Project CB690 (KTM 690 engine in a CB550f frame)

Awesome man, great job. Will almost be tough to ride it for a while and enjoy it, then pull it down for finishing and wait to ride it again! Haha
 
I got a tail light unit from a 2016 Thruxton, I love it. It will really clean up the lines of the bike and get rid of those ugly black blinkers. I will cut the tabs off of the grab rail, grind them down, and rechrome it. Also got an LED leadlight. I'll make new fork ears too, to move the headlight rearwards almost 40mm. The SV650 headlight ears that are on there now are almost 110mm long, which is unusually long.
 

Attachments

  • IMG_5869.jpg
    IMG_5869.jpg
    583.3 KB · Views: 207
  • IMG_5870.jpg
    IMG_5870.jpg
    634.4 KB · Views: 196
  • IMG_5871.jpg
    IMG_5871.jpg
    558.7 KB · Views: 199
  • IMG_5872.jpg
    IMG_5872.jpg
    549.6 KB · Views: 199
Reworked the headlight brackets to accept the Triumph ears and new headlight, and replaced the clutch and brake cables to fit the shorter bars. Very happy with how it all looks. The wiring didn't fit into the headlight shell initially, so I had to shorten some sub harnesses and replace some large connectors with smaller ones. Fits in very nicely now.
Also you can see my new bead blaster in the background.
 

Attachments

  • IMG_6008.JPG
    IMG_6008.JPG
    2.2 MB · Views: 156
  • IMG_6009.JPG
    IMG_6009.JPG
    1.9 MB · Views: 167
  • IMG_5997.JPG
    IMG_5997.JPG
    1.6 MB · Views: 156
  • IMG_6001.JPG
    IMG_6001.JPG
    3.3 MB · Views: 168
  • IMG_6002.JPG
    IMG_6002.JPG
    3.3 MB · Views: 188
  • IMG_6005.JPG
    IMG_6005.JPG
    4 MB · Views: 164
  • IMG_6013.JPG
    IMG_6013.JPG
    4 MB · Views: 174
Just some more glamour shots. It's almost ready for the full teardown!
 

Attachments

  • AAGP7235.JPG
    AAGP7235.JPG
    3.5 MB · Views: 178
  • DUCN9935.JPG
    DUCN9935.JPG
    3.8 MB · Views: 176
  • IMG_6020.JPG
    IMG_6020.JPG
    6 MB · Views: 174
  • JLBP8576.JPG
    JLBP8576.JPG
    4.1 MB · Views: 175
Thank you guys! Indeed, this whole thing is just a giant mockup before it gets torn down for bead blasting, painting, chroming, etc. All the manky fasteners will be replaced with swish button heads and stainless bits, it will get new tyres, everything will be cleaned and inspected and sorted. THEN, it will be done.
When it is 'done', I think I will ride it for a little bit, then consider any offers I may get on it. I'll be into it for about £10k. What do you think I could get for it?
 
I haven't shown this much, but here is the eccentric brake pedal height adjust eccentric. It goes around the footpeg mount where the brake pedal would normally pivot around. You loosen the footpeg, adjust the eccentric, then tighten back up again. Not necessary, but thought it would be cool.
 

Attachments

  • 4EAC94D1-7B67-4A22-8255-E417D5A9D758.JPG
    4EAC94D1-7B67-4A22-8255-E417D5A9D758.JPG
    304.5 KB · Views: 167
  • 013FE81F-F852-4EB3-82F4-996A735C39BE.JPG
    013FE81F-F852-4EB3-82F4-996A735C39BE.JPG
    278.4 KB · Views: 173
Current view of the workshop. I got an Inca Euro 260 bandsaw for £188, it is in perfect condition with all the extra bits like t-square, fence, beltsander attachments, manual and documents, etc. Well pleased. Ernie has inspected it and deemed it fit for service.
 

Attachments

  • IMG_6089.jpg
    IMG_6089.jpg
    964.2 KB · Views: 161
  • 09B09AB2-4DDD-4DBD-9B47-08567630DC37.JPG
    09B09AB2-4DDD-4DBD-9B47-08567630DC37.JPG
    336.6 KB · Views: 157
  • IMG_6158.jpg
    IMG_6158.jpg
    581.4 KB · Views: 160
Back to the radiator again. Here the radiator is removed and the hoses mocked up. I removed both wheels and tilted the bike up for easier access to the area.
My aluminium welding is awful, and this is not the project to practice on. I think I will take the radiator I got and mock it up, tack it together, and use the radiator as a tool to show a professional radiator fabricator what I need. The prices are not too bad, £450 for a full custom radiator.
 

Attachments

  • IMG_6124.jpg
    IMG_6124.jpg
    584.5 KB · Views: 158
  • IMG_6125.jpg
    IMG_6125.jpg
    582.9 KB · Views: 158
  • IMG_6119.jpg
    IMG_6119.jpg
    528.2 KB · Views: 151
  • IMG_6131.jpg
    IMG_6131.jpg
    647.9 KB · Views: 150
  • IMG_6132.jpg
    IMG_6132.jpg
    569.6 KB · Views: 145
  • IMG_6133.jpg
    IMG_6133.jpg
    583.9 KB · Views: 144
This plate supports the frame where it needed to be ground down. All tacked in. The radiator top support will weld to this new plate.
 

Attachments

  • IMG_6164.jpg
    IMG_6164.jpg
    554 KB · Views: 142
  • IMG_6165.jpg
    IMG_6165.jpg
    559.7 KB · Views: 148
Top support welded on. I'll make a triangular brace to secure it to the plate after it is all mocked up.
 

Attachments

  • IMG_6166.jpg
    IMG_6166.jpg
    655.2 KB · Views: 147
  • IMG_6167.jpg
    IMG_6167.jpg
    589.9 KB · Views: 144
  • IMG_6168.jpg
    IMG_6168.jpg
    664.5 KB · Views: 150
  • IMG_6169.jpg
    IMG_6169.jpg
    403.7 KB · Views: 143
Bottom support done. This actually started as a top support but I measured wrong and it was too short, so it was repurposed into the bottom support. I decided to mount it to an engine bolt since it was convienent and it only needs to keep it from moving left and right. It is plenty secure.
 

Attachments

  • IMG_6170.jpg
    IMG_6170.jpg
    441.5 KB · Views: 138
  • IMG_6171.jpg
    IMG_6171.jpg
    666.9 KB · Views: 147
  • IMG_6172.jpg
    IMG_6172.jpg
    405.8 KB · Views: 140
More radiator inlet and outlet mockup pictures. In the 3rd picture you can see my blood on the case cover, this was the result of essentially punching my vice. I was hacksawing through some aluminium and on the last stroke the metal gave way and my hand and hacksaw went right into the vice, bending back my index fingernail. It's not as bad as it sounds! Will be more careful in the future, however this is not the first time I've punched my vice and knowing me it won't be the last.
Next I will tack on the tubes to the radiator and do some more fitment trials.
 

Attachments

  • IMG_6173.jpg
    IMG_6173.jpg
    735.2 KB · Views: 144
  • IMG_6174.jpg
    IMG_6174.jpg
    647.2 KB · Views: 148
  • IMG_6175.jpg
    IMG_6175.jpg
    851.3 KB · Views: 151
  • IMG_6176.jpg
    IMG_6176.jpg
    646.1 KB · Views: 150
So I may as well have a go at welding this radiator myself, because if it works it works! With that in mind I made some modifications to my home made tubing beader and tried it out. It was very successful. The tubing diameter is 25mm, and the bead can be made to almost any diameter. I chose around 26.5mm for one hose and 27.5mm for the other hose. Being able to control the bead diameter was really useful for that, because 26.5mm felt way too loose in the bigger pipe, and vice versa.
 

Attachments

  • IMG_6177.jpg
    IMG_6177.jpg
    528.5 KB · Views: 145
  • IMG_6178.jpg
    IMG_6178.jpg
    523.9 KB · Views: 136
  • IMG_6179.jpg
    IMG_6179.jpg
    470.4 KB · Views: 142
Back
Top Bottom