DIY Egli Sohc 4

[mec]

hello from austria,

I started my project end of september 2008. my goal was to build an Egli Racer, as I had in the late 70ies.










frame tubes are ST37, dimensions 28x1.5mm, 70x1.5mm, 100x1.5mm. TIG weldet. frame weight 8.5kg, swingarm 3.4kg





marzocchi 38 fork with magnesium fork clamps, marvic magnesium wheels, D=315 rotors,







the black engine is a dummy engine (without all the internals), the sandblast engine is something like a plus 1000ccm cobra engine

frame and swingarm nickel plated


notice the carbonfibre front fender (a friend of mine made) and the carbon fibre brake lines (http://www.micronsystems.de/):


all aluminium parts handmade from 7075 aluminium


all engine mount bolts and rear axle made from titanium grade 5, all other screws made from titanium (http://www.jaeger-motorsport.de/) or aluminium


34er mikuni flat slide carbs, LiFePo 9,6Ah batterie pack (http://www.durbahn.de/), no e-starter nor alternator:


on the right side of the Kröber speedometer is an oil pressure gauge (cant be seen on the picture):


soon be ready for paint





happy new year to all
mec

[void909]

Great post cant wait to see more!!!

[d3buttz]

jesus..............i i  thaught i was cool by making my own seat. this is awesome. great work!

[syth82]

I might need help getting my jaw off the floor.... Please keep this one updated!

[retro rocket]

Excellent work mate. I bet you could sell a few of those frames as well....

Mick

[Terry in Australia]

That is brilliant mate! I hope you won't mind if I "borrow" your idea, I always wanted to make my own frame............ Cheers, Terry.

[Ecosse]

I'm speechless!

Wait, no I'm not... you sir are my hero! I wait impatiently for further progress.

[754]

I was going to say, "ecosse will get wOOd !!", but too late..

so I wont...


What is on the dyno end of the crankshaft on the engine?




Sehr GUT gemacht....

[Ecosse]

I was going to say, "ecosse will get wOOd !!", but too late..

so I wont...

You have nooo idea how much I had to restrain myself to type legibly. 

I'm still fixated on the frame and bits... can't think straight... engine output... too much for Ecosse to handle now... must rest.



edit:mec, if this is mock up stage and you break down your project can you do me the huge favor of photographing the bare frame... maybe with some sultry mood lighting? I'm not joking.

Ah yes, happy new year to everyone!

[DollarBill]

Ummm...I think I'll just make my own frame...  HOLY SH%T.  That is AWESOME my friend.  Cannot wait to see more.

[MikeB]

I might need help getting my jaw off the floor.... Please keep this one updated!

Ummm...I think I'll just make my own frame...  HOLY SH%T.  That is AWESOME my friend.  Cannot wait to see more.

DUHHHHHHHH!!!
Just couldn't find the right smiley WOW
     
looking forward to UPDATES

[HavocTurbo]

I was going to say, "ecosse will get wOOd !!", but too late..

so I wont...

You have nooo idea how much I had to restrain myself to type legibly. 

I'm still fixated on the frame and bits... can't think straight... engine output... too much for Ecosse to handle now... must rest.



edit:mec, if this is mock up stage and you break down your project can you do me the huge favor of photographing the bare frame... maybe with some sultry mood lighting? I'm not joking.

Ah yes, happy new year to everyone!

Add me to this list...... Ecosse I'm glad to see I'm not alone in the spine framed love.

[Spikeybike]

and nickle plated too ,   ...i love your choice of materials,        titanium and carbon fiber.. how can you go wrong with that 

[ieism]

Ehg..rlll...ah.?

[Speed King]

Fantastic.

[mec]

hello,

thanx for your positive feedback.

some more information and thoughts:

# the "old" egli frame has 62.5° rake and 120cm trail. this is good for long straight roads. I wanted to go for a more modern design. the bikes of today have ~ 65° and 90cm. the all new KTM RC08 has 67° rake!!
I gave my frame 65° rake and <90cm trail. this will be good for all the twisty roads waiting for us.
all tubes are as short as possible to give the max rigidity. the 34 mikuni fit pretty well, but I doubt if the OEM keihin fit the frame.

# according to the modernization I used a lot of titanium and carbon fibre to reduce overall weight of the bike. all the titanium parts saved 2kg, disappointing when compared to the costs. all I have learned during my long time playing with bikes: when you want to save weight radically, you have to omit all parts that are not essentially.
nevertheless, my goal is to stay under 160kg ready to start (without fuel). I prefere 10kg less more than 20hp more.

# doing the frame and swingarm, it was much more work than I expected! all the cutouts of the tubes to fit their counterparts (this determines the distortion after welding and cooling), fabricating all the small parts (mounts for dyna coils, oil cooler, oiltank, fuel tank, rear shocks, batt, frame pressure gauge,.....)

# this thread is for all to animate to try to do something similar by your own. its not easy, it is a lot of work, but it can be done. all you need is two hands (at least 4 fingers on each hand), a brain with more than 4 gyrus (one for eat and drink, one for sleep, one to always remember that the steering tube is in a right angle to the swingarm shaft, and one to switch on/off your welding machine), the will and patience.

# and yes, there are some machines which make life easier:

my milling machine (a bigger one is better):



my lathe (a smaller one does it the same):



a small and very cheap bandsaw for all the aluminium stuff:



again a bandsaw for the steeltubings (do not know the correct term):



my Messer Griesheim AC/DC TIG welder with watercooled welding torch:



and last but not least, most important of all, my Makita band sander:



at the moment I am doing the seat mounts including the wiring connectors which will be attached to the frame on the one hand, and on the other to the seat. putting the seat  on the frame will give contact to the wires and the seat will have to be fixed with two Dzus fasteners only (this system is well known to modellers, that way the wings including connecotrs are attached to the fuselage).


mec

[754]

Is that a Magneto or CDI ignition on the motor with the different cover on left side of  crankshaft? Does it need a battery to run?

Your work is very impressive for the amount of tools used. It sure shows that it is not just the tools that do the job, but more the person using them..

[mec]

Is that a Magneto or CDI ignition on the motor with the different cover on left side of  crankshaft? Does it need a battery to run?

no, there is nothing behind the cover.
the engine runs on LiFePo Batterie exclusively.

mec

[voxonda]

Hello mec,

Following your endeavours sometime now because am playing with the thaughts of building a copy of the EGLI myself. Have build swingarms and welded on frames but never a complete frame. Am impressed with what you have made. Through a friend I managed to find drawings with, most, measurements of the frame so inspired by you I think I will have a go. Have a beautiful MARTIN frame to play with but like the EGLI more. Where the originals not bronze welded?

Cheers, Rob

[voxonda]

Just one of the originals from 1973.

[mec]

Hello mec,

Following your endeavours sometime now because am playing with the thaughts of building a copy of the EGLI myself. Have build swingarms and welded on frames but never a complete frame. Am impressed with what you have made. Through a friend I managed to find drawings with, most, measurements of the frame so inspired by you I think I will have a go. Have a beautiful MARTIN frame to play with but like the EGLI more. Where the originals not bronze welded?

Cheers, Rob

hi rob,
yes, the original was bronze welded(?). we say "hartgelötet".
later F.W. Egli TIG welded the frames due to economical reasons (as far as I am informed).

a comment to the "frame incorporated oil tank":
this was an idea I loved very much.......untill I had such an frame. minor problems (ventilating the "fill in cover", sorry for my bad english, i hope you can understand nevertheless) forced me to use an oil pressure gauge to see whats right or wrong with the oil pressure. that was the moment I started hating the inframe-oil-tank. under braking no oil pressure, long downhills - no oil pressure. adding oil to the system - oil overflow the ventilating tubes.....

remember: you will not see any problems using the OEM oil pressure switch. this switch reacts at +/- 0.3bar. when you run your engine at 0.4bar several minutes, you will have to replace all bearings weekly. the oil pressure gauge gave me the chance to understand whats going round in the engine. this problem was known by Egli of course. therefore he mounted a secundary hopper tank behind/under the carbs. but this tank was way too small. in seconds it was empty and the problems stayed the same. what helped was a oil tank with similar size to the original. thats the way to go.
I made the same experience with my Egli Bol d´Or a few years later. the engine was a RSC 1130ccm motor with dry sump lubrication and dry clutch.

hope it helps.

mec

[SamCB750A]

Hey guys, don't be fooled by this Mec fellow.....He is the real Egli under an assumed name

Nice work Mec. don't worry about your English especially with Rob   he's Dutch.

Welcome to the nut house (forum).

Sam.

[Ecosse]

mec, couldn't help but notice your rubber ball work stool. I've got a problem back and heard good things about these. I'm thinking of trying to find one and wonder how you like it.

BTW: Your English is just fine and better than my... well, anything.

[fuzzybutt]

what kind of tubing (or is it bar stock) that you made your swingarm with?

[mec]

mec, couldn't help but notice your rubber ball work stool. I've got a problem back and heard good things about these. I'm thinking of trying to find one and wonder how you like it.

sorry, I do not like the rubber ball stool at all. so therefore I cannot tell you, if it will help you (maybe?). physiotherapy helps the best (for my back problems which I have for many years).

what kind of tubing (or is it bar stock) that you made your swingarm with?

swingarm was made from 20x50x2 oval/flat tube St 37. tube for the swingarm bushings (with alu inserts) 50x1.5mm


mec