Project CB690 (KTM 690 engine in a CB550f frame)

[goodoltup]

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.

 

[goodoltup]

Made the tank level sensor bung. Not complete yet, I will weld studs into the 5mm holes for mounting.

 

[goodoltup]

Clutch cable stay. Just made quick with 1mm sheet, formed around a tool and drilled.

 

[goodoltup]

Beginning of the rear master mounting.

 

[Maritime]

Coming along great

 

[Pete12]

Looking great, good luck with the MOT.

 

[goodoltup]

Brake pedal work

 

[goodoltup]

Steering stop and steering lock.

 

[goodoltup]

Time to fix that hole in the tank. I made a patch piece with 1.2mm thick plate, and tig brazed it into place. I pressurised the tank and checked with soapy water. It leaked.

 

[goodoltup]

So I moved on to the vent. I tig brazed it into place. It also leaked.

 

[goodoltup]

How about instead I fix the mess in the back of the tank where I blew some holes. Created a patch. Yes, it leaked.

 

[goodoltup]

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.

 

[goodoltup]

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.

 

[goodoltup]

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.

 

[goodoltup]

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.

 

[goodoltup]

This is final project on the Haas mill at work before I left. The centre hole will hold the fender stay.

 

[goodoltup]

Just painted it with some black to protect it pre bead blasting.

 

[goodoltup]

I mounted the fan temporarily on a plate to jig for welding, made the tabs, and welded them to the frame.

 

[goodoltup]

Fan in.

 

[goodoltup]

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.