Project CB690 (KTM 690 engine in a CB550f frame)

goodoltup

Member
Also mounted the dash and got the headlight ears and blinkers all straightened out. The first pic is a POV shot from the sitting position. I will need to get different clutch and brake lines, which is a pity because they were custom made. But they are both too long and obscure the dash, so I would like to re-route them. Also mounted the exhaust.
 

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goodoltup

Member
After hours of remelting tig braze and fixing pinholes, it is all together and leak tight. It didn't help that I was over pressuring the tank when checking for bubbles and it stretched out quite a bit and stressed the welds and caused micro cracks. This welding was way over my head but I did get it done.
 

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goodoltup

Member
With the tank leak tight, I drilled a big hole in it for the level sensor. I wanted to finish all the patches and vent before moving on to the sensor. I drilled the hole and tacked on the boss, using a bolt as a hold down. I just used tig wire for this one, no braze. I am not good enough with braze yet. This welded up fine, no leaks on the first try. It was a bitch to weld the upper part, it was hidden under the other tank half and I could barely see it.
 

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goodoltup

Member
Just some pictures of where the brake is at. I still have to do the return spring and the stop, and finish weld it all up. The pedal was a little loose side to side, even though I made the piece on the lathe to the same width as the stock brake pedal. So I made a nylon spacer on the lathe at work.
I have left my current role at work to go to another company, and have lost access to the lathe and mill. The last few weeks of work I had to use the lathe a lot to finish all the little do-dads and bits that I would need to finish the bike. Hopefully my next place will have a manual lathe I can use.
 

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goodoltup

Member
Tacked on the steering stop and steering lock. They are on there fine, but will get more welding after the frame is bead blasted and before final frame paint.
 

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goodoltup

Member
Just some random shots of how it sits now.
A to do list/
  • enlarge the hole in the tank level sensor boss and install sensor
  • install the tank and vent line and fuel line on bike
  • get the front end back together including wiring routing
  • rear brake return spring and adjustable stop, final welding on pedal
  • front fender stays
  • rear passenger brackets
  • various wire routing tabs and other bits

And that's it. It's really almost done.
Well, ready to test ride. It won't be done until it has it's MOT and it can be test ridden then completely stripped for final painting and clean up. Then it will be done.
 

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