For Kel: B Grades bucket build

[cotswold]

I have a dream........mmm nice, but I digress
My bucket is mostly there but not actually more than a pile of bits.
The empty motor in the frame is being fitted with the aid of a gas ax and a welder over the holidays, the front end which i am worried is a bit OTT is also going in (unless someone yells out NOOOO don't do it it's too freaking fat) but that big brake should impress even Henk into the hairpin at Mt Wllgntn.
The swinging arm in the photo is probably in the too hard basket and I will try the standard back end for now.
The proper motor is at a top secret engine builders shop in Ellerslie and like a good cheese will take time to finish. So my plan is to lob a standard motor in the chassis for now and wobble around near the back until my ballistic missile is ready to fit.
I will update as things happen.

[speedpro]

The proper motor is at a top secret engine builders shop in Ellerslie and like a good cheese will take time to finish.

So, you're hoping for 40hp as well??

[cotswold]

So, you're hoping for 40hp as well??

I think that would out power the rider who will be happy with 38rwhp :lol:

[F5 Dave]

what is the SW? shock looks suzuki-ish.

[Ivan]

could you not put those brakes via a bracket onto the RS forks the rs forks are really good

[Moooools]

could you not put those brakes via a bracket onto the RS forks the rs forks are really good

Brake caliper is on the wrong side. Think about it. (Could put it on completely upside-down I guess)

[Ivan]

lol i didnt even look at that

[Sketchy_Racer]

Haha nice, those are my old RS125 Fairings from waaay back :)

[cotswold]

what is the SW? shock looks suzuki-ish.

TZR250 I think

[cotswold]

Haha nice, those are my old RS125 Fairings from waaay back :)

I bought 3 from a racer up north, thats going to be my long track fairing

[kel]

That chassis looks very smart, from what I've heard those RS50's ride really well, are the wheels the right size for slicks?
You've engaged an engine builder, is that allowed?

[F5 Dave]

The next model RS rides real nice, if a little heavy stock. not sure on earlier ones. Queer wheel sizes mean slicks are a squeeze. on the rear & no go on the 16" front.

[cotswold]

That chassis looks very smart, from what I've heard those RS50's ride really well, are the wheels the right size for slicks?
You've engaged an engine builder, is that allowed?

I am actually being a philanthropist as a young lad is doing the work after school.
The rear wheel is going to have to do, it's a 2.75 17 so should take a slick ok ish, but like Dave said the front is a 16" so has to go ( unless I import a Motard tyre from europe at huge expense )

[cotswold]

The next model RS rides real nice, if a little heavy stock. not sure on earlier ones. Queer wheel sizes mean slicks are a squeeze. on the rear & no go on the 16" front.

The Rolling frame weighs 55 kgs so is not exactly a light weight but no dumbo either. ( any one know what an FXR roller weighs? ) The rear will have to be be ok at 2.75 17 but the front is a dud. Still not sure on that Yamaha front end I bought as it looks a little on the large side with 38mm fork tubes, any ideas on a better suited front within a realistic budget. ( Already way past the limit her indoors agreed on )

[F5 Dave]

yeah I've seen a 2.75 get away with a 115 ok.

55kg, heck my complete 50 weighs that. well almost.

[Kendog]

yeah I've seen a 2.75 get away with a 115 ok.
I had a 115 on the 2.15 FXR rear wheel. So 2.75 should be no worries.

[speedpro]

The Rolling frame weighs 55 kgs so is not exactly a light weight but no dumbo either. ( any one know what an FXR roller weighs? ) The rear will have to be be ok at 2.75 17 but the front is a dud. Still not sure on that Yamaha front end I bought as it looks a little on the large side with 38mm fork tubes, any ideas on a better suited front within a realistic budget. ( Already way past the limit her indoors agreed on )

I have a very similar front end on my bucket and it works sweet. My front wheel is from the 3LN model and is 2.75" wide. The earlier model with the single disc is 2.15" I think. Lighter wheels would be good but they're fine to get going. Clean the forks out and put in something like 20W oil. Ideally you want to adjust the compression damping. I forked out for some emulators but just closing up the compression damping holes will help.

[F5 Dave]

20W is syrup. Will make it feel great on braking, but can't keep up on stutter bumps.

[cotswold]

20W is syrup. Will make it feel great on braking, but can't keep up on stutter bumps.

5w required at mt wllngtn then

[F5 Dave]

or water, which I suppose is 1w

[Henk]

Bloody two stroke light weights, we run 15wt in the diesels.

[cotswold]

Bloody two stroke light weights, we run 15wt in the diesels.

Smokers are only allowed to be 100cc water cooled how come diesels can be 150cc

[jasonu]

smokers are only allowed to be 100cc water cooled how come diesels can be 150cc

stirrer!!!!!
(looking forward to some witty replys though)

[Ivan]

wow that photos amazing!

[Henk]

Smokers are only allowed to be 100cc water cooled how come diesels can be 150cc

Weight penalty, all those extra moving parts, and us fat lazy diesel riders need all the help we can get.
How come two strokes go bang so often?

[speedpro]

How come two strokes go bang so often?

That is really cheeky coming from an FXR owner.

[Henk]

Me? Cheeky? Anyway, I've only killed one FXR motor,and that was through mechanical incompetence.

[Henk]

You going to have this finished in time to run in B grade at Taumarunui?

[cotswold]

You going to have this finished in time to run in B grade at Taumarunui?

Probably not. I have pretty much all the bits but turning them into a bike may take a little time.

[Rick 52]

wow that photos amazing!

What he said ! Who was behind that pic ? Bloody brilliant ..

[Henk]

Some motard guys turned up and decided it was a bit wet to ride so took pictures instead. Not many people keen that day for some reason, I was trying to see how hard you can push through standing water, turns out that there is not much difference in turn one exit speed between all good and front wheel aquaplanes.

[cotswold]

What he said ! Who was behind that pic ? Bloody brilliant ..

I spotted it whilst looking at Googled photos of bucket bikes (sad eh )

[crazy man]

why do so meany bucket racers quote around 39-40 hp there getting out of there engine's when l know a honest dyno with a 95-2000 rs125 is that?

[jasonu]

why do so meany bucket racers quote around 39-40 hp there getting out of there engine's when l know a honest dyno with a 95-2000 rs125 is that?

I don't recall anyone quoteing those numbers. Wishing maybe...

[TZ350]

why do so many bucket racers quote around 39-40 hp there getting out of there engine's when l know a honest dyno with a 95-2000 rs125 is that?

DIN rear wheel horse power recorded on a DynoJet that records about 42rwhp for Av's std 2007 RS.

253458 30rwhp for Speedpro and 28.9 for TeeZee

These are the highest documented readings that I know of.

Anything else higher posted on the ESE thread is probaly graphs from our new toy, the EngMod2T simulator which suggest the development potential and direction to take.

253459

The simulator gives crank hp, you have to deduct workmanship and transmission losses to get a realistic picture of rwhp, whats 39 crank hp on the simulator will be less in reality but probably more than 30 rwhp.

And what I am realy confident about, is the curve will be pretty much what the simulator suggests.

[crazy man]

I don't recall anyone quoteing those numbers. Wishing maybe...l have seen sum dyno figgers on here must be taking the piss

[crazy man]

DIN rear wheel horse power recorded on a DynoJet that records about 42rwhp for Av's std 2007 RS.

253458 30rwhp for Speedpro and 28.9 for TeeZee

These are the highest documented readings that I know of.

Anything else higher posted on the ESE thread is probaly graphs from our new toy, the EngMod2T simulator which suggest the development potential and direction to take.

253459

The simulator gives crank hp, you have to deduct workmanship and transmission losses to get a realistic picture, whats 39hp on the simulator will be less in reality but probably more than 30rwhp. But what I am confident about, is the curve will be pretty much what the simulator suggests.your on to it (-:

[TZ350]

your on to it (-:

Thanks, hope so ....

253464

Over the next few weeks, we (Team ESE) are going to see how close we can get to making this simulation in reality, soon 30+ rwhp might become the norm for good strokers, like 20+ was a while ago.

[crazy man]

Thanks, hope so ....

253464

Over the next few weeks, we (Team ESE) are going to see how close we can get to making this simulation in reality, soon 30+ rwhp might become the norm for good strokers, like 20+ was a while ago.the most l remember was 26-28 hp 20 year ago with mike greens tf100 with a rgv barrel so l was told. l did ride the bike and yes not to bad at all

[cotswold]

The Engine is in the frame I will post a couple more photo's after I have cleaned up the welds and painted the ugly bits.
I now need to find a front sprocket to match the pitch on the rear, fit the forks, find a plastic tank to fit under the tank cover, fit the exhaust, find a carb, buy some bars ( am Thinking flat ) and a list that seems endless. How do people finish a bucket??

[Henk]

How do people finish a bucket??

By going massively OCD and doing nothing else until the job is completed.
Going to be finished in time for Taumarunui? :)

[TZ350]

253949

Sparkes ... Fuel Jerry Can ... now whats next, no don't tell me, I am sure I know the answer to this one ... :scratch:

Anyway great to see the progres, and I thought you had a complet running std motor that you could use for a bit ...

[Henk]

253949

Sparkes ... Fuel Jerry Can ... where is this going ... :scratch:

Flame paint job

[Ivan]

newmans got those 3 litre tanks pretty cheap

[Pumba]

How do people finish a bucket??

They are never finished, just complete for the moment

[cotswold]

By going massively OCD and doing nothing else until the job is completed.
Going to be finished in time for Taumarunui? :)

Not a snowballs, would like to think I could have it up and going with a stock motor by the end of Jan meet at mt wllgtn but even that may be a reach, will I have it ready for Taupo ??

[Henk]

Not if the last guy to ask that question is anything to go by.
As an aside we probably won't be making the GP this year, it's a toss up between the GP or Te Puke AND Kaitoke so we will likely do the NI rounds instead.

[cotswold]

253949

Sparkes ... Fuel Jerry Can ... now whats next, no don't tell me, I am sure I know the answer to this one ... :scratch:

Anyway great to see the progres, and I thought you had a complet running std motor that you could use for a bit ...

Ooops Sparks and fuel, best kept inside a cylinder. Yes I have 2 motors as I managed to get that 125 I picked up in Taupo going yesterday. The missing spark was just a rotted out Plug cap, the motor sounds as sweet as a nut considering it has stood for a year or 3, I feel a bit bad taking that one apart as it is not too bad so will most likely put the 100 in.
I still need to fit the front end so I can put tyres on.

[cotswold]

Not if the last guy to ask that question is anything to go by.
As an aside we probably won't be making the GP this year, it's a toss up between the GP or Te Puke AND Kaitoke so we will likely do the NI rounds instead.

Expect I will do the North Islands as I enjoyed them so much this year, hope to have something running for the 2nd round though it wont be a rocket.
Now you can do me a favour at the 1st round as I won't be able to attend, if they hand out any trophies for the year do not let Rick collect mine as he has a tendency to keep them.:laugh::laugh:

[Henk]

If he doesn't promise to hand any trophies you have coming to you over I won't let him have any of the execptionaly outstanding Romanian plum brandy I'll be bringing along.

[cotswold]

newmans got those 3 litre tanks pretty cheap

Cheers Ivan, will give them a try.

[cotswold]

They are never finished, just complete for the moment

You need to delete that comment in case her indoors reads it :shit:

[cotswold]

If he doesn't promise to hand any trophies you have coming to you over I won't let him have any of the execptionaly outstanding Romanian plum brandy I'll be bringing along.


Thanks and eeek

[Ivan]

this http://newmanz.co.nz/shop/index.php?main_page=product_info&cPath=4_27&products_id=78


or im going to run this or build something the same as this

http://newmanz.co.nz/shop/index.php?main_page=product_info&cPath=4_27&products_id=150

[Henk]

Thanks and eeek

I'll endeavor to save you some if Rick and Clive don't drink it all.

[cotswold]

or im going to run this or build something the same as this

I reckon I'll need at least 3ltr probably 4 but also want one of the flatter types, Gav up here bought one from a carting place so will try and get a look at that. I'll post a pic when I get something.

[Hilleye]

or im going to run this or build something the same as this

I reckon I'll need at least 3ltr probably 4 but also want one of the flatter types, Gav up here bought one from a carting place so will try and get a look at that. I'll post a pic when I get something.

Could you fit two small 2L tanks then plumb them in together using a Y or T junction? Short race, run off one tank, long race, use both tanks.

[cotswold]

Could you fit two small 2L tanks then plumb them in together using a Y or T junction? Short race, run off one tank, long race, use both tanks.

I like the sound of that, this is why these forums are so good, people come with stuff you just don't think of

[Rick 52]

if they hand out any trophies for the year do not let Rick collect mine as he has a tendency to keep them.:laugh::laugh:
Ok Ok I will bring them to the new years party!!:laugh:
Mmm brandy !!

[cotswold]

I seem to be a bit stuck, the original Aprilia rear sprocket is a must keep due to it's weird shape and the fact it is splined they are easy enough to get hold of as well.
The front suzuki one is s different pitch.
The Aprilia is I think 415 and I need to make a suzuki front in the same pitch, any idea's would be gratefully received.

Thes guys make them but I hate to think what they would cost http://www.rebelgears.com/sprockets.html

[Henk]

You might have to do a bit of digging about but

http://www.jtsprockets.com/48.0.html

Is about the best site I have found for sprocket info, I think your engine is a TS125 in which case the stock from is a JTF425

[jasonu]

I seem to be a bit stuck, the original Aprilia rear sprocket is a must keep due to it's weird shape and the fact it is splined they are easy enough to get hold of as well.
The front suzuki one is s different pitch.
The Aprilia is I think 415 and I need to make a suzuki front in the same pitch, any idea's would be gratefully received.

Thes guys make them but I hate to think what they would cost http://www.rebelgears.com/sprockets.html

415, 420 and 428 all have the same pitch but differ in width. I would be surprised if the Aprilia has 415 as standard.

[TZ350]

Isn't 415 used by Honda RS125's? I have seen Chambers slim down 428's to match RS sprockets.

[cotswold]

415, 420 and 428 all have the same pitch but differ in width. I would be surprised if the Aprilia has 415 as standard.

Well if that is the case I can get 415 rears for the Aprilia and then get the front ground down?. I was a bit suspicious of the rear I have, as the chain off the suzuki starts riding over it at about 1/2 way.
http://www.andysmotorcycles.com/index.php?main_page=index&cPath=2_22_145

[Ivan]

i had the same problem they do run a 415 standered im pretty sure and i had the sprocket machined down and then a bolted a fatter sprocket onto it dont know how it came out kyle now has the bike talk to him quallman1234 he is running a ts engine in his frame as well i think

[Bert]

A KTM65 also runs a 415 chain and sprocket; not sure what the spline looks like for the front nor the mounting on the rear; but someone could find out if they looked hard enough.

These guys have been great to deal with. they also stock a good selection chains (415 from $39):
http://www.mxshop.co.nz

[jasonu]

Isn't 415 used by Honda RS125's?

Yes that is correct.
Last century I had some front 420 and 428 sprockets ground down to 5mm (415 thickness).

[jasonu]

Well if that is the case I can get 415 rears for the Aprilia and then get the front ground down?. YES
I was a bit suspicious of the rear I have, as the chain off the suzuki starts riding over it at about 1/2 way. Either your chain has a different pitch to the sprocket or the chain and/or the sprocket is stuffed.http://www.andysmotorcycles.com/index.php?main_page=index&cPath=2_22_145

10characters

[cotswold]

If it had an exhaust , brakes and sprockets that matched it could almost be ready to try a driveway run. I still have to get something done with the front engine mount and am thinking of running a removable down tube from under the twin spars.
The dummy tank is nice and quick to remove so plug access is easy.
The main tank on the bike is plastic and too deep with the GP in it, does any one know if it is feasible to cut off the bottom and plastic weld a flat base to it?
If not it will be the twin plastic tank idea that somebody came up with.

[cotswold]

10characters

The chain and front sprocket are off a Suzuki GP125 I bought so should be 428 but the rear is the Aprilia one and I have no idea what pitch it is apart from what I could find on the net. ( 415 )

[koba]

does any one know if it is feasible to cut off the bottom and plastic weld a flat base to it?


No idea, but I was possibly going to try it as an option. Let me know how it goes if you try it first! :lol:

[Pumba]

..........does any one know if it is feasible to cut off the bottom and plastic weld a flat base to it?
If not it will be the twin plastic tank idea that somebody came up with.

I don't have a clue if plastic welding a new base is possible. Personally I would want assurances that the tank would not leak once it was completed and I am not sure anyone doing it would give you that.

If it was me I would cut the base out and then place the plastic tank(s) in the cut out upper and then foam fill around it with expanding polyurethane foam.

[jasonu]

The chain and front sprocket are off a Suzuki GP125 I bought so should be 428 but the rear is the Aprilia one and I have no idea what pitch it is apart from what I could find on the net. ( 415 )

Get a 415 chain and have your 428 front sprockets ground to the correct 415 thickness (5mm from memory). That will give you a lighter set up.

[cotswold]

I don't have a clue if plastic welding a new base is possible. Personally I would want assurances that the tank would not leak once it was completed and I am not sure anyone doing it would give you that.

If it was me I would cut the base out and then place the plastic tank(s) in the cut out upper and then foam fill around it with expanding polyurethane foam.

I am going to do something similar using the tank cover, I was just thinking of modifying the tank I have rather than buying another

[F5 Dave]

erm, ideally 420 goes to 415. 428 has a different pitch as the bushes are a bigger size. Think you have to take it down to 4.3 to give clearance & bevel the edge (numbers only from jaded memory). Ally rear spk is easy to do on mill & file the bevel. Front spkt will need munty cutters so take to an engineer to grind.

[cotswold]

erm, ideally 420 goes to 415. 428 has a different pitch as the bushes are a bigger size. Think you have to take it down to 4.3 to give clearance & bevel the edge (numbers only from jaded memory). Ally rear spk is easy to do on mill & file the bevel. Front spkt will need munty cutters so take to an engineer to grind.

Chain Pitch Width Roller Diameter
415 12.70mm 4.88mm 7.75mm
420 12.70mm 6.35mm 7.75mm
428 12.70mm 7.75mm 8.51mm Just found this: pitch is the same but like you say rollers are bigger, does this mean I can just mill the front to the required thickness and run a 415 chain or will the teeth on the front sprocket be too far apart?? My head hurts, it was easier just riding Johns diesel.

[Henk]

Looking at that you should be able to machine down a 420 front sprocket to fit, 428 is a non starter. Is getting the weird rear sprocket machined to turn it into a sprocket carrier for a more standard sprocket an option? If so I think I'd be leaning in that direction.

[cotswold]

Looking at that you should be able to machine down a 420 front sprocket to fit, 428 is a non starter. Is getting the weird rear sprocket machined to turn it into a sprocket carrier for a more standard sprocket an option? If so I think I'd be leaning in that direction.

Oh this looks easier all ready, suzuki do a number bikes with 420 sprockets, plus a few yams and Kwakas, I have a long list if anyone is interested

http://www.ebay.com/itm/Suzuki-Yamaha-YSR-RX-YZ-MX-Kawasaki-KDX-MT-KV-50-60-75-80-420-11T-Front-Sprocket-/300343697878?pt=Motorcycles_Parts_Accessories&vxp=mtr&hash=item45ede121d6#ht_1731wt_1110

[jasonu]

Looking at that you should be able to machine down a 420 front sprocket to fit, 428 is a non starter. Is getting the weird rear sprocket machined to turn it into a sprocket carrier for a more standard sprocket an option? If so I think I'd be leaning in that direction.

Good thinking that man!
I always thought 428 was the same pitch but wider. Lucky I never actually tried to use it.

[Grumph]

Chain Pitch Width Roller Diameter
415 12.70mm 4.88mm 7.75mm
420 12.70mm 6.35mm 7.75mm
428 12.70mm 7.75mm 8.51mm Just found this: pitch is the same but like you say rollers are bigger, does this mean I can just mill the front to the required thickness and run a 415 chain or will the teeth on the front sprocket be too far apart?? My head hurts, it was easier just riding Johns diesel.

That's not definitive either...OK pitch is the same right through and i think 415/420 uses the same roller diameter,yes, but there's at least two different roller diameters for 428...and i don't know if you've quoted the std Jap size or the British...
This is why it's a pain using 1/2 X 1/4 - 428 in modern terminology, for primary chains on British stuff - use the wrong roller diameter for the sprockets and nothing lasts very long.

For your rear, it may be easier to make one from a blank if it's a weird pitch or width - just go 420.

[cotswold]

That's not definitive either...OK pitch is the same right through and i think 415/420 uses the same roller diameter,yes, but there's at least two different roller diameters for 428...and i don't know if you've quoted the std Jap size or the British...
This is why it's a pain using 1/2 X 1/4 - 428 in modern terminology, for primary chains on British stuff - use the wrong roller diameter for the sprockets and nothing lasts very long.

For your rear, it may be easier to make one from a blank if it's a weird pitch or width - just go 420.

It's the shape of the rear that is the pain as it is splined and dished so will give the machining the front a go 1st

[Pumba]

I am going to do something similar using the tank cover, I was just thinking of modifying the tank I have rather than buying another

Hmmm, yea didn't realise/forgot that the tank was just a cover for another tank.

[Moooools]

why don't you just get a 428 chain and put it over each sprocket to check that the pitch is right?

[Henk]

why don't you just get a 428 chain and put it over each sprocket to check that the pitch is right?

I'm pretty sure that is what he was showing us in post #70

[Henk]

Tim

If you want to try a 420 chain on your rear sprocket for pitch let me know. I'm pretty sure I have one somewhere.

[Moooools]

oh right. Half asleep still.

As you were.

[aircooled]

all my bikes run 415 chain & 428 sprockets ground to 415 pitch, about 4.3mm thick.

never had any chain wear problems yet, ones been running 4yr,s same set up.

[F5 Dave]

I run 420 down to 415. Front spr is where it gets critical as such a tight bend. Power to be lost there.

With the dished sprocket, what a pain, but can you (help me out Grumph) Scotch key(?) it to another sprocket? What I've done on mine is use a larger 50 tooth MX ally sprocket & cut the original down to fit inside the skinny MX one. Then bored 3 holes (that's the key bit) & bolted together with washers. Think of it like a rivited floating disc brake.

It's ye olde method & used on brit stuff from time to time.

You may not have enough diameter room.

[jasonu]

I run 420 down to 415. Front spr is where it gets critical as such a tight bend. Power to be lost there.

With the dished sprocket, what a pain, but can you (help me out Grumph) Scotch key(?) it to another sprocket? What I've done on mine is use a larger 50 tooth MX ally sprocket & cut the original down to fit inside the skinny MX one. Then bored 3 holes (that's the key bit) & bolted together with washers. Think of it like a rivited floating disc brake.

It's ye olde method & used on brit stuff from time to time.

You may not have enough diameter room.

As the Aprilia sprocket is dished and therefore offset I would cut down the original then remove the center from (say) a 50t so when placed on top of the Aprilia center they overlap. Then work out how much more offset you need, make the appropriate spacers then drill and bolt them together. That way you could do the same with other sized rears and use the same Aprilia center part as the mount.

[F5 Dave]

Yeah, even if you recess it into the wheel 2mm & make a step in the original sprocket.

Look at JT website for large skinny sprockets. Mine is KX80 (420 thinned to 415) & have large inner, thus I can match any KX sprocket to my fitting with just 3 semicircles filed or bored in the right place.

[Grumph]

As the Aprilia sprocket is dished and therefore offset I would cut down the original then remove the center from (say) a 50t so when placed on top of the Aprilia center they overlap. Then work out how much more offset you need, make the appropriate spacers then drill and bolt them together. That way you could do the same with other sized rears and use the same Aprilia center part as the mount.

Personally, I'd just make up a sprocket carrier to attatch where the original sprocket does, and which is drilled to accept a flat readily available sprocket. Preferably a cheap, readily available sprocket...Get the thicknesses right and the offset is correct.

this is similar to working with the original Dymags...they came with machined large holes in the hubs and a ring of tapped holes on each side. You had to make up bearing and sprocket carriers to suit. Non machinists need not puchase.

[cotswold]

Just had a 420 front sprocket arrive in the mail, it fits the spline and is the same pitch as the Aprilia rear, just need to get it skimmed to 5mm and I will have drive.
Need to find one with 11 teeth now and I'll be happy.

[F5 Dave]

just make sure you give the chap a section of 415 chain to match it to. Pretty sure it is less than 5mm for clearance. Also will need a bevel like std, flat edge will cause issues & derailment.

[cotswold]

just make sure you give the chap a section of 415 chain to match it to. Pretty sure it is less than 5mm for clearance. Also will need a bevel like std, flat edge will cause issues & derailment.

Thanks for that.

[cotswold]

Queer wheel sizes mean slicks are a squeeze. on the rear & no go on the 16" front.

I just plonked a 17" RS honda wheel in the standard forks and it all but fits, need to either skim a smidgen off the top of the disc or slot the brake caliper a tiny wee bit. will need to find bearings to suit or knock up a spindle. Photo to follow.

[F5 Dave]

Hmm, sounds like it would be best to send me the RS wheel & in return I'll tell you the best modification. Then you just need to find another wheel & you're away. Send me a spare rear as well please.

[cotswold]

Hmm, sounds like it would be best to send me the RS wheel & in return I'll tell you the best modification. Then you just need to find another wheel & you're away. Send me a spare rear as well please.

Very tempting offer but I think I'll struggle through.
Toooo slow on the rear Rick has his name on that one

[F5 Dave]

ok how about this one? I have a straight Honda disc that is RS pattern & offset & about 10-20mm smaller dia. Swap you for the RS one? If the RS one is straight.

[Buckets4Me]

Very tempting offer but I think I'll struggle through.
Toooo slow on the rear Rick has his name on that one

I may have a disk that fits for you will just have to go and check it
can drop it off saturday or sunday if you want to try it

[husaberg]

OK the worlds Biggest sprocket catalog

It is great because it gives the spline measurements.
As well as the bolt hole dimensions

http://www.jtsprockets.com/catalogue/


To slim done a Steel sprocket heat to cherry red alloy to cool down slowly
then attack with the lathe while its in its soft annealed state.

Reheat to cherry red and then plunge into the dirtiest carbon incrusted oil you have the blacker the better. If you were a belts and braces type, an engineer will tell you to reheat to 200-300 degrees or so for a period of time like a couple of hours then cool slowly to re-temper. But as is it will be bucket ready.

RMX 50 looks the same, other than offset.
There are plenty with .5 mm narower splines ie 20 16 3.5mm that could work with a few stokes of the file and are more common styles carried by suppliers.

Dave you could just do an adapter plate for a RGV250 or similar Disk if you want a flatter offset front disk.
They are here or you could make your own. M5C

http://home.exetel.com.au/bkm/cast-wheels-motard-drz/motarding-other-bikes.htm

[cotswold]

[QUOTE=husaberg;1130240506]OK the worlds Biggest sprocket catalog

It is great because it gives the spline measurements.
As well as the bolt hole dimensions

http://www.jtsprockets.com/catalogue/


RMX 50 looks the same, other than offset.
There are plenty with .5 mm narower splines ie 20 16 3.5mm that could work with a few stokes of the file and are more common styles carried by suppliers.


Thanks for that, I have had one turned down and it looks ok but not sure it was re-hardened.
The engine is in the frame good and tight so on to the wheel fitment.

[Rick 52]

That's looks great ! Keep up the good work ..so will you take up Johns offer for Te Puke?

[Henk]

Tim is too soft to race at Te Puke, so he is going to come down bike less and wave flags as an excuse to get horribly drunk and sand bag the hop scotch contest on Saturday night.

[cotswold]

That's looks great ! Keep up the good work ..so will you take up Johns offer for Te Puke?

Don't think so, trying to save my money so I get mine finished, spending too much for her indoors liking at the moment.

[cotswold]

Tim is too soft to race at Te Puke, so he is going to come down bike less and wave flags as an excuse to get horribly drunk and sand bag the hop scotch contest on Saturday night.

Mmm hop scotch sounds harmless, I'll leave the plaster-cast kit at home

[quallman1234]

This is looking much better than my one ;).

With the sprocket carrier, someone machined off the sprocket teeth and then bolted another sprocket behind it. Explains why when i went to buy a 428 sprocket, there wasn't any in the JT catalog.

[cotswold]

Still not finished but not too far off.
Need to buy a chain, fuel tank and get the exhaust and front wheel fitted ( have the bearings just got to fix up some spacers) , Tee Zee has offered to set up my KX ignition and it will be mobile.

Will have to give it a lick of paint as well

[husaberg]

This is looking much better than my one ;).

With the sprocket carrier, someone machined off the sprocket teeth and then bolted another sprocket behind it. Explains why when i went to buy a 428 sprocket, there wasn't any in the JT catalog.


Found this cattledog today it a euro one so useful for weird euro stuff
http://http://www.pbr.it/index.php?option=com_content&view=article&id=8993%3Aaprilia-50-rs&catid=39%3Acorone-e-pignoni&Itemid=99&lang=en (http://www.pbr.it/index.php?option=com_content&view=article&id=8993%3Aaprilia-50-rs&catid=39%3Acorone-e-pignoni&Itemid=99&lang=en)

[cotswold]

Found this cattledog today it a euro one so useful for weird euro stuff
http://http://www.pbr.it/index.php?option=com_content&view=article&id=8993%3Aaprilia-50-rs&catid=39%3Acorone-e-pignoni&Itemid=99&lang=en

Just tried the link but it's not working

[husaberg]

Just tried the link but it's not working

fixed now. Weird tested it too?

[cotswold]

A big thanks to all involved ( you know who you are ) I now have a KX ignition and my RS pipe fitted ( and looking sweet )

The last photo shows who will be riding the bike in a couple of years so watch out boys as the bike should be well sorted by then.


Still a standard motor but a works one is in the pipeline:clap:

It started! and sounded very ring ding will have to rush out and buy a petrol tank, put the slicks on and have it ready for B grade this month .

[F5 Dave]

Looks like it will be a great little bike

[crazy man]

cotswold the bike has come together very nice

[cotswold]

Promise this is the last photo's until the works motor goes in.

Hopefully will be at MT Welly for the next round.

I am using the over wide 3" wide front rim I bought by mistake as a wet but will need to make up stepped spacers as the bearings are 25mm and my spindle 12mm.

[mossy1200]

Promise this is the last photo's until the works motor goes in.

Hopefully will be at MT Welly for the next round.

I am using the over wide 3" wide front rim I bought by mistake as a wet but will need to make up stepped spacers as the bearings are 25mm and my spindle 12mm.

Looking good. Im doing axel mods and its frustrating. I need my own lathe as I can only do one part per day then fit, measure and do the next bit the next day.

[cotswold]

Looking good. Im doing axel mods and its frustrating. I need my own lathe as I can only do one part per day then fit, measure and do the next bit the next day.

your bike looks fantastic, I have been watching with interest.

[Gigglebutton]

Promise this is the last photo's until the works motor goes in.

Hopefully will be at MT Welly for the next round.

I am using the over wide 3" wide front rim I bought by mistake as a wet but will need to make up stepped spacers as the bearings are 25mm and my spindle 12mm.

Bring them along on Saturday and we can nock out some spacers aswell

[mossy1200]

your bike looks fantastic, I have been watching with interest.

Your vote doesnt count because you own a Buell and my bucket has Buell on the tank. That makes you biased.
Im picking yours would lap mine.

[cotswold]

Your vote doesnt count because you own a Buell and my bucket has Buell on the tank. That makes you biased.
Im picking yours would lap mine.

Not with me on it too old, the Buell tank does add a certain something

[Henk]

Not with me on it too old, the Buell tank does add a certain something

Bollocks, Tim is faster than he tries to make out. Was struggling to stay with him before he crashed and I ran him over.

[cotswold]

Bollocks, Tim is faster than he tries to make out. Was struggling to stay with him before he crashed and I ran him over.

You old flatterer,
Henk loaned me wider rims after the running over episode, ( he thought he'd maimed me ) it is a bit annoying to ride off the edge of a pinched slick.

[cotswold]

I have just been yarning to a work mate and he asked what the bucket is made from. I thought about it and came up with Honda front wheel, Aprilia chassis, Suzuki motor with Yamaha piston and kawasaki ignition, front sprocket off a pit bike (so it will probably round off all the teeth) seat is Honda, so all in all a bit of a mongrel, I hope it turns out as tough.

[cotswold]

First up thanks R and C.
I spent a couple of hours at a top secret location (with a Dyno) last night to get the timing and jetting sorted out.
It pulled a mighty 11rwhp on the first pull and after changing the jet and flooding the area with gas it made about 6rwhp, this lead us to believe we had maybe gone the wrong way and the next pull was nearly 14rwhp, the final pull was with an ignition tweak and it hit the lofty heights of 14.4rwhp. I was expecting very little as it is untouched and spent a number of years sat in a shed near Taupo so am pretty happy with what transpired.
So looking forward to Mt Wllgtn and it's first track excursion.

[cotswold]

Started attacking the ports in a spare cylinder, it was such a prime day that the power tools got left in the garage and i broke out the files, on the deck, in the sun what could be better.

[F5 Dave]

That does look a nice day. Now you need to put a generous chamfer on all those ports or it will doofer the rings in short order. Be generous & finish with some sandpaper to make it smooth. eyebrow shape.

[cotswold]

This was the engine cases being ported to match the work done on the cylinder, the crankshaft has been modified to take an RGV rod kit and balanced.

[cotswold]

This was making up a few insulated spacers out of something Tee Zee had in the scrap bin.
22 is the tools I used
24 is getting ready to drill the stud holes
25 scribing the shape I need
20 is half finished
29 is fitted to my ported cases and 30 is to show how much metal was removed from the cases

[cotswold]

The four sets of spacers ready to be removed from the boards.

[cotswold]

This just rocked up in the mail, vintage Suzuki and no it's not out of an mx'r.

[F5 Dave]

Depends what you call vintage but TS125s got 6 speed, just won't fit in a GP I understand.

How much else was 6 speed this side of a T20 Super six? Nah, you wouldn't:nono:

[cotswold]

Depends what you call vintage but TS125s got 6 speed, just won't fit in a GP I understand.

How much else was 6 speed this side of a T20 Super six? Nah, you wouldn't:nono:

No I wouldn't. Re count the gears, one is a bit skinny and has nothing to play with on the other shaft.

http://www.suzukicycles.org/TS-TC-series/TS125.shtml

[Henk]

Depends what you call vintage but TS125s got 6 speed, just won't fit in a GP I understand.

How much else was 6 speed this side of a T20 Super six? Nah, you wouldn't:nono:

Wouldn't suprise me if he does, Could be that since he's not allowed to sandbag B grade any more he has decided to cheat instead.

[Pumba]

8 speed high/low box? :confused:

What I can say for sure is that it came from the US and somthing cost you $33

[cotswold]

Wouldn't suprise me if he does, Could be that since he's not allowed to sandbag B grade any more he has decided to cheat instead.

It hurts that you could say such a thing, I have not officially been thrown out of B grade, although that is mute as I have nothing to ride at this time (which is why I have been a hive of industry with my one.)

[cotswold]

8 speed high/low box? :confused:

What I can say for sure is that it came from the US and somthing cost you $33

Did you notice the freight was almost twice that :eek:

[TZ350]

Depends what you call vintage but TS125s got 6 speed, just won't fit in a GP I understand.


Early 76 78 TS125's had a 5 speed box and its what we modify to fit the GP's. A bit of work is required to shorten the clutch input shaft and the GP selectors have to be built up on their thrust faces but otherwise the clusters fit OK. Hopefully Cotswold will post the details as he goes along.


An early 5 speed TS gear box can be modified to fit a GP by shortening the clutch input shaft and modifying the GP gear selectors buy building two of them up on the outside of the forks to fit the sliding dogs and opening up the ID of the other to clear its dog.
273987

Red Line is the standard Suzuki GP125 gear box.
Blue Line is the standard Suzuki TS125 gear box.
Purple line is the TS Box with modified gears, the different size gears can be made to fit by modifying the shape of the teeth.

A std TS gearbox suits a GP very nicely on a long track and a modified one works well on a short track.

There was a post on the ESE thread about modifying the GP gear box.

[Henk]

It hurts that you could say such a thing, I have not officially been thrown out of B grade, although that is mute as I have nothing to ride at this time (which is why I have been a hive of industry with my one.)

I'm sure you got officially thrown out of B grade over a year ago and put your self back in because "I'm riding a B grade bike" Sandbagger.

[F5 Dave]

No I wouldn't. Re count the gears, one is a bit skinny and has nothing to play with on the other shaft.

http://www.suzukicycles.org/TS-TC-series/TS125.shtml

I just quickly counted 6.

TS125 'Duster'. Thats a new one on me. Loved those 60s/70s Japanese names. Cobra, Titan, Stinger, Wolf, Hustler, Invader, Marauder, Savage (fist time around), Raider. And it probably goes on.

[F5 Dave]

Hey I just had a little poke around that suzi site

What was the photographer thinking??? What was up with those guy's trousers, they look 1/2 grey & 1/2 white & more importantly why would you want to look like him? (I'm assuming the rest of his leg is still attached but just out of shot)


All the gear, all the time? I have a red cardy.

http://www.suzukicycles.org/photos/T/T305/1969_T305_sales_800.jpg

[cotswold]

Hey I just had a little poke around that suzi site

What was the photographer thinking??? What was up with those guy's trousers, they look 1/2 grey & 1/2 white & more importantly why would you want to look like him? (I'm assuming the rest of his leg is still attached but just out of shot)


All the gear, all the time? I have a red cardy.

http://www.suzukicycles.org/photos/T/T305/1969_T305_sales_800.jpg

His and hers Cardies, love it

[koba]

Hey I just had a little poke around that suzi site

What was the photographer thinking??? What was up with those guy's trousers, they look 1/2 grey & 1/2 white & more importantly why would you want to look like him? (I'm assuming the rest of his leg is still attached but just out of shot)


All the gear, all the time? I have a red cardy.

http://www.suzukicycles.org/photos/T/T305/1969_T305_sales_800.jpg

<img src="http://www.kiwibiker.co.nz/forums/attachment.php?attachmentid=278830&d=1361382061[/B]/>

:lol::lol::lol:

[TZ350]

This just rocked up in the mail, vintage Suzuki and no it's not out of an mx'r.
278839



I just quickly counted 6

Cots has confused you by leaving the kick start idler gears on the left hand end of the gear clusters. In the original picture there are only five transmission gears on each cluster plus the kick start/oil pump idler gear. On a later six speed TS/TF you would have counted seven gears.

278838

Early 76-77 TS125, the specs list it as a 5 speed.

[koba]

Hey I just had a little poke around that suzi site

What was the photographer thinking??? What was up with those guy's trousers, they look 1/2 grey & 1/2 white & more importantly why would you want to look like him? (I'm assuming the rest of his leg is still attached but just out of shot)


All the gear, all the time? I have a red cardy.

http://www.suzukicycles.org/photos/T/T305/1969_T305_sales_800.jpg

“With a bit of luck, his life was ruined forever. Always thinking that just behind some narrow door in all of his favorite bars, men in red woolen shirts are getting incredible kicks from things he’ll never know.”

[Henk]

“With a bit of luck, his life was ruined forever. Always thinking that just behind some narrow door in all of his favorite bars, men in red woolen shirts are getting incredible kicks from things he’ll never know.”

Got a red woollen shirt have we?

[koba]

Got a red woollen shirt have we?

Not yet, but that ad makes me want to go out and buy one!

[Str8 Jacket]

Not yet, but that ad makes me want to go out and buy one!

That's nice dear. I will find a way to destroy it.......

[cotswold]

I have just spent a couple of hours in the garage with an arm full of electrical bits to try and cure the back firing and popping I was getting.

http://www.youtube.com/watch?v=eaHpanau3Yw&feature=youtu.be

1st up I replaced the standard GP coil with one from an MX'r this did nothing to cure it so Tee Zee had loaned me a KX cdi that he knew was a goodie and It now revs like a mad thing and sounds bloody fantastic. I will post up a video later.

I am hoping to go to the track on Sunday to dial it in, with a bit of help from a friend.

[cotswold]

Started it 1st kick and am a happy old fella.

http://www.youtube.com/watch?v=PvAQAOSsLCc


I have since taken it to the track and the best I can say about it is that the chassis and brakes are all good and the engine failed to explode.
It is very slow....

[Henk]

Started it 1st kick and am a happy old fella.

http://www.youtube.com/watch?v=PvAQAOSsLCc


I have since taken it to the track and the best I can say about it is that the chassis and brakes are all good and the engine failed to explode.
It is very slow....

Wish I had your excuse book. Looking for a downgrade to B again? :)

[cotswold]

Wish I had your excuse book. Looking for a downgrade to B again? :)

It's too slow for B grade and will be put in the naughty corner until it can at least keep up with your 100.

[Henk]

Won the last B grade race on Saturday at Kaitoke on the 100, felt like a complete bastard so parked it in the van on Sunday.
Your target would be eight HP then?

[cotswold]

You can see from the photo that the shaft from the donor TS125 is longer and fatter than the GP125 one.
This is a pain in the butt as it necessitates some engineering, which means I can't do it myself. 2 methods have been suggested,
1) cut off both the shafts and join the gp one to the ts to the correct length by making a spigot and socket and welding.
2) have the TS one shortened and machined to match the spline on the GP.

I will let you know which method gets used.

[F5 Dave]

bioy I don't envy you on either of those paths. Machining hardened shafts will be a total bear, but welding that straight, I would doubt it, but no expert.

[quallman1234]

Righto, i've given up on the Aprilla RS50 frame, and gone for something normal.

Would you like the remains? Being, frame/swingarm/rear wheel (That could be quite handy actually)...
Ivan says he wants the rear assembly to put in his frame, to give away to someone. But i highly doubt someone wants his frame.

[cotswold]

Righto, i've given up on the Aprilla RS50 frame, and gone for something normal.

Would you like the remains? Being, frame/swingarm/rear wheel (That could be quite handy actually)...
Ivan says he wants the rear assembly to put in his frame, to give away to someone. But i highly doubt someone wants his frame.

yes please, pm sent

[koba]

Yeah, even if you recess it into the wheel 2mm & make a step in the original sprocket.

Look at JT website for large skinny sprockets. Mine is KX80 (420 thinned to 415) & have large inner, thus I can match any KX sprocket to my fitting with just 3 semicircles filed or bored in the right place.

This is a bit of a dredge but I'm now thinking of how to make all the RS shit fit.

Is this post referring to the 50 or the 100?

If it's about the 50, what are you using for the 100?

[F5 Dave]

erm on the 50, but I'll mod the 100 at some time. Just need to cut an old spkt or make a disc so it fits inside an easily bought sprocket like the KX. Then I fit 3 shouldered bolts with washers between them, like a semi floating disc rotor. Scotch lapping, or french polishing or summit like that.:killingme

[Henk]

I've got some impulse / GSXR250 sprocket carriers that I think take FXR sprockets that you could try and munter for an adapter plate if you want me to drag one to Roy's Hill for you.

[quallman1234]

I was looking through the JT sprockets book with all the dimensions etc on them (dont think they are on the JT site) the other day at TSS and i skipped over sereval RS looking sprockets.... Must investigate tomorrow.

[F5 Dave]

Andrew gave me an old (2005) book some years back. Hmm, JTR1780 36mm hole 56mm di for mounting holes. Seems a bit small, 420, teeth range erm 28?!? No other sizes. Or JTR255 another 42 same bolt holes, 29.2mm hole. teeth: 40, 42, 45.

Nah turn an old one down & match it to the inside of an available one.

[cotswold]

erm on the 50, but I'll mod the 100 at some time. Just need to cut an old spkt or make a disc so it fits inside an easily bought sprocket like the KX. Then I fit 3 shouldered bolts with washers between them, like a semi floating disc rotor. Scotch lapping, or french polishing or summit like that.:killingme

Photo's are better than 10 chars.... please

[F5 Dave]

yes they are but I'm at werk & the bike is in the shed.

imagine what a Disc rotor looks like when apart, heck I'll do it for you. Make the inner look like this & the outer (KX80 in my case) the opposite. Then use shanked bolts instead, I used 4, heck use disc bobbins, I don't care.
http://www.ebbo.org/brake_discs/bobbins.jpg


Please excuse my excessive use of the potty mouth H word.

[quallman1234]

yes they are but I'm at werk & the bike is in the shed.

imagine what a Disc rotor looks like when apart, heck I'll do it for you. Make the inner look like this & the outer (KX80 in my case) the opposite. Then use shanked bolts instead, I used 4, heck use disc bobbins, I don't care.
http://www.ebbo.org/brake_discs/bobbins.jpg


Please excuse my excessive use of the potty mouth H word.

So you just turn out the inside off the KX80 sprocket and the holes line up i gather?

I went to TSS and found 1 in the 2010 catalog. JTR216... 420 chain, 3 hole 72mm, but has a 50mm middle hole instead of 40mm. Its for a NSR50...
TSS Couldn't get them, but ill like abroad. Bert's doing a order of vortex ones, but 72NZD is a little pricey esp since i dont know what size i really want.
I have plently of old used ones from 35 - 40, which are fine for a bucket. But too long for a FXR

http://www.jtsprockets.com/catalogue/sprocket/JTR216
36, 37, 40, 41, 42, 43, 45, 47

47 tooth... http://www.ebay.com/itm/Kettensatz-Honda-NSR-50-NSR50-AC08-Kettenkit-13-47-126-Moped-RK-420-neu-/150859637641?pt=Motorrad_Kraftradteile&hash=item231fef6389
with a free chain and useless front sprocket (well it might fit an mb100)

Search NSR50 rear sprocket...
http://www.ebay.com/sch/i.html?_odkw=nsr50&_osacat=0&_from=R40&_trksid=m570.l3201&_nkw=nsr50+rear+sprocket&_sacat=0

[husaberg]

You can see from the photo that the shaft from the donor TS125 is longer and fatter than the GP125 one.
This is a pain in the butt as it necessitates some engineering, which means I can't do it myself. 2 methods have been suggested,
1) cut off both the shafts and join the gp one to the ts to the correct length by making a spigot and socket and welding.
2) have the TS one shortened and machined to match the spline on the GP.

I will let you know which method gets used.

Why does the spine have to be matched to the GP one?

[cotswold]

Why does the spine have to be matched to the GP one?

pretty sure the clutch basket sits on that bit, but stand to be corrected. We are having a look at spark erosion at the moment.

[husaberg]

pretty sure the clutch basket sits on that bit, but stand to be corrected. We are having a look at spark erosion at the moment.

OK?but why change it?(the shaft)
The basket will likely have a press-in steel female spline in the alloy Clutch hub
Just a thought?
If it is anything like Honda's the drum/hub will be fairly generic casting with a different primary gear riveted on and steel spline adapter pressed in for different models.
You will likely need to rivet on the correct gear but it may be easier. Worth a crack anyway?
Some Hondas have rather wide shoulder behind the drum in the casting to accommodate different shaft lengths with the same basic hub casting shared between models.
Could also be an opportunity to get rid of those funny clutch springs pressure plate at the same time.
Have a look for cross over clutch plates from a aftermarket cattledog to see what drums are likely to be very similar say Dr125 etc.
Rob was going to get one off Kicka at one stage to see how they match up i recall.

These all share similar plates
GP 100 C/UC 78 CK3319
RM 100 A 76 CK3319
RM 100 N/T/X 79-81 CK3319
GP 125 C/N 78-79 CK3319
RG 125 CG/CH/J (NF12A) (Gamma/Rear Drum Brake Model) 86-90 CK3319
RG 125 UCG/UCH/UCJ/J/BUJ (NF12B) (Gamma/Rear Drum Model) 86-90 CK3319
RG 125 FN/FP/FR Gamma (NF13A / Rear Disc Model) 92-94 CK3319
RG 125 FUN/FUP/FUR Gamma (NF13B/Rear Disc Model) 92-94 CK3319
RG 125 UN - Wolf (NF13E / Naked) 92-94 CK3319
RM 125 N/T 79-80 CK3319
RM 125 G/H 86-87 CK3319
TS 125 XUE/XUF/XUG/XUH/XUJ 84-90 CK3319
TS 125 RK/RL/RM/RN/RP/RR 90-94 CK3319
GT 185 K/L/M/A/B/C/EC 73-79 CK3319
TS 185 K/L/M 73-75 CK3319
TS 185 B/C 77-78 CK3319
TS 185 ERN/ERT/ERX 79-81 CK3319
DF 200 EV/EW/EY (SH42A) 98-99 CK3319
DR 200 G/H/J 86-89 CK3319
DR 200 SEP/SER/SES/SEV/SEW/SEX/SEY (SH42A) Djebel 93-00 CK3319
DR 200 SE Trojan CK3319
DR 200 SEK1-SEK9 01-09 CK3319
GT 200 EN/EX X5 79-80 CK3319
RV 200 K2/K3 02-03 CK3319
SB 200 N/X 79-80 CK3319
SX 200 R/R-Z/RJ/RM 90-91 CK3319
GSF 250 N/ZM/P/NP/ZP/R/NR (GJ74A) 92-96 CK3319
GSX 250 RCH/RH (GJ72A) CK3319
GSXR 250 CJ (GJ72A) CK3319
GSXR 250 CK (GJ72A) CK3319
TS 250 XE/XG/XH/XJ/XK 85-89 CK3319

[cotswold]

The new one is also longer so still needs to be shortened but the idea of having a better clutch set up is appealing.

[cotswold]

I have just picked up the gear box shafts from heat treatments and they look a little sad. Off to the engineers next. I may have a working bucket soon (ish)

[TZ350]

They look OK, just a bit discolored from the annealing process, a wire brush and a bit of oil and they will be good to go.

[Moooools]

I have just picked up the gear box shafts from heat treatments and they look a little sad. Off to the engineers next. I may have a working bucket soon (ish)

Real question is: How much did they warp? Surely that gear in the middle could not be favourable for heat treating.

I assume they are getting surface ground at the engineers?

[TZ350]

I assume they are getting surface ground at the engineers?

No need for any special treatment, after the shafts are modified and welded then surface hardened again. A skim of the weld and a quick linish with emery tape to clean up the bearing surfaces and finished with a bead blast will be all that's needed to have them as good as new again.

[Moooools]

No need for any special treatment, after the shafts are modified and welded then surface hardened again. A skim of the weld and a quick linish with emery tape to clean up the bearing surfaces and finished with a bead blast will be all that's needed to have them as good as new again.

Were they being carburised?
Or some other process for surface hardening?

We had significant warpage in shafts much shorter and about the same OD as that during carburising. With much less dicky geometry too. We just surface ground it out though.

Although they went to Heat Treatments Ltd I am sure they would have sorted you out. They are good like that and always tell us if we are doing something stupid before hand.

[TZ350]

Heat Treatments Ltd I am sure they would have sorted you out.

Not knowing a lot about heat treating materials when I did the Team ESE ones for the GP's I relied on Heat Treatments advice and it all seemed to work out OK.

Previously I have converted three LC350 boxs the same way to TZ length on the input shaft so they could run the TZ air cooled clutch.

[cotswold]

....................................

[TZ350]

Looks like you have got great value for money there, those adjusters and cable plate will be very useful.

[kel]

....................................

Make sure you loose the bolt on bell mouth, then ball radius the inlet. You may be able to shorten it up a couple of mm at the same time.
I thought long and hard about using one of these but decided for the RV motor a shortened and taper bored PWK was the way to go. Funny that Im now having so much trouble getting my jetting right.
Pumpers are great for tight spaces or odd angles but of no advantage on a RV.

[cotswold]

Make sure you loose the bolt on bell mouth, then ball radius the inlet. You may be able to shorten it up a couple of mm at the same time.
I thought long and hard about using one of these but decided for the RV motor a shortened and taper bored PWK was the way to go. Funny that Im now having so much trouble getting my jetting right.
Pumpers are great for tight spaces or odd angles but of no advantage on a RV.


The Tillotson appeal is the fact I will not have to take the carb off a million times during the course of a weekend.

[cotswold]

Popped over to see Rob for a chat and to show him the carb. He took a look at my porting effort and suggested where it could be improved.

[Yow Ling]

Thats a large tool !!

[FastFred]

284383


Thats a large tool !!

Compensating is my guess .... :laugh:

[cotswold]

Thats a large tool !!

Once you gone large you never go back