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Author Topic: Project CB690 (KTM 690 engine in a CB550f frame)  (Read 17287 times)

Offline goodoltup

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Re: Project CB690 (KTM 690 engine in a CB550f frame)
« Reply #100 on: Jan 01, 2019, 11:18:52 »
Mocked up the lower engine mounts. These will be tacked up so the motor can be removed, so they can be properly welded in. Had to lay the frame over to get them mocked up.

Offline goodoltup

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Re: Project CB690 (KTM 690 engine in a CB550f frame)
« Reply #101 on: Jan 01, 2019, 11:28:01 »
Off the frame jig now, as the swingarm pivots and plates are tacked in, the jig now is not needed. I will use it for convenience only from here on out. I wanted to get the frame off the jig in order to final measure up the steering head and bearings, so the stem can be drawn and ordered. Took this opportunity to do some more frame work. The steering lock was removed and the hole welded up.

Offline goodoltup

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Re: Project CB690 (KTM 690 engine in a CB550f frame)
« Reply #102 on: Jan 01, 2019, 11:31:34 »
Also removed the cb550 front right motor mount. It came off pretty easily actually, as it was only welded on two sides. My Bosch angle grinder got quite a workout, though. Also removed the cb550 rear fuel tank mount / frame brace. This was interfering with the K&N air filter that I bought for the bike, so I cut it out and will replace it with a custom part later.

Offline goodoltup

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Re: Project CB690 (KTM 690 engine in a CB550f frame)
« Reply #103 on: Jan 01, 2019, 11:39:04 »
Quickly made a jig to mock up the footpeg locations. I put the bars, tank, and seat on, and had a sit on the bike. I found actually that the footrest location felt pretty good close to where they were located on the cb550 originally, maybe just a touch to the rear. The footpegs are Honda cb250 or something, the mounts are gsx650f. The aluminium brackets shown will not be used, only the pivot bracket.

Offline goodoltup

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Re: Project CB690 (KTM 690 engine in a CB550f frame)
« Reply #104 on: Jan 09, 2019, 17:07:43 »
Swingarm mounts came in the mail today.

Offline Pete12

  • Posts: 332
Re: Project CB690 (KTM 690 engine in a CB550f frame)
« Reply #105 on: Jan 12, 2019, 08:58:26 »
You've probably thought of this already, but you will really need a good jig (or the swing arm) in place before you finish welding up the swing arm pivot brackets. Great work on the project though, can't wait to see it finished.

Offline goodoltup

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Re: Project CB690 (KTM 690 engine in a CB550f frame)
« Reply #106 on: Jan 18, 2019, 04:23:21 »
Late last year I drew up the lower shock mount as shown in the above post. It was quoted by three rapid prototyping machinist companies, and finally produced by a company called Shift.BZ. The cost was around 200 EUR for two, delivery time was less than 5 weeks. As an engineer I typically get 8 weeks for machined parts for our business, so 5 is great. Highly recommended.
Below is a CAD model of the shock mount with the bolts and washers installed. I decided on using a through-bolt instead of a clevis type, because of the distance needed between the shocks would have required quite a weird looking lower mount. The lower mount as machined will be welded onto the existing KTM swingarm. I cut all the parts shown in blue out of titanium on the lathe.

Offline goodoltup

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Re: Project CB690 (KTM 690 engine in a CB550f frame)
« Reply #107 on: Jan 18, 2019, 04:46:01 »
Phone pictures of the finished components.
Next, I manufacture the upper shock mounts.

Offline XS750AU

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Re: Project CB690 (KTM 690 engine in a CB550f frame)
« Reply #108 on: Jan 18, 2019, 06:36:08 »
Hi
Question on the Hitbox  TIG200P, is it any good?
Pro's & Con's
Thanks
“Engineering is the art of being approximately right rather than exactly wrong.”

Yamaha XS750-2D
Yamaha XS896
Husaberg FE550
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Offline goodoltup

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Re: Project CB690 (KTM 690 engine in a CB550f frame)
« Reply #109 on: Jan 18, 2019, 07:19:35 »
Hi,
I have no problems with the Hitbox at all. Other than the fact that the first one that I bought was dead right out of the box, it's replacement has been perfectly suitable. I'm a beginner TIG user and don't put that much use on it, so perhaps with heavy use it might struggle, but I don't know. Build quality is acceptable, and no bits or pieces have broken yet. The MMA welding function works fine as well. I'm not totally sure that the tig cups are interchangeable with major brands, that remains to be seen. I'm honestly struggling to say anything bad about it.
« Last Edit: Jan 19, 2019, 03:50:23 by goodoltup »