Topic: trying to buid a CR 750 look alike

[754]

We should call you Silberhand.. Omi wurde stolz sein...

What do you have for tools? Drill press I assume..

 Giving you an A for effort..

[silvercr750]

Thanx 754

Ja, meine Handen waren verschiedene Abenden Silber.

I have a few tools; drill, flex, dremel and some handtools.
Electric welding for steel.

At work we can weld aluminium and a neighbour can weld thin plates (oiltank)

Soon a simple polishmachine will be installed.

see you
Coos

[scottly]

I appreciate hand made parts! I have carved all sorts of things out of aluminum with only a drill-press, a hacksaw, and an assortment of files.

[jimbocafe]

Coos, fantastic creativity with the metal work, much more organic than the CNC stuff, almost like building a bike in the 1900's?
I wanted to share a trade secret, I have cut over 100 feet of aluminum plate tubing and steel using this 18volt hand saw, model 6320-20, I picked up on ebay for 50.00 new! It still has the original blade.I then sneak up on the scribe line using the Ridgid drum/belt sander and finish with a file. This has saved me countless hours in fabricating. Hope this helps.
Thanks for the inspirational build, james
This is my first venture into forums so I hope it's not too rude of me barging in a bit off topic, lots to learn about eticit.

[silvercr750]

Hi James,

It's always cool to see how others fabricate there parts.
These are interesting tools for working with metal.

A handmade part on the bike gives it an even more personal result.
Offcourse there are all kinds of perfectly made parts that look very much like the originals.

for now I've bought me a Monza gascap.
I know it's not the original CR gascap but for now this is good for my bike.
Now I'm trying to find a collar or fllance for this 2,5" cap

I know it's for sale but not where in the Netherland's.

By silvercr750 at 2010-09-05

still going on

[lordmoonpie]

Coos,

you can get various flanges for your Monza cap at: http://www.demon-tweeks.co.uk - go to the main page and search on "fuel cap"

Hope that helps? 

[silvercr750]

Good Morning Simon,

Thanx, send some emails for the Flange.

[silvercr750]

Hi there,

Yesterday the small flange for the tank was thinned.
I drilled a few holes in it for some grip in the bottom of the tank.

And this way it will be mounted


By silvercr750 at 2010-09-08


By silvercr750 at 2010-09-08

[silvercr750]

Also the brackets for the frontbrake are back in the house.

They'll need some work but they fit very well.

Can't wait to get the frontwheel on a scale and see what the kilo's are now.

Now a distance flange has to be made to get the frontdisks in the right place.
They will all be made of aluminium.


By silvercr750 at 2010-09-08

[fishhead]

Silver, are you making those brackets without a milling machine.. Ie drilling, grinding, & sanding? If so. good for You..
Nice to see someone that does not say cant!

 I agree..

 However,

 Your 3 piston calipers came off a bike that had a linked braking system where the rear brake also worked the front brake(using part of the front brake calipers). That's why they have fittings for 2 hoses on each caliper. I believe the separate fittings don't connect to each other(they are separate for the linked brake system- fluid wont go from 1 part to the other through passages in the caliper).

 I'm not going to say it can't be done though,

 It great to see other people who have the "I can do it and I'm going to do it" attitude. When I didn't have machines to work metal, I still had my wits and a drill, files and determination and got it done, it just took a lot longer.

2 thumbs up!!!

[silvercr750]

Hi there Fishhead,

Nice website with great projects.

I understand that with these calipers the middle pistons are worked by the rear brake.
And there is no connection inside the caliper.
So there will be a need for an "outdoor" connection.
I'm not sure yet how to fix this challenge.
With a splitter in the brakelines so 2 lines go into each caliper.
Or with a connection-hose from one to the other fitting on the caliper.

I'll have to look into this to find a good and goodlooking solution.

For now the calipers are in place with my alu-brackets.
I'm drawing the spacers for the brakedisks so they can be made.


By silvercr750 at 2010-09-08


see you
Coos

[754]

Easy way to make spacer is to use plate/sheet aluminum.

 That way it is already parallel, if you find the right thickness.
 If the spacer & disc fits on the lip, the holes dont have to even be accurate.

 If the spacer needs a lip or has a lip hidden in it, then it is a lot more work..

[silvercr750]

Hi 754,

These spacers have a 60 mm hole in the middle and a lip of 64 mm where the disk is centred on.
So either way this spacer needs to be machined to give it the sizes it needs.

When they are ready I'll surely post a pic.

see you
Coos 

[silvercr750]

Hi,

While the spacers are manufactured I took apart the frontfork.
Everything looked nice and clean.
I've dicided to increase preload from the spring by adding 2 cm.
This way the fork feels more solid and isn't so weak in this bike.

Maybe wenn I ride this CR this way it turns out that the springs sould be stronger or oil has to be thinner or...
But this is for later on in the proces, for now I'll try with this cheep solution.


By silvercr750 at 2010-09-14
 

[silvercr750]

Hi all,

the spacers are ready.
Looking very cool.

Now the front can be completed.

By silvercr750 at 2010-09-17

And the brackets for the Calipers had to be changed a little.


By silvercr750 at 2010-09-17

Tomorrow to Assen for the Centennial TT

[silvercr750]

Hi there,

Things are going the right way.
I´ll post more pics later.
For now a question.

The picture on the box of the Tamiya scale-model shows a cover over the upper rearshock mounting.
This cover isn´t visible on any other CR.
But I can´t believe the people from Tamiya added a part on a model that isn´t on the original.

Can anybody help me with this question?

[silvercr750]

the collar for the gascap is in.
looking good, now a way to mount it in the gastank.

By silvercr750 at 2010-09-22

[Old Scrambler]

I have a similar cap on my vinyl-resin tank..........the guy who mounted it said he used an epoxy with the parts mounted on his drill-press to get them centered and level. I see you have a poly-resin tank............it should have a threaded bung but if not you will need to mix some resin to mount the collar. When completed you can line the tank with Red Kote to protect the resin from alcohol in the fuel. Vinyl resin tanks do not breakdown from alcohol and are reported to be stronger than poly-resin (fiberglass).   

[silvercr750]

Hey Old Scrambler,

Thank for the info. A vinyl-tank sure would be a better option.
As I'm using a poly-tank I've stambled on to another way of manufacturing.
Actually some guy over here, classicbikefanatic, has found this way of 'connecting' aluminium and polyester

I've already welded a plate of aluminium on to the collar.
In thsi plate there will be several holes drilled in as in my collar for the gas crane??
This way there is more material to hold the collar on the inside of the tank.

What material is specificly used in the tank I'm not sure but when it's finished I will post.
To protect the inside of the tank a substance also used in poly-tanks for boats is put on.


By silvercr750 at 2010-09-23

[silvercr750]

Hi there,

It's been a while but I've been bussy whit other things than builing my bike.
Not that I've done nothing but just little parts are prepared.

The gascap and flange are ready and of to the guy who builds my  gastank.

By silvercr750 at 2010-10-17

[silvercr750]

And as I'll be waiting for my tank My son has bought himself a bike. He just got his driverslicence and got himself a 2002 R1 (you sould start slowly)

I've picked up the work and started with the Exhaust.
Got myself a set of 4 old exhausts and cut them up. I was thinking that I wouldn't be needing the mufflers so away with them.

By silvercr750 at 2010-10-17

[silvercr750]

I've put the pipes on the engine.
With the original pipes the outer ones are 1,5 cm forward to the inner pipes.
This is not what I want zo they'll need to be changed.

By silvercr750 at 2010-10-17

from the side you can see what I mean.

By silvercr750 at 2010-10-17

[bwaller]

Make a kerf cut & weld on the inside of the bend.

[silvercr750]

Hi Bwaller,

Offcourse that's a way to do it.
And for sure it will be the easyest way.
I am thinking more about welding some new tubes together.
I have a 4in1 exhaust and cut off the corners to see if this can be made into a new exhaust.

But these are 38 mm tubes and the originals are 35 mm. This way there will be a narrowing from 38 mm to 35 mm or the hole exhaust should be made of 38 mm.

Will there be a performance "boost" if the pipes are at about 5 mm greater?

Here a pic of the parts I have to fabricate from.

By silvercr750 at 2010-10-17

[silvercr750]

Hi There,

As I was this far I put the fairing in place so I can see if the outer pipes are in place.
  the lines of the original pipes where diverent from the lines of the fairing.
And I wanted the pipes to follow the fairing.

Now I've dicided I will make it all by myself.

Started with the flanges. Cut them all and placed them in the cilinderhead.

By silvercr750 at 2010-10-24