Building a "first bike" for my 17yo son...

Figured out how I want to run the shifter side controls. Modeled it up based on actual positional geometry taken right from the bike. The mid controls put the foot pegs too close with the seat height being so low. Had to stretch them out just a little. The hex extension mounts to the front motor mount bolt (which is replaced with a longer grade 8 version). Hopefully get it made up this week. Now on to the brake side.

shifterassembly.jpg
 
Need some opinions... I redesigned the setup and worked out the mounting details, etc. I've got a bunch of hex stock around here so I think I'm going to use that.

hexassembly.jpg


Think the toe peg should be knurled like the footpeg? Or maybe both should stay hex with just some detail grooves? Or do they look ok as is?

And if anyone cares... here's the internal workings:

section.jpg
 
Either hex or knurled will fuck up your boots. Should be round with grooves for O-rings. That's classic design, because it fucking works.
 
I hate the O-ring look though. Reminds me of $10 Custom Chrome catalog specials. Maybe I'll see what I can come up with for rubber sleeve or something.
 
You can always use rubber heater hose, and sculpt it in a lathe with a cutting disk on a Dremel, or angle grinder.
 
cut some trial pieces to see how the geometry works. the cosmetics may change in the final product. Will try it out this weekend. probably should have ordered the bushings...oh well... maybe the hardware store has them.


20140306_123811.jpg
 
Thanks!

Haven't made much progress on it lately. Trying to finish mine and get it off the lift. I swear there's always some delay or another. Had to build a few custom parts, but I may be pretty close after this weekend.

As far as this build goes, about all that's changed is I stripped the tank and filled the emblem recesses, smoothed the filled section at the back of the tunnel, oh, and the dent from when it accidentally hit the floor (oops). Also picked up a fuel sight gauge kit from Monster Craftsmen and tig'd it in place. Haven't taken any pics of it though...was kinda waiting to finish smoothing the filler and get it in primer.

Also figured out the arms that hold the shift pedal and brake pedal were a little short. Designed some new ones, they'll be cut on the laser tomorrow.

I really got get this thing back on the forefront if we're going to hope to have it ready for him to ride after his motorcycle rider's course in May. Still need to work out the brakes and wiring, battery, controls, paint, rear fender support and seat upholstery. And even then, that's not even TOUCHING the motor yet.
 
For some reason I liked the ape hangers on this bike it just looked cool with the fat tires and I would have kept it that way.

What is that rear fender from?
 
Well, consider just clicking on the "notify" button at the bottom rather than making a non post. That way, all the rest of us following the thread don't end up coming here just to see that you are watching the thread. :)

Improves the signal to noise ratio a bit.
 
AlphaDogChoppers said:
Well, consider just clicking on the "notify" button at the bottom rather than making a non post. That way, all the rest of us following the thread don't end up coming here just to see that you are watching the thread. :)

Improves the signal to noise ratio a bit.
Click to expand...

LOL OK but isn't ^^^^^ the same thing ? And NO ADC I'm not going to get in a pissing match with you over right or wrong just wanted to say nice work on the guys build so far which I forgot to add in my first post !
Sorry
Enjoy !!!!
 
The arms for the controls were a little short. So I drew up some new ones. Finally got a chance to run them through the laser today.

shiftarm.jpg

20140331_111430.jpg
 
I'm thinking it's about time to order the chain and sprockets. I was thinking about going with a 520 chain and matching sprockets from sprocket specialists. Anyone know what length chain I need? 114 links? 120?
 
When you talk to SS ask them what stock calls for . They should have the right size you need but always better a few links longer as you can take some links out to get best fit for your needs !
 
DreadRock said:
When you talk to SS ask them what stock calls for . They should have the right size you need but always better a few links longer as you can take some links out to get best fit for your needs !
Click to expand...
That was my thought as well. But since chain prices seem to vary wildly online for the exact same product (I've seen $50-$125 for the exact same EK chain) I was thinking of ordering the chain elsewhere if their price is too high.
 
O yea the D.I.D 530 I just got for my FJ was from 132-240 pending who I called . Best deal was from Indysuperbike at 132.00 shipped might want to give them a call !
 
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