 06, 2018, 19:28:25
Hoops just got dropped off here at my work! It's gonna be a work of art if I can fit this 17x3.5" in the yz85 front end, I may be having to buy another hoop that's skinnier. They look damn good tho!
Title: Re: Thetoolman's 197? At1?!? Build
Post by: teazer on Mar 06, 2018, 19:56:30
Interesting project.  I can't get past the 3.5" x 17" front rim though.  That's a touch wide for the front end of a seventies 125/175 dirt bike isn't it?  What are you planning for the rear and what's the overall plan - mini motard or something different?
Title: Re: Thetoolman's 197? At1?!? Build
Post by: Thetoolman on Mar 06, 2018, 21:25:27
Interesting project.  I can't get past the 3.5" x 17" front rim though.  That's a touch wide for the front end of a seventies 125/175 dirt bike isn't it?  What are you planning for the rear and what's the overall plan - mini motard or something different?

The 17x3.5" front might have not been the best choice if I'm being honest lol. The plan has been 17x3.5" front with 110-70 front tire, 17x3.5" rear with 130-70 tire, I'm gonna have to mount up a tire on this front hoop and see what it's gonna look like, if I'm not happy with the outcome I'll put the 110-70 on a 2.5".

The overall plan is I guess cafe with a bit of scrambler in it. This dt125 that I'll post a pic of has a huge inspiration to me on this build.
Title: Re: Thetoolman's 197? At1?!? Build
Post by: Aussie Steve on Mar 07, 2018, 06:00:03
Looks like a cool project. Good luck!

Sent from my Lenovo A6020a40 using DO THE TON mobile app (http://r.tapatalk.com/byo?rid=89466)

Title: Re: Thetoolman's 197? At1?!? Build
Post by: WhyNot on Mar 07, 2018, 06:38:30
 Interesting.

But I like the wheels being almost the same size front and rear.

I'm in search of a little CB175 engine myself to do something like this.
Title: Re: Thetoolman's 197? At1?!? Build
Post by: Maritime on Mar 07, 2018, 09:29:15
Signing up to watch, looks nifty so far.
Title: Re: Thetoolman's 197? At1?!? Build
Post by: SONIC. on Mar 07, 2018, 10:58:20
Very cool, Nice work on the steering stem as well.
Title: Re: Thetoolman's 197? At1?!? Build
Post by: Thetoolman on Mar 10, 2018, 17:36:27
Thanks guys! I took the frame up to work and got a bit of work done.
I decided to do something a bit different with the tail cowl this time, I bent up some tubing and cut it in half, then welded up a piece of straight tube in between them to give it a squared off look in the back, then I skelotonized the cowl with 3/4" chromoly tubing and welded it all up. I'm gonna make filler pieces out of fiberglass to inclose it. I should be able to get 2 anti gravity batteries back there.

Only thing left to do on the frame is enclose the subframe so the wiring will be hidden and make seat mounts and then the frame will be ready for powdercoat.
Title: Re: Thetoolman's 197? At1?!? Build
Post by: Thetoolman on Mar 10, 2018, 17:38:07
View from the back.

Does anyone know why my photos keep getting turned sideways? I'm using the "attach files" underneath the message area.
Title: Re: Thetoolman's 197? At1?!? Build
Post by: Thetoolman on Mar 11, 2018, 15:24:55
Got a little bit done last night and this morning.
got my triples back from the powdercoater last Friday so test fitted them to make sure this stem length is gonna work and that I got it straight lol. It's looking good!

Also got my woodcraft clip ons in the mail so test fit them, I'm probably gonna take them to be powdercoated, not really liking the matte black when everything else is gloss.
Title: Re: Thetoolman's 197? At1?!? Build
Post by: Thetoolman on Mar 11, 2018, 15:25:55
The clip ons
Title: Re: Thetoolman's 197? At1?!? Build
Post by: Hurco550 on Mar 11, 2018, 15:36:15
Watching. This is neat!

Sent from my SM-G920V using Tapatalk

Title: Re: Thetoolman's 197? At1?!? Build
Post by: Thetoolman on Mar 11, 2018, 15:38:40
Thanks hurco550, glad to have ya here!

I also got the forks disassembled, and will get the upper tubes over to the powdercoater tomorrow. The fork tubes, wheel hubs and other random parts will be a really cool copper color.

My lowering springs came in last thursday from cannon racecraft and am still waiting on my spacers from racetech. Racetech has been kinda giving me the run around so hopefully they will be shipped out to me Monday and be here before I get the powdercoated parts back.
Title: Re: Thetoolman's 197? At1?!? Build
Post by: Thetoolman on Mar 11, 2018, 15:42:10
And to give y'all an idea of how much clearance I'm gonna have with the 17x3.5" front wheel in a yz85 front end it's gonna be super close but I can work with this!

Custom Spokes have been ordered from buchanan's, as soon as they come in I'll get it laced up and trued and then can really start working out the front wheel clearance.
Title: Re: Thetoolman's 197? At1?!? Build
Post by: irk miller on Mar 11, 2018, 16:09:01
Are you sure you can work with that?  What about tire clearance?
Title: Re: Thetoolman's 197? At1?!? Build
Post by: Thetoolman on Mar 11, 2018, 16:15:37
Are you sure you can work with that?  What about tire clearance?

I'm thinking so,  If my calculations are correct the tire will only be 1/8 inch wider than the wheel. So .062 per side, I should be able to squeeze it in there (fingers crossed)!
Title: Re: Thetoolman's 197? At1?!? Build
Post by: Thetoolman on Mar 11, 2018, 16:16:31
I'm gonna go pick up a 110-70 here in about an hour to get some actual measurements off of to make sure.
Title: Re: Thetoolman's 197? At1?!? Build
Post by: Thetoolman on Mar 11, 2018, 20:13:41
Fiberglassing this evening! Hopefully this goes better than the last 4 times I've tried to make a tail cowl. Wish me luck!
Title: Re: Thetoolman's 197? At1?!? Build
Post by: teazer on Mar 12, 2018, 14:08:46
You might want to try to stick a sheet of thick card stock on there and retain it with aluminum duct tape and then way it all so it can be removed from the card.  Then create a slight frenched in rear panel to take the tail light.

Or get some flashing material from your local hardware store to use to create a semi stiff backing to avoid sagging.  No one wants to see a saggy tail...  :o
Title: Re: Thetoolman's 197? At1?!? Build
Post by: Thetoolman on Mar 12, 2018, 18:59:49
You might want to try to stick a sheet of thick card stock on there and retain it with aluminum duct tape and then way it all so it can be removed from the card.  Then create a slight frenched in rear panel to take the tail light.

Or get some flashing material from your local hardware store to use to create a semi stiff backing to avoid sagging.  No one wants to see a saggy tail...  :o

That is normally what I would have done, either make a "mold" out of cardboard or foam but in this case I specifically wanted it to be saggy in the center  to get the curves that I wanted going off the skeleton tubing. Which I think work great! I'll post a few pics of what I ended up with.
Title: Re: Thetoolman's 197? At1?!? Build
Post by: Thetoolman on Mar 12, 2018, 19:01:27
Pic 1
Title: Re: Thetoolman's 197? At1?!? Build
Post by: Thetoolman on Mar 12, 2018, 19:01:59
Pic 2
Title: Re: Thetoolman's 197? At1?!? Build
Post by: Thetoolman on Mar 12, 2018, 19:03:09
Pic 3
Title: Re: Thetoolman's 197? At1?!? Build
Post by: Thetoolman on Mar 12, 2018, 19:58:18
I tried to drop my seat pan at the upholsterer on Saturday, we talked over what exactly I'm wanting and because I want my seat to angle at the front and back to match my tank and tail I had to make a few changes, So brought the bike up to work today to sort everything out. He needed me to box in the part I cut out for the rear tank mount and also extended it up to the tank, he also needed me to add an angle at the back that matches the angle of the cowl so when he puts the cover on it doesn't make the foam buckle.
The plan for the Upholstry is black leather with the center of the seating area to be white diamond stich and white piping. It should look great if it ends up what I'm seeing in my head.

Anyways, I got all that sorted and here's thefinished seat pan.
Title: Re: Thetoolman's 197? At1?!? Build
Post by: Thetoolman on Mar 12, 2018, 19:58:42
Front of pan
Title: Re: Thetoolman's 197? At1?!? Build
Post by: Thetoolman on Mar 12, 2018, 19:59:07
Back of pan
Title: Re: Thetoolman's 197? At1?!? Build
Post by: Thetoolman on Mar 13, 2018, 02:19:44
Just finished up the seat mounts. Only things left to do on the frame should be to weld in the wiring tray and the mounts for the tail fiberglass. Then it will be ready for powdercoat.

Gonna try to get all of that finished up this week but family is coming into town so we will see.
Title: Re: Thetoolman's 197? At1?!? Build
Post by: Thetoolman on Mar 15, 2018, 15:30:52
I spent the better part of last night trying to get the cartridge out of the lower forks and finally said screw it and dropped them off at my local mechanic to have him install my lowering spacers in the forks. I should be able to pick those up tomorrow along with my powdercoated parts so hopefully can get these forks back together next week.
 
Spent this morning sanding the frame getting everything smooth, it will be sandblasted and powdercoated so I only took it to 80 grit. Then shot a coat of black on it real quick to keep it from rusting.
 I'm still trying to decide if I wanna mono shock the rear or not so I'm gonna wait a while to have the frame powder coated.

 I also finished up my fiberglass tail pieces. I'm no fiberglass guy but I think these turned out pretty great. Just need to make my mounts for them and then they will be ready for paint.
 
Also I dropped my seat pan off to the upholsterer yesterday so should get that back next week.
Title: Re: Thetoolman's 197? At1?!? Build
Post by: Thetoolman on Mar 15, 2018, 15:31:22
More pics of tail with tank on to give an idea of the look of the bike
Title: Re: Thetoolman's 197? At1?!? Build
Post by: Thetoolman on Mar 15, 2018, 15:32:18
One more
Title: Re: Thetoolman's 197? At1?!? Build
Post by: Thetoolman on Mar 19, 2018, 18:07:10
I wasn't able to get a whole lot done over the weekend due to having family in town but I was able to do a little bit.

I tried and tried to get the cartridges out of the lower forks to install the lowering spacers last week but couldn't get it done so I took them over to my local motorcycle tech who does just about everything for me that I can't. Anyways, I picked them up from him Friday morning and picked up my powdercoated parts from the coater. Got the forks put back together and that's about it.

My new steering stem bearings should be here tomorrow, my wheel spokes should be here next week and I need to paint the lower lugs on the forks gloss black. Other than that the front end will be completely done.

Here's a pic of the forks, the picture doesn't really do them justice, they kinda look brown but are actually a dark copper with a bit of flake in it.
Title: Re: Thetoolman's 197? At1?!? Build
Post by: Thetoolman on Mar 19, 2018, 18:09:53
Also... I have changed up what I'm gonna do with the rear suspension, I will be using a pull style shock from a buelll and mounting it under the engine. Because of this my swingarm design will have to change and I'll probably be cutting off the down tubes on the subframe and bending up some new ones to kind of change up the look back there.

More on this in a few weeks after I buy the shock.