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Author Topic: XS750 to XS896 big bore  (Read 40946 times)

Offline XS750AU

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Re: XS750 to XS896 big bore
« Reply #110 on: Sep 23, 2016, 08:46:38 »
Hi Dave
Had a look at your build, your tank and front fender came out beautifully using the wheel, hammer and crimper. Obviously the English wheel you used was much higher quality than my Chinese masterpiece. Now when you say crimper what exactly are you referring too? Couple of photos of what I think you may be referring too, but if you could confirm that would be great. Did you have to anneal the bronze with all that forming work?
Spent an hour tonight, with 600 grit paper and the wheel being rotated at 800rpm in my mill, the wheel is much smoother, pity about the 10 thou run-out. Might have to have a play with the tool & cutter grinder to see if I can true it up. Despite all the problems with the Chinese Wheel I did have a go on a bit of 1.4mm Ally and it took about 40 minutes to get the curve about right for a front fender. The edges are the issue, so I am going to have to get the shrinker/crimper.
“Engineering is the art of being approximately right rather than exactly wrong.”

Yamaha XS750-2D
Yamaha XS896
Husaberg FE550
Yamaha TT250
Yamaha IT200N

Offline JadusMotorcycleParts

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    • Jadus Motorcycle Parts
Re: XS750 to XS896 big bore
« Reply #111 on: Sep 23, 2016, 09:46:42 »
Loving watching you give it a crack man.  I have always wanted to have a similar set up in my workshop and I'm sure many others do too.  Nice to follow along someone who is actually doing it  :D  Good luck! 

Offline canyoncarver

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Re: XS750 to XS896 big bore
« Reply #112 on: Sep 23, 2016, 13:04:02 »
Cool stuff man.  I've been watching those same universal oil coolers for a bit.  Curious to see how yours works.
--
KZ400 The Rabbit
YZF750/1000R The Fly
KZ 750 Twin
ZRX 1100
65 Norton, My damn Shovelhead chop
more YZF750R's, the KZ's, a Zephyr750...and the unfinished 75' CB550 cafe.
--

Offline XS750AU

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Re: XS750 to XS896 big bore
« Reply #113 on: Sep 24, 2016, 06:57:14 »
Took my lovely into the art gallery this morning for an exhibition of quilting - maxed out on time credits.
That meant shed time this afternoon and Gentlemen's ride tomorrow ;)
First was to true up the Chinese Wheel and make it a true English Wheel. The video is how I did it between centres on the tool and cutter grinder, running on the wheels bearings. It was 7 thou out to start with, and perfectly true after. Started with a course stone, the video shows the final cut with a 600 grit stone, then I span it in the mill and finished it with 800 grit wet&dry. Very happy with the result. Before due to the eccentricity the curve in my practice fender was not even, now it is. The improved surface finish now gives the fender a much better, gloss/polished finish. Shrank the sides in using a nylon hammer and wooden block. Donating it to the wife as a Tapas bowl, more credits ;D.

Canyon - Yep the universal oil cooler was really my only option. The biggest issue is the width of the cooler. It is going to sit just below the top of the rocker cover and above the header, per the picture. I am tempted to cut the end mounts off and pick-up on the hose fittings. Not sure at this point??
For all those riding tomorrow have a great day. It is meant to rain overnight for us and be clear by ride time tomorrow.
Cheers
Tim
“Engineering is the art of being approximately right rather than exactly wrong.”

Yamaha XS750-2D
Yamaha XS896
Husaberg FE550
Yamaha TT250
Yamaha IT200N

Online Psycrow

  • Posts: 94
Re: XS750 to XS896 big bore
« Reply #114 on: Sep 24, 2016, 08:29:27 »
awesome stuff!

Sent from my SM-G903W using Tapatalk


Offline datadavid

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Re: XS750 to XS896 big bore
« Reply #115 on: Sep 25, 2016, 09:15:51 »
The crimper i used is basically the same you have in that pic, but blue! :) Yes lots of annealing, it turns into a super tough springy hardness when deformed. Hopefully a durable type of springiness that will last for eternity!

Offline XS750AU

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Re: XS750 to XS896 big bore
« Reply #116 on: Sep 26, 2016, 05:17:55 »
Dave - your spot on about the work hardening. The aluminium was basic garden variety 5005 H34 which is "half hardened" and soft to start with. I was worried is was going to be too soft and thin and easily damaged. No way, once it has been work hardened by forming with the English Wheel it is very tough, rigid and springy - bloody perfect. I did not anneal the ally.
I did use the tool and cutter grinder to true the wheel as I have it to use. You could do the same by setting it up between centres in a lathe and then holding a router or die grinder in the tool post. Very important to protect the bed from the grinding grit. This cheap English Wheel was crap quality but after a bit of tweaking the capabilities have exceeded my expectations. ;D
Cheers
Tim
“Engineering is the art of being approximately right rather than exactly wrong.”

Yamaha XS750-2D
Yamaha XS896
Husaberg FE550
Yamaha TT250
Yamaha IT200N

Offline datadavid

  • Posts: 1271
Re: XS750 to XS896 big bore
« Reply #117 on: Sep 26, 2016, 09:49:49 »
Dave - your spot on about the work hardening. The aluminium was basic garden variety 5005 H34 which is "half hardened" and soft to start with. I was worried is was going to be too soft and thin and easily damaged. No way, once it has been work hardened by forming with the English Wheel it is very tough, rigid and springy - bloody perfect. I did not anneal the ally.
I did use the tool and cutter grinder to true the wheel as I have it to use. You could do the same by setting it up between centres in a lathe and then holding a router or die grinder in the tool post. Very important to protect the bed from the grinding grit. This cheap English Wheel was crap quality but after a bit of tweaking the capabilities have exceeded my expectations. ;D
Cheers
Tim
The wheels on ours seem true enough 👍 still waiting for the garage member who moved out and left it to ask for money for it..

Offline XS750AU

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Re: XS750 to XS896 big bore
« Reply #118 on: Sep 29, 2016, 05:59:13 »
Love Ebay as you can get almost anything you need. But sometimes it does take a long time to arrive >:(, the 16.5mm drill has taken 5 weeks to arrive - but it was cheap!! ;D
I have now tapped the oil cooler sandwich plate (M18 fine) so the hose fittings can be assembled. Not sure the colours will stay as supplied. The hoses are way too long, but they are standard hydraulic fittings so it is easy to cut the hose to length with an angle grinder and then reassemble.
“Engineering is the art of being approximately right rather than exactly wrong.”

Yamaha XS750-2D
Yamaha XS896
Husaberg FE550
Yamaha TT250
Yamaha IT200N

Offline datadavid

  • Posts: 1271
Re: XS750 to XS896 big bore
« Reply #119 on: Sep 30, 2016, 01:16:35 »
Hold on, did you just make that oil cooler plate yourself? :) you should seriously pat yourself on the back a few times, thats awesome work!