Follow along with the video below to see how to install our site as a web app on your home screen.
Note: This feature currently requires accessing the site using the built-in Safari browser.
We noticed you are blocking ads. DO THE TON only works with community supporters. Most are active members of the site with small businesses. Please consider disabling your ad blocking tool and checking out the businesses that help keep our site up and free.
Long story short, I picked up this bike in july and restored it to its former glory. Here is the links to a thread I had when I got it to now: http://www.mopedarmy.com/forums/discuss/18/60111/60111/
http://www.mopedarmy.com/forums/discuss/18/27391/27391/
I eventually got everything back to stock and had loads of fun with it, smoke and all. I found this pick and I instantly wanted to replicate it.
I cnc cut my own mold out of mdf board and layed 4 layers of fiberglass. After many hours of preping it I made a bracket that suported the fairing and also the gauge cluster. Earlier in the year I made custom clipons to give it the right stance. I'm now getting onto the pexiglass windshield. I also just aquired a '74 yamaha rd250 that had some extra expansion pipes. I'm going to weld on new headers on those pipes so they'll bolt onto my bike. Heres some pics of my progress so far:
Song of a GUN! This has gotta be one of the best first posts on a forum I've ever seen. Awesome project man, loving the custom fairing! Keep it up, back in the day these things were the big 250 to beat and would nudge the ton on a good day.
I'm friends with a plastics guy who has a hookup with a vacuum form machine. I've already cnc cut another mold for the windscreen. What happens is there will be a layer of felt over the mdf mold. When they get the pexiglass up to temp, right before they drop it, they take cold compressed air and blow it on the inside of the pexiglass. It forms a thin hard layer that won't stick to the felt, but the rest forms around the mold. The tire on the back is a Kenda, and the front is a chen chin, or something like that. I've had the bike upto 85mph or so, which is about top speed stock. I've found that with the clipons and laying on the tank, it increased the top speed greatly. After I'm finished with this fairing, it should add 5-7mph at least. Added to the expansion pipes, I should be able to break 100mph without breaking a sweat.
Heres the mold I made for the windshield. I've since then smoothed out the edges that you see
I've slowly been working on it. I've found a much better way to mount the mirror. It was originally a bar end mirror, and I hated it. In the original picture, it was mounted directly on the fairing. I was able to mount the mirror through the fairing onto the bracket, making it rock solid. I also finished up the bottom mount that will secure the "tails" of the fairing. The actual paint is a dark gloss black, unlike what you see in the pic. For $10 shipped I got flush mount turnsignals that will be mounted onto the fairing. Whats cool about these is the lightbulb is pointed towards the "front" of the turnsiginal, so they are barely seen from the front view, but very bright when lit up. I'll try to get more updates done, I'm still waiting on the windshield. Joe
I had to take a small detour from the fairing and focus on the engine. I took it completely apart because of a suspected crankshaft seal leak. Apparently it was just stitting for too long and I couldn't drain all of the gas/oil out of the crankcase. While I was in there, however, I cleaned it all up and did a few things I wasn't able to get to this past summer. I found that the cylinder transfer port didn't match up with the base very well at all, so I port matched it. I also sandblasted and polished the heads. I talked to the plastics guy and with my mold I made, there is no good way of getting a clear plastic off from it. It would take way too much work to get it to work. What I can do though is have it made out of a solid color abs plastic. I will still need to paint it but it should turn out decently. And get this, to pay for the material and his time, I get to spend a day at his shop and do some manual labor! What a great way to get my name out and do some real life work at a place where I want to start my career in. Heres a few pics to show my progress. Also, If anyone has any questions on torque settings, measurements, timing, etc, I know this engine inside and out and I should be able to help you. Thanks, Joe
Jesus...now THATS a transfer port, not to mention a cylinder head! Looking very, very good there man. This thing will run like some sort of cliche once you get it on the road!
Beautiful stuff man! You should have your plastics guy make a fairing out of plexi. Wouldnt it be lighter than the glass? I just picked up a 72 T250. Id be interested in one of those fairings if ya feel like making another, or another mold so I could make the fairing...
I started the fairing by spending a good month on the design. I used mastercam, a 3d cad software that my dad uses at his machine shop. Heres what it looked like on the pc:
I used 2 4'x8' sheets of 3/4" mdf to create the molds. I made it in two halfs and used a cnc machine to cut it out.
Here is the final product:
It took about 10 hours of cutting on each half, not including setup time and tool changes. I first layed 2 layers of fiberglass. It held the shape well, but it was way too flimsy to hold its own. I added two more, using larger pieces of fiberglass and it is now very firm. It was about 1 hour for each layer. After that, it was countless hours of priming and sanding to smooth out the imperfections. Von, sorry, but I think it would be way too costly to make another fairing. Even if I only lay out the fiberglass and cut it out, no sanding, finishing, etc, it would be worth about $250 of material and my time to create it. I made this fairing not as a “one off” but I do have the mold to make more in case something happens to my current one. This is what I have run into when doing custom work. Some people aren’t willing to pay me for my time. Thanks, Joe
What I can do is give you detailed drawings and the cad file if you would like to replicate it. I can measure my bracket and what I've done and the problems I've ran into to make sure yours will go much more smoother than mine has.
This site uses cookies to help personalise content, tailor your experience and to keep you logged in if you register.
By continuing to use this site, you are consenting to our use of cookies.
