DO THE TON

Blood Sweat Tears and Grease => Projects => Specials => Topic started by: Bevelheadmhr on Mar 27, 2015, 05:55:27

Title: A Blast from the Past
Post by: Bevelheadmhr on Mar 27, 2015, 05:55:27
My mate Jeff won a bid on a few parts on Ebay last week, by one of those flukes, turns out the seller owns the first drag bike Jeff built back in the eighties, the bike that Jeff was slowly acquiring parts to replicate one day. Its been changed a bit over the years, it now has a 250cc engine, a Wade supercharger, an air shifter, hydraulic clutch and a different tank and seat etc. The home made frame and handmade yokes (the first he ever made) are still the same as is the front end. Well, turns out the chap was happy to sell, so we brought it home along with a pile of spares. Including a half completed engine, which Jeff had started to build when he sold the bike more than twenty five years ago. This spare 350cc engine has a much stronger home made three speed box, built by Jeff using CB750 parts, as running it on Nitro used to break the standard box regularly. Its in poor condition so its being rebuilt with a lot of changes, which I'll no doubt be roped in to help out here and there, be interesting to see how it turns out.

Title: Re: A Blast from the Past
Post by: stroker crazy on Mar 27, 2015, 05:59:19
What a story!

Keep us posted on progress.

Crazy
Title: Re: A Blast from the Past
Post by: Bevelheadmhr on Mar 27, 2015, 06:07:24
The old supercharged we took off Jeff's drag bike has a date stamp.. it was made 06/01/1943... what's interesting is that its original use wasn't on an engine, but to pressurise the cockpit of an aircraft, it would've been fitted to either a DeHavilland Mosquito or Supermarine Spitfire photo-reconnaisance aircraft.

By the end of the first day the bike was totally dismantled, with plans to make quite a few changes. The rear Astralite wheel was deemed too narrow and was soon sold on Ebay, as was the Supercharger (pity I would've liked to keep it). A wider Astralite was bought but had to go back as its condition wasnt as advertised. In the meantime a scrap Japanese 3 spoke rear wheel would have to do.

The points / coil ignition will be replaced by a Lucas Magneto, while the rusty fuel tank will be replaced with an alloy one which will live behind the headstock under the top tubes.

We have a new supercharger to fit, along with this empty case which will be used for setting up, along with a manifold and bigger SU carb. The Pistons in the background are from a Yamaha XJ650 Turbo and will give a cc of just under 350cc and a low CR of 5:1 using a plate beneath the block.
Title: Re: A Blast from the Past
Post by: Bevelheadmhr on Mar 27, 2015, 06:12:33
Jeff had been given a rear wheel with a knackered hub which was dusted down and put to use. The wheel came from a newish Suzuki which had a new tyre fitted (dunno where yet).. a week later on the motorway, the rear wheel bearings collapsed. When the wheel was inspected, the bearings and hub had disintegrated, because the bearing spacer was missing.

I would have thought that wheel was good for nothing but weighing in for scrap, but not to Jeff.. He machined up new plates for the bearings and had them welded to the wheel. There's no need for a cush drive and the sprocket needs spacing out to clear the tyre, so all in all it worked out ok. Then again if another nice Astralite turns up, the Jap wheel wont make the final build.

I did my bit by grinding off the casting marks, the wheel centre will be painted gold and the rims polished when we get time.

Title: Re: A Blast from the Past
Post by: interceptor on Mar 27, 2015, 08:02:09
So cool!
Title: Re: A Blast from the Past
Post by: irk miller on Mar 27, 2015, 08:16:27
Great stuff. 
Title: Re: A Blast from the Past
Post by: TranceMachineVienna on Mar 27, 2015, 08:45:07
Cool!
Title: Re: A Blast from the Past
Post by: Bevelheadmhr on Mar 27, 2015, 09:26:59
great story great bike

ive been on the constant lookout for my first build a 76 z750 chop BSH did a feature so it was special to me, sold it to fund the next bike ,35-40 builds later i aint never got the same buzz as the first, bit like your first love i suppose  :'(

If you know the reg number you can check online to see if its taxed or sorned. I have all the old BSH mags, if you know roughly when it was featured I could probably find the article.
Title: Re: A Blast from the Past
Post by: Maritime on Mar 27, 2015, 11:56:15
signing up for the ride
Title: Re: A Blast from the Past
Post by: Bevelheadmhr on Mar 30, 2015, 03:50:45
cheers for that Bevelheadmhr i dont want to threadjack you
it must have been BSHs all time best selling month only because i brought loads of them LOL ,ive still got a few copies but do you think i can find them ,moved twice since then but wouldn't have thrown them ,i will give you the details when they turn up ,should be good for a laugh, it was when bling was the thing and this frankenbike certainly had enough
would luv to buy it back and redo it properly
i remember the reg what site is it to find out if its still alive

(http://i661.photobucket.com/albums/uu333/bt1100/DSCF0012.jpg) (http://s661.photobucket.com/user/bt1100/media/DSCF0012.jpg.html)

I'm sure everyone buys a few copies of a magazine their bike is featured in, well I do anyway :)

You just need to go to the DVLA site.. This is the link, you need the Reg number and make and it'll tell you if its currently MOT'd and taxed or on a SORN.  https://www.vehicleenquiry.service.gov.uk/ 
Title: Re: A Blast from the Past
Post by: Bevelheadmhr on Apr 06, 2015, 17:36:37
The bike is in a million pieces now, but at least the rear wheel has a newly machined axle and nut, while the front wheel is in need of a new tyre.. I hope the previous owner didn't race it in this condition. Suitable tyres in this size (18x2.0) are no longer available, so looks like we're going to have to go up to a phat 18.2.25  :)   
Title: Re: A Blast from the Past
Post by: john83 on Apr 06, 2015, 23:31:56
Very cool.
Title: Re: A Blast from the Past
Post by: Bevelheadmhr on Apr 10, 2015, 20:03:04
The rear wheel had a non standard bolt pattern for the sprocket, so I blank Renthal one had to be drilled to fit, along with the obligatory lightening..

Then a spacer was required to ensure the chain cleared the drag slick, that's after the wheel was painted gold and the rims given a quick polish, wheel a new disc carrier had to be made.. Next up is to make some Ti wheel spacers..




Title: Re: A Blast from the Past
Post by: Bevelheadmhr on Apr 16, 2015, 21:36:41
Last time I went round to Jeff's he'd mentioned that the stretch to the clip ons felt a couple of inches too long, he reckoned the frame had been altered more than he thought. I was sceptical and replied, well maybe your not quite as flexible as you were thirty years ago. But no, Jeff insisted it was the frame not him that had changed. Yesterday I called in while I was passing and was surprised (though not that surprised  ;) ) to see the frame was now in three pieces, the headstock/top and down tubes had been cut off, while the back half of the frame had been split into the left and right sections. The plan it seems is to widen the rear end by and inch to take the wider rear wheel more easily and the front half will be shortened by three inches to make a more comfortable reach to the bars. The front end had already been cut and mocked up onto the engine, and it did look better to me.

Title: Re: A Blast from the Past
Post by: Bevelheadmhr on Apr 21, 2015, 18:41:40
New yokes have been made which are the same as were made for the bike originally. The original yokes having been modified by the previous owner. The forks look smaller than those on my mountain bike, they're 26mm and are from an early Honda SS50.

Title: Re: A Blast from the Past
Post by: Bevelheadmhr on May 03, 2015, 09:49:23
The frame is back in one piece now, it doesn't look that different but its now shorter and wider with additional bracing and new engine mounts. I was surprised Jeff was keeping the old rear brake caliper and its old mount that he made thirty years ago with just a drill and a hand file. But he wants to keep as much of the bike original as possible, which means modifying old parts rather than making new and better replacements. At least the wheel spacers are new and made from Titanium.

 
Title: Re: A Blast from the Past
Post by: Bevelheadmhr on May 03, 2015, 09:51:56
With the frame completed, it'll be painted next week, but first time for a tea.. :)
Title: Re: A Blast from the Past
Post by: Bevelheadmhr on Jun 15, 2015, 07:11:19
The frame was taken to Triple S in Bingley, Yorkshire to be powder coated, if they could fill a small dent in one of the square section frame tubes with some kind of filler that could survive the heat of the powder coating process. Turns out they couldn't, so the frame was blasted clean for 40 and brought back home where it'll be painted by Jeff.

Turning to the engine, the plan was to build a 350 motor with a Sprintex supercharger running Nitro through a big SU carb. A used set of pistons and sleeves from a Yamaha XJ650 turbo were bought off ebay, which would give a capacity of approx. 330cc and a compression ratio of 5:1. That's very low, but with the blower making up to 30psi its what's needed.

All was going well until it was discovered that the ACU / NSA capacity bands had been changed sometimes over the last twenty years, and now the upper limit for the class was 400cc and not 350cc as it once was. Running a 330cc engine in a 400cc class isn't the best idea, yet the pistons had been bought and the barrels machined out to fit the Yamaha sleeves already.

I thought Jeff was joking when he said sod it, I'll make me own bloody pistons... but he wasn't


Title: Re: A Blast from the Past
Post by: Bevelheadmhr on Jun 15, 2015, 07:12:38
Another job is to make the engine plates which hold the engine in the frame, and double up as mounts for the magneto and supercharger etc.

In this picture the plates are being test fitted to an empty crankcase. The front plate mount will be for the magneto, the centre hole will take an extended crank to provide drive to the supercharger and magneto via belts and pulleys. While the hole over the drive sprocket will house an external support bearing for the drive shaft.
Title: Re: A Blast from the Past
Post by: Bevelheadmhr on Jul 04, 2015, 12:49:46
Lot of work on the supercharger this week.. of the two we had to hand, one Eaton was just the right size but badly worn, while the other was in good condition but a little too wide. Another was bought off Ebay which came from a Merc SLK, it was cheap as it had a long cast inlet snout which made it pretty useless for any other application.

But not for Jeff, he cut off the snout, machined the blower case and made a new end plate which will be welded onto the blower case. This will then receive more machining to make it match the rest of the cast blower case. That's why in this picture the machining looks a bit rough, its supposed to be. Notice that the edges of the plate have been bevelled where it meets the blower case, this is to make it easier to weld.
Title: Re: A Blast from the Past
Post by: stroker crazy on Jul 04, 2015, 21:53:03
A brilliant rebuild!

Crazy
Title: Re: A Blast from the Past
Post by: Bevelheadmhr on Jul 13, 2015, 17:44:30
What's that saying.. ''One mans junk is another mans treasure''... in this case its true. A friend of mine mentioned he had a friend (John) who had some stuff that may be of interest for the Honda build. The other day I drove down to visit John (who is an engineer at Bentley in Crewe), and after checking out his workshop and cool turbo Kawasaki's, drinking tea and chatting away for an hour, he gave me a box of various used Gpz 750 Turbo pistons for free. 

Although some are beyond use, there are enough to make up a couple of decent pairs, which will take the Honda out to 370cc. Being Turbo pistons they should survive a little longer in the blown motor..

Title: Re: A Blast from the Past
Post by: Bevelheadmhr on Aug 08, 2015, 07:05:12
The Mercedes SLK supercharger new end case has been welded and machined, while the other end (the drive side) has a new billet case too. The rotors went back in with new bearings and spin nicely now. The next step is to make the inlet manifold which will connect the blower to the engine, which has been started.. 
Title: Re: A Blast from the Past
Post by: Bevelheadmhr on Jun 01, 2016, 21:37:01
Found this old video I took on the day the Honda came into the workshop, so I posted it up on youtube...

https://youtu.be/V7B0sQMhdf4

And the reason the Honda hasn't made much progress recently, is due to this taking up every spare hour in the workshop..

https://youtu.be/fKOkL4WEUYs
Title: Re: A Blast from the Past
Post by: Bevelheadmhr on Jun 09, 2016, 19:17:26
Since we are working on a different Blast from the Past project this year, I'll keep it in this thread for now. So here's part 2 of the Spares Bike, a retro Z1100 based supercharged drag bike we are building from all our spare parts..

https://youtu.be/3K0SmnVBb5A
Title: Re: A Blast from the Past
Post by: Bevelheadmhr on Jun 18, 2016, 17:24:49
Making good progress for a change, it wont last, so while things are going well, here are a couple of vids showing what we've been busy doing...

https://youtu.be/5vN58vybptI

https://youtu.be/hz0mFJouy3A

Title: Re: A Blast from the Past
Post by: Bevelheadmhr on Jul 23, 2016, 19:28:57
Next couple of updates ..

https://youtu.be/_g60R9bUVVQ

https://youtu.be/Rm1pIIVsLqQ



 
Title: Re: A Blast from the Past
Post by: Bevelheadmhr on Nov 26, 2016, 12:41:10
We've not had much time to work on the 'Spares Bike', so progress has been slow, but progress none the less, so here's the latest updates..

https://youtu.be/PYcgLAyybEM

https://youtu.be/Afb1pXyxc-E
Title: Re: A Blast from the Past
Post by: cobraace2 on Dec 17, 2016, 22:33:00
Fantastic keep it coming
Title: Re: A Blast from the Past
Post by: JadusMotorcycleParts on Jan 19, 2017, 14:03:20
Damn this is way cool!
Title: Re: A Blast from the Past
Post by: Bevelheadmhr on Jan 21, 2017, 06:44:00
Cheers, not many folks on here appreciate how much work is in a bike like this... anyway, here's the next instalment..

https://youtu.be/A22a-EFPpNo
Title: Re: A Blast from the Past
Post by: ridesolo on Jan 24, 2017, 10:33:14
Fantastic work.  Following along.
Title: Re: A Blast from the Past
Post by: datadavid on Jan 24, 2017, 13:16:31
Oh we do appreciate.. please keep updating
Title: Re: A Blast from the Past
Post by: Bevelheadmhr on May 14, 2017, 04:08:51
After a break, work has restarted on the Spares Bike, here's the latest update..

https://youtu.be/bEnjgoIH89U
Title: Re: A Blast from the Past
Post by: stroker crazy on May 14, 2017, 05:59:11
Beauty in function!

Crazy
Title: Re: A Blast from the Past
Post by: Bevelheadmhr on May 24, 2017, 08:59:05
The engine in the Spares Bike isn't the one we'll use to race it, as its just for setting up. The race engine, another built from spares is now coming together. The head for which returned from Roger Upperton last week, who recut the valve seats, flowed it and no doubt did other stuff which I don't understand, but it does look very pretty...

We'll use another billet block, with 1327cc pistons, as that's what we've got. Almost all the machining for the engine is done now, next up is to make a fuel tank to sits behind the headstock. It'll be a sort of pyramid shape, with the top cut off. Made from folded and welded sheet aluminium, I'd prefer Geoff the Welder to make it, but Jeff wants to try and make it himself, so we'll see how it turns out.

That said no matter how much you do yourself, to get the bike completed its still going to cost money. So with progress at a snails pace, I've decided to throw some money at it, and hope to get it running before we're all pensioners..

Here's some pics.. In the second pic I'm pointing to a wedge like spacer, which was added to the manifold to tuck the SU carb in closer to the engine.

Title: Re: A Blast from the Past
Post by: Bevelheadmhr on May 31, 2017, 13:43:54
Made a start on the fuel tank for the Spares Bike, its going to fit below the top rails, behind the headstock. Its going to look like a pyramid, with the top chopped off, on its side... Well, that's the plan anyway.

A sheet of alloy was marked and cut out to make the top, bottom, front and back, the left and right sides will be welded on once the alloy plate has been folded and welded up.

As I sort of expected trying to fold the plate, using a vice, some steel blocks and some effort, didn't go according to plan. The plate wasn't following instructions and refused to fold neatly.

So we stopped, and will take it to a nice man who owns a suitable folder & press to get it shaped probably.

Here's the sheet after our attempt at folding..

Title: Re: A Blast from the Past
Post by: Bevelheadmhr on Jun 03, 2017, 19:45:59
Got the main part of the fuel tank folded and cut. After checking the fit, the next step will be to drill the base to house the rubber mounts and outlet, then make the side pieces and finally weld it all together..

Title: Re: A Blast from the Past
Post by: Bevelheadmhr on Jul 10, 2017, 08:14:22
With the frame and main parts of the bike pretty much done, it'll soon be time to finally lift the bike from its frame jig. But first something would have to be done about that awful old seat unit. We did consider making one in alloy, which we may still do in the future, but for now we went for a cheaper option.

The old seat unit had sagged, twisted and cracked over the decades since it was made, and didn't even fit on the new frame in any case.

We sliced it up, narrowed it at the back, lengthened it at the front and build up the top and sides. That's what's going on in the photo below. All this work is just the start. The cut up old seat unit will be used as a template, which will be used to made a mould, which in turn will be used to make the new seat unit. That's a lot of hours of effort, but it'll give us what we need, with the only cost being fibreglass, resin and filler.

Here's a short video of all this, and you get to see the new frame jig too...

https://youtu.be/DGRkLHzFcKE

 
Title: Re: A Blast from the Past
Post by: Bevelheadmhr on Sep 02, 2018, 06:37:23
Been awhile since an update, both these bikes.. the Honda and Kawasaki are still being worked on, if slower than we'd like. Work on the rolling chassis of both is pretty much done, so attention has been moved to the engines.

For the Z1100 based motor, the standard conrods would be too weak for the power we want to get out of it, so we're making our own set from billet alloy. The small ends will be phosphor bronze, while the big end bearing will be machined out of an original set of Kawasaki conrods and pressed into the new alloy conrods. Easier to write than to do.. clearances will be critical for this mod to work..

 
Title: Re: A Blast from the Past
Post by: Bevelheadmhr on Sep 02, 2018, 06:42:42
Meanwhile work on the Honda CB72/77 engine is progressing well, its now got a homemade billet block which will take it out to 400cc, while its Eaton supercharger is being remade with matching billet end cases and centre case, the latter is being made at the moment. No performance reason for making a new case, but it'll look cool..

 
Title: Re: A Blast from the Past
Post by: Brodie on Sep 02, 2018, 17:24:35
Rad
Title: Re: A Blast from the Past
Post by: Bevelheadmhr on Mar 26, 2019, 05:00:19
This project has been waiting for space to work on it, but its finally coming together. One point that isn't obvious is that the crank centre has been moved 4mm inside the engine to allow for the 400cc big bore conversion. That meant machining out the crank bearing mounts which also meant using bigger / strong crank bearings. A lot of work to say the least.

   
Title: Re: A Blast from the Past
Post by: hooligan998 on Mar 27, 2019, 01:03:59
Now that I've wiped the drool outta my beard, I'm in!
Title: Re: A Blast from the Past
Post by: WhyNot on Mar 27, 2019, 06:56:08
wow.......just.........wow
Title: Re: A Blast from the Past
Post by: Bevelheadmhr on Mar 27, 2019, 08:26:13
Found a couple of old photos of the bike when my mate first built it in the early 80s..

Here's a video of us talking about progress with the bike.. starts here... since I made the video, Jeff has been busy making a tool to fold sheet aluminium which is needed to make a new fuel tank for the bike.

https://youtu.be/dPAxnpEkP4E

Title: Re: A Blast from the Past
Post by: Bevelheadmhr on May 06, 2019, 05:42:17
Because of the way the supercharger needed to be mounted behind the engine, and with the constraints imposed by the frame etc, it was decided that the best solution, if not the easiest, was to make a new supercharger case. This new case would have its inlet and outlet moved from the standard location, to one ideal for the bike. Making a supercharger case isn't an easy task to say the least, but its almost done now. Actually once the fixtures and machining steps have been worked out to make one, its not much more work to make another, so that's what we've done.. 4 made so far.

 
Title: Re: A Blast from the Past
Post by: Bevelheadmhr on Jun 10, 2019, 14:03:06
This rear wheel came off a Yamaha R1, its been painted and polished to be used on the Honda. But its also had its cush drive removed and an alloy plate welded onto to the hub in its place to mount the sprocket. This was done to keep the wheel as narrow as possible and also because a drag bike doesn't need a cush drive.