Topic: Project "Hard Luck - The Red Racer" - updated 07/30/2010 w/new project!!!

[KB02]

Okay, with a little creative hose routing, I have gotten the rear MC mounted, plumbed and bled and I can now stop using the rear wheel. Now I've just got to find that little spring I lost that actuates the brake light switch...



I have also gotten the first layer of fiberglass over my seat mold. It's going to take a while to get the seat right. I ca see bit that I will have to cut off and reshape already. BUT, might as well do it right, right?

[Toxic]

Partsandmore or Z1 has that spring for next to no money if you can't find it.
Probably rolled away.
You have the switch installed so I would use any spring from your typical BigBox auto store.

Great looking build

[Spikeybike]

lookin good man ... real good

i might have one o those springs layin around if ya don't find it ...or like toxic said just go find one at like Ace or Home depot

[KB02]

Well, we're off on vacation for a little over a week, so there won't be any updates until I get back. Headed across the pond to merry ole London.  Gonna see about stopping into the Ace Cafe for lunch some day. Just because. 

When I get back, my bike funds will have recovered enough from all the little things that I have been buying and I will be ordering my new shocks. What do you all think?
These:
$399.99
Length: 340 mm
Type: Self Adjusting Gas Shock with Piggyback Reservoir
Features: Pre-Load Adjustment — Fork Fittings for Honda, Suzuki and all Scooters — Eyelets and Springrates Model specific or customized — (Included: Ride Height Adjuster (Length Adjuster))
Application: ON and OFFROAD — for MOTORBIKES and SCOOTERS
Category: Stereo

or These:
$459.99
Length 340 mm
Type: Self Adjusting Gas Emulsion Shock
Features: Pre-Load Adjustment, Rebound Adjustment 80 Clicks — Fork Fittings for Honda, Suzuki and all Scooters — Eyelets and Springrates Model specific or customized — (Included: Ride Height Adjuster (Length Adjuster))
Application: RACING ON and OFFROAD — for MOTORBIKES and SCOOTERS
Category: Stereo

The first ones look cooler, but the second ones have better adjustability. It's a $60 difference. I've been going back and forth on which ones to get.

[KB02]

Well, we're back from our trip. We saw some great stuff like:

Tower Bridge (as seen from the River Themes):

Big Ben (as seen from the London Eye):

The Eiffel Tower (as pictured from afar - but we did go all the way to the top  ):

And...:

The Ace Cafe.   


Yeah, it's a little bit of a dive, but it's THE DIVE for anyone into Cafe Racers. It is where it all started, after all.  And our Hotel was only like half an hour away by the Tube.

Now I just have to figure out what to do about those shocks. I will be ordering them tomorrow, so I'd better think fast.

[HavocTurbo]

Hate to ask this question....

Hows the remote reservoir going to drain into the M/C when it's lower than the hose entrance point?

[KB02]

Well, with the hydraulic system, as long as there is no air anywhere else in the system (meaning, I have bled it properly), there shouldn't be any problems. If more fluid is needed it will be pulled right out of the reservoir. At least, that's the theory. Worse come to worse, I may have to relocate it. We'll see.

[KB02]

$459.99
Length 340 mm
Type: Self Adjusting Gas Emulsion Shock
Features: Pre-Load Adjustment, Rebound Adjustment 80 Clicks — Fork Fittings for Honda, Suzuki and all Scooters — Eyelets and Springrates Model specific or customized — (Included: Ride Height Adjuster (Length Adjuster))
Application: RACING ON and OFFROAD — for MOTORBIKES and SCOOTERS
Category: Stereo

Ordered.   

[HavocTurbo]

I have some parts I want... care to order them for me too? 

Should look nice on that newly finished rear end.

[HellFishTat]

I got a low, low mile K8 for free.  I left it in the garage for 6 more years, tinkering with it from time to time.  I did get it running and actually rode it up the street.  That was enough for me.  I bought a '77 CB750F that had been owned and operated by the same guy for 15yrs.  I figured that the chances of having a catastrophic failure was less on a bike that had been ridden once a month than one that hadn't been ridden since '82.

I have stripped it down and am going to use the motor if/when the F2 ever #$%*s a valve.

[KB02]

The shocks I ordered are no longer being actively made. They can still be produced, but that guy that makes them will be out for a couple of weeks. So it looks like I have to wait a little bit longer to get my shocks. Oh well. Not the worst thing in the world, right?

In the mean time, I've got to figure out what to do about the seat. My building of one is not working out the way I hoped it would. The front section is coming out fine, but the rear is just a mess. I might have to explore other options.  We'll see...

[KB02]

Well, I kind of gave up on the first version of the seat I had built as it was really kind of a flop. The seat itself was coming out okay, the back end was a mess. I just cut it off and going to make a temp seat just so I have something to sit on as I should be able to ride it soon (as long as the weather holds out).

SO, I started in again.

I'm using a better foam this time and am going to make a buck-and-mold rather than just trying to lay the fiberglass over a form like I tried before.

Starting out with cutting some pieces and holding them together with tooth pics




Then starting to cut out the shape that I wanted



Gluing the pieces together


And then a little sanding to smooth things out


Cutting out the rounds to make the brake light mounting spot


Ready for some mud


And then the mud




I'm using drywall compound for the mud as it will sand really easily once it dries. Then I'll grease up the buck and pour over over some Plaster of Paris to make the mold. Stay tuned...

[rachet]

I'm pretty interested in the rest of this process so post lots of pics!  It's looking great.

Rach-

[andy750]

I'm pretty interested in the rest of this process so post lots of pics!  It's looking great.

Rach-

+1 good luck!

[KB02]

Well, the maiden voyage wasn't as smooth as I would have liked, but for the first time (in Lord knows how long) the bike has ridden under it's own power!! 

... I've got some major tuning work to do... 

I also got some more work done on a few things.
Got some sanding done on the seat.
Before:

After:


I also had my Dad make up a little cam to slide over the throttle tube to quicken up the ratio of the twist a little bit.



I had to do just a little bit of clearance-ing out of the housing for the cam to fit.

I was going to measure the amount of the twist before I put it in, but I forgot. It does twist a lot less now, though.

[HedNut]

Very Cool!! Love the idea of shortening the throttle twist... good digs!  And I'm truely keen on watching your seat unfold...as I just picked up myself some blue styrofoam to take a similar approach... You do great work, and are tres inspiring!! CHEERS!

[DarkRider]

Looks good man.

[MCRider]

Very Cool!! Love the idea of shortening the throttle twist... good digs!  And I'm truely keen on watching your seat unfold...as I just picked up myself some blue styrofoam to take a similar approach... You do great work, and are tres inspiring!! CHEERS!

Yes, KB02, on the throttle. You should have a bunch of those made up for sale. I'd pay $20.

I have a quickthrottle unit, but it adds about 3/4 inch to the switch gear, making the right side out of balance with the left.

Probably prefer your method.

[KB02]

Got a little more work done on the seat. Time to make the mold!

Got a box made up to hold the mold. After putting a light coating of oil on the mold to ease in it's release, this is what I had:


Mixed up some plaster of Paris and started to pour it in:


After some more plaster:


Then spraying in some expanding foam to help support the mold for when I go to remove it:




The whole thing is pretty much covered with expanding foam at this point. After I get out of work tonight I plan to pull the plug out of the mold to see what I've got. Hopefully I will be happy with the results and I can continue working with this project. If not, well, there are a few nice seats on ebay right now... hopefully I won't have to go that route and will be able to keep saying, "I built this..."

Stay tuned.

[Laminar]

I'm on the edge of my seat.

[KB02]

I'm on the edge of my seat.

[KB02]

I had some problem with my mold. (Arthur Flemming said that, too, didn't he?) It turns out that if the Plaster is mixed too thin, that blue foam will float a little bit in it. Opps. I'm have a little trouble loading pictures, but once I get them loaded I'll post my mistakes so others can see.

[KB02]

Well, first of all, blue foam tends to want to float in plaster of Paris. Leading to this:


After doing some digging, I was left with this on one end:


Finally got the buck out (note the small section missing from one side...):


The rest of the mold actually looks okay, but I've got to figure out what I am going to do with the section of the side that broke out.




That's where it sits at the moment anyway.

[J.Webster Designs]

personally, i would just redo it.... check out this forum for mold making techniques and tips.....


http://fiberglassforums.com/

[KB02]

After letting the mold sit, while I was deciding what to do, it has dried a bit more and expanding foam has contracted a bit in the cold and I can now see even more cracks in the plaster. I don't think I have the ambition or the cashflow to make another buck and mold. I may just buy the seat off of ebay. We'll see.