Shake the Box CL360/378

irk miller

You've been mostly-dead all day.
DTT BOTM WINNER
The stretch of I-20 between my house in Augusta, GA and Columbia, SC is Hell's Vent.
 

ridesolo

You only bear responsibility for your own actions
No new pictures to post, but I've spent time finalizing the fairing fit and getting the horn set up to hide back in there. I need to find some some 6mm transfer screws for the top braces, 1/4-20 is close but not close enough. Funny about transfer screws... A while back I acquired some (SAE) sets in a box of tools at an auction and didn't know what they were. BUT they were obviously something precision and good quality so I put them into a tool box drawer. A couple weeks ago I was going through a thread over in the Bodywork / Painting / Plating section and found out what they are and what they are used for. Even an old dawg like me can learn stuff, I guess. Ain't DTT a wunnerful place? ;D

EDIT: Turns out the 1/4-20 were close enough and screwed in just enough to get the job done. I was able to accurately mark and drill the upper part of the fairing and it's now securely mounted.
 

ridesolo

You only bear responsibility for your own actions
Reached a milestone today! I finally got done w/ the preliminary assembly and the old beast is now ready for tear-down so all the final painting can be done in preparation for final assembly. The frame needs a complete job of smoothing and clean-up then it'll be painted. Everything else just needs a last coat of color, then sand, stickers, and clear. Much of the electrical work has been done as sub-assemblies so much will be, hopefully, plug 'n' play. We'll see, kinna sounds like famous last words to me. So, here's what it looks like right now, tomorrow it's going to become piles of pieces again.

Still have to buy:
Mirrors (Bar-end)
Battery
Seat (upholstery)
Chain & sprockets (520): 38t rear & 17t front w/ 1/2" offset

Still not sure what I'm going to do w/ the license plate, probably will end up hanging it off the rear axle, I can't think of any other viable alternative.

EDIT: Oh yeah, forgot the $tainless $teel brake lines.
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teazer

Well-Known Member
DTT BOTM WINNER
That's looking pretty clean. Might I suggest rotating the fairing forwards so that the upper edge is more horizontal.

If it's too much work, don't bother. I just think it might look cleaner.
 

ridesolo

You only bear responsibility for your own actions
Yes some adjustment is in the plans. Fortunately there's a bit of outward adjustment on the upper supports that'll allow the top to rotate forward some. I hope it's enough but if not I can bend new supports.

Sent from my Moto G (5) Plus using Tapatalk
 

crazypj

Split personality, I fake being smart
Usually you set upper edge close to parallel with your arms in 'tuck' position. Sit on bike and get someone to take a profile picture, you'll see what I mean
 

ridesolo

You only bear responsibility for your own actions
It's been a while but some work is getting done, though not as much as I'd like. Add in the building of a new back porch, putting up a flag pole, and family obligations and progress has only been advancing at a snails pace.

Some of the final finish of the "tins" is complete but I'm not going to post pix here for now so I can show more of a complete package when it's closer to done. I may get raised eyebrows from fellow DTTers here because it isn't going to have a sparkling, shiny, showroom finish when it's done. It's not going to be a "rat bike" but it's going to mimic an item that I've seen many examples of over the years and I've never seen one, even a well-maintained specimen, that didn't have an "experienced" look to it. The other side of it is that I'm more interested in the ride ability and reliability rather than having to spend lots of time cleaning and polishing. (Of course who knows maybe the thing will fall flat on it's face. We'll see.)

I did get the rear brake disc drilled for the little clip-in magnet that came w/ the Danmoto dashboard and then got the hole drilled in the rear caliper bracket for the speedometer Hall Sensor. (Must have been a good day, the two parts are even gong to match up like they should.) I may have to end up pushing the thing but I'll know how fast I'm going!

It's mostly in pieces now and the preparation of the frame has started. Lots of sanding, filing, filling/sanding, and more sanding to get rid of grind wheel marks. I'll take it as far as my patience will let me then I'll shoot paint and cross my fingers. Hope it turns out OK. One thing for sure it ain't going to be an old beater w/ a bunch of parts hacked off and covered w/ flat black from a rattle can.

Here's the magnet mounted in the disc and the Hall Sensor in the bracket.


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ridesolo

You only bear responsibility for your own actions
I forgot one major milestone. I found a battery that fits. I had been reading through the specs on different AH rated batteries and based on the measurements listed I was concerned that finding one to fit under my seat hump was going to cause me to settle for one on the smallish AH side. I decided to stop by an Interstate Battery store and told the guy I wanted to see his smallest sized 12v battery. He came out with this thing; it's rated 5AH and fits perfectly under there. Looks like I shouldn't have to worry about idling at a stop light for too long.
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ridesolo

You only bear responsibility for your own actions
Sonreir said:
Nice get!
crazypj said:
Cool, and it's SLA so it won't catch fire like a lithium
Thanx guys. Yeah, I just couldn't justify spending the $$ for a lithium. At $35 I thought this was a good alternative for a great price and Interstate is one of the major battery manufacturer/suppliers, so I've got a dealer right down the road rather than trying to rely on some unknown Bozo on eBay.

And speaking of eBay... I've found a guy there who's been providing (most of) my special order vinyl stickers/graphics for the bike. This guy is definitely NOT a Bozo, is doing a fabulous job for me, and his prices are beyond reasonable. Last night I decided I need two more sheets of (something) and a couple other items. I got an answer right back with a price. We made agreements, he sent a PayPal invoice, and the stuff was made up and in the mail this morning. Granted, the things are single color but he's made exactly what I asked for; custom one-off stuff, and is excited to see the final product.
 

crazypj

Split personality, I fake being smart
It's always good when you can find a seller who can interpret what you want or is interested in what your doing. The place I got hydraulic clutch lever wants to see pictures of finished product when it's fitted (plus know how well it works, any problems, etc) Didn't have the heart to tell them it may be a couple of years until I get around to it. (spend too much time repairing stuff around house and gardens - the 'joy ' of having a 60+ yr old house which hasn't had much maintenance since 1968 (bit like me , that's when I started riding motybikes ;D )
 

ridesolo

You only bear responsibility for your own actions
crazypj said:
... (spend too much time repairing stuff around house and gardens - the 'joy ' of having a 60+ yr old house which hasn't had much maintenance since 1968 (bit like me , that's when I started riding motybikes ;D )
Yeah, tell me about maintenance on old houses, this one was built in the late 1940s. I spent lots of time the last couple of weeks rebuilding a back step that I rebuilt over 15 years ago. It had composite decking on top that was doing fine but the frame below only held up for 15 years and wasn't doing it's job so time for new. The old concrete step below had been covered and we haven't wanted to break it up because of causing possible damage to the foundation. So we removed the old frame and 5' wide decking:

Made a new frame of pressure treated 2X6 lumber and made a new step/porch with new composite decking that's 8' wide.

Mrs is happy, I'm happy, and hopefully by the time it needs replaced again it'll be somebody else's problem! Now back to the Shop!!!
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ridesolo

You only bear responsibility for your own actions
Re: Shake the Box CL360/378 - Finally, reassembly!!!

It's about time, reassembly started today!

While I was painting the frame I decided I wasn't going to be happy w/ trying to mask and separately paint the electrics tray, I wanted the bottom side of it black so it would be less visible once things are back together. I had to drill out the rivets, paint the bottom of the tray, and finish spraying the frame. Once all that was done and paint set I put the tray back into place. Also one of the fork legs had been leaking a little bit of oil so I had to take that all apart to repair it.

I finally got to the point were I decided all was ready so the long overdue day finally arrived. I gathered up my nuts, bolts, and brackets and then lay the engine on it's side and slid the frame down over it. I put in and hand-tightened a couple of the mount bolts and then turned it upright. So far no scratches on the freshly painted frame.


View attachment 220337

I tightened up the mount bolts and then mounted the forks and wheel. I cleaned up the coils and mounted them and something didn't look right. Wouldn't you know it, the 500T tank wouldn't fit over the coils mounted in their usual spot! Dang, I didn't pre-fit them.

View attachment 220338

The two holes you can see below the coils on the pix above are where the horn and key switch use to be mounted. I did a trial fit and it all fits so I drilled another hole and was able to mount the coils a bit lower. The coils now fit under the tank and are still out of sight so all is good.

Next I'll be putting the swing arm and rear suspension back on but I can't remount the rear wheel until the new sprockets arrive... hopefully it won't be a long wait but I'm not sure how long it'll be before they get here; the front sprocket is is a special-ordered 17T w/ a 1/2" offset and the rear is also nonstandard because it's a 34T replacing the standard EX500 41T. I'd like to get it back up on the table to start the wiring so I may just slide the axle and wheel in place w/o a full reassembly so it can be wheeled around.
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pidjones

Well-Known Member
Besides appearance, wouldn't the front fender function much better if it were mounted the other way?
 

ridesolo

You only bear responsibility for your own actions
pidjones said:
Besides appearance, wouldn't the front fender function much better if it were mounted the other way?
It isn't symmetrical so if I were to put it on backwards it wouldn't follow the contour of the tire. Wouldn't fit that way anyhow because the way it's made and the way the mounting ears are made it won't fit and bolt up if it were in there backwards. When I decided to use the Ninja wheel use of the original fender followed in my reasoning. I like the shape of that front fender enough that I bought a second matching one and adapted it to be a hugger fender for the back wheel. Personal taste, I guess. .
 

ridesolo

You only bear responsibility for your own actions
Small amount of progress today. Got the swing arm and spring/linkage back in place. I had mentioned earlier that I didn't like the fact that the black colored spring disappeared back in there. If I were doing the thing in a different paint scheme I probably would have painted it white or red or gold or something else purty... in this case I felt it was best to just change it from black to silver. At least it's more visible now. Anyway, here's a couple of shots. Hopefully tomorrow I'll be able to roll it back onto the work table and start the wiring.
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Hurco550

Keep er' Between the ditches
DTT SUPPORTER
DTT BOTM WINNER
Looking great man! Love how its coming together.

Sent from my SM-G920V using Tapatalk
 

ridesolo

You only bear responsibility for your own actions
Hurco550 said:
Looking great man! Love how its coming together.
Thanx! It's getting there for sure. Made a small start on the wiring today. Rear wheel back on temporarily, kickstand on.
 
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ridesolo

You only bear responsibility for your own actions
I decided that it's going to be easier to do most of the wiring while it's on the ground so just moved it to a suitably prominent place and have started tinkering away.

I got the top triple in place and got the tapered collets (see page 19 of this build) in place and tightened up. Yep, they're overkill, but certainly cool. I wish now that I had let my brother, The Mad Scientist, talk me into putting them on the top rather the bottom; they look impressive. My concern at the time was that if it ever got rained on the socket head bolts would hold water and then potentially rust. I hope this thing is never out in the rain anyway. Oh well, shoulda', woulda', coulda'.

Top triple w/ the Danmoto dashboard in place. ;D ;D ;D ;D
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