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Classic Bike Trackdays

RG250 Mark 1 Dual Sport
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Pezz



Joined: 14 Sep 2013
Posts: 68
Location: Sydney Australia

PostPosted: Sun May 25, 2014 11:05 pm    Post subject: Reply with quote

Had a productive afternoon roughing out the new steering stem to within about 1mm of desired diameter.

The old lathe took a bit of fettling to stop the chattering, and I was cutting it a bit slowly to start with.

Now the slow and time consuming part as clearances will need to be spot on.


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gammaguy21



Joined: 07 Jan 2011
Posts: 70

PostPosted: Mon May 26, 2014 1:15 pm    Post subject: Reply with quote

Clap
Love machining pics!
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eyrey1



Joined: 29 Nov 2012
Posts: 82
Location: WAKEFIELD

PostPosted: Tue May 27, 2014 1:44 am    Post subject: Reply with quote

gamma guy watch this if you like machining its incredible what it can do
and cuts like butter,
you wont believe its metal
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gammaguy21



Joined: 07 Jan 2011
Posts: 70

PostPosted: Tue May 27, 2014 12:26 pm    Post subject: Reply with quote

eyrey1 wrote:
gamma guy watch this if you like machining its incredible what it can do
and cuts like butter,
you wont believe its metal

hi eyrey1,
Is there a link/video with this? I don't see one Question
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gammaguy21



Joined: 07 Jan 2011
Posts: 70

PostPosted: Tue May 27, 2014 1:09 pm    Post subject: Reply with quote

Think I found it from another thread you have
http://www.youtube.com/watch?v=A_qHR_H_2cg#t=125

Shocked HOLY SMOKES! That's amazing.
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Pezz



Joined: 14 Sep 2013
Posts: 68
Location: Sydney Australia

PostPosted: Mon Jun 02, 2014 3:52 am    Post subject: Reply with quote

Well it's getting a little more exciting, now just need to make a spacer for below the bottom bearing and all will be ready to fit the DR600 front end on. Took a little bit to sort this out and I must thank my friend Malcolm, a retired toolmaker for his help with this. I have so much to learn when it comes to machining. Having a great mentor is always a big advantage. If I may offer advice, just keep asking lots of questions, 'cause the skills of these old tradesmen are disappearing these days.

New bits sitting together ready to reassemble Smile



the 2 stems side by side


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Pezz



Joined: 14 Sep 2013
Posts: 68
Location: Sydney Australia

PostPosted: Wed Jun 04, 2014 11:26 am    Post subject: Reply with quote

Spacer ring on, probably should have cleaned it first



triples back on, next is insert the forks legs



On the crate, waiting for some more loving



sorry about the ordinary phone pics
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Pezz



Joined: 14 Sep 2013
Posts: 68
Location: Sydney Australia

PostPosted: Fri Jun 06, 2014 10:56 am    Post subject: Reply with quote

Again Im sorry about the poor phone pics, Canon camera has died Sad

Well I got the forks on and then jacked the bike up and sat the swingarm in for a check and look and see.

Realy quite impressed how it is coming together. The swingarm is too long and I have been given another swing arm by JonW, which looks like it will fit the bill nicely.



I will try to take some decnt pics over the weekend, as I look at ways to get the rear suspension working.


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eyrey1



Joined: 29 Nov 2012
Posts: 82
Location: WAKEFIELD

PostPosted: Sat Jun 07, 2014 2:47 am    Post subject: Reply with quote

coming together nicely mate !
im looking for a set of rg250 mk1 mirrors ?
did any come with the bike ?
got to be mk1
mk2 and 3 are different
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Pezz



Joined: 14 Sep 2013
Posts: 68
Location: Sydney Australia

PostPosted: Mon Jun 09, 2014 5:58 am    Post subject: Reply with quote

I didnt get mirrors with the bike, sorry. I have one but it is cracked

Below are some better pictures taken in daylight.

I decided to re-fit the exhaust and foot peg carriers to check for clearances. Things are pretty tight in there and on the upside, with the extended and twisted DR600 swingarm sitting in there its too wide and hits the mufflers on both sides. Sort of eases the frustration of the fabricator.

Measure 6 times cut once.

Like I said above, Once I get the other RGV250 Mk1 swingarm and see if I can make it work in there. I will then be working out how to get the rear suspension to operate, but may just dump the linkages and go a straight shock. Fabricating a new trop shock mount.

Over the next few days I will be making all the fairing brackets to hold the lowers to the frame.

Thios has been an enjoyable day and its coming together nicely!!













Laughing Laughing
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Pezz



Joined: 14 Sep 2013
Posts: 68
Location: Sydney Australia

PostPosted: Tue Jun 10, 2014 7:13 am    Post subject: Reply with quote

One step forward 2 steps back it seems

Well I put the other swingarm in the back of the RG and it is an early RG alright. Same length as the one I have . . . . Laughing

I am going to fabricate a new one out of chromoly using the stock ones dimensions and 50mm longer.

Just had a look at the steering head angle and its about 33 degrees on the bike lift. I will have to lift the back end a bit and feed the forks through the triple a bit to compensate.

The joys of bike building Cool
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Pezz



Joined: 14 Sep 2013
Posts: 68
Location: Sydney Australia

PostPosted: Wed Jul 02, 2014 10:42 pm    Post subject: Reply with quote

I now have the bushes made and the swing arm in, now adjusting the clearances. The lower shock mount was hitting the chambers underneath, as were the mufflers. However whilst contemplating I losened the foot peg carriers and with 2mm spacers each side i will get my clearance. Once this has been done I will shorten the swingarm about 50mm.

I have better get busy as I now have some competition, 4 stroke competition, Steel frame competition

Kansas Charlie has started his Scrapper build
Introducing the FZWHY250, what you get when you cross a TM250 with an FZR250, long way to go, but looks like it will be a fun ride Smile


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Pezz



Joined: 14 Sep 2013
Posts: 68
Location: Sydney Australia

PostPosted: Wed Jul 16, 2014 12:20 pm    Post subject: Reply with quote

The Joys of building Scrappers

Today has been a bit of a set back. Or a lot of a set back . . . . Im not giving up . . . . yet

My mantra has been to build a bike that wont destroy the donor bike.

The two photos below tell the story . . . .

I need to lift the bike, quite a bit actually, to fit on it

BUT . . . the countershaft sprocket is 150mm (6in) in front of the swingarm pivot, so as the chain needs to bend around the pivot when the bike is lifted it creates a big problem.

I can run an idler pulley, but there isnt a lot of room for that. Its pretty tight in there. Still contemplating this . . . .

Also I really need to lower the swingarm pivot abour 40mm to make it work. Then the wheel offset to the counteshaft sproket needs to be lined up as it will be out by 10mm

I will need to find another RG frame and hack the living daylights out of it . . . . anyone know where I could possibe find one, cheap?

Now in this image the swingarm is not sitting where it needs to be . . . its hanging on the pivot bolt . . .




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Pezz



Joined: 14 Sep 2013
Posts: 68
Location: Sydney Australia

PostPosted: Sat Jul 19, 2014 6:06 am    Post subject: Reply with quote

After a little contemplating today . . . . .

It will work out ok, now to get the new swingarm built 50mm longer than this one


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arlurt
Show Star !
Show Star !


Joined: 28 Nov 2006
Posts: 680
Location: North Yorkshire

PostPosted: Sat Jul 19, 2014 7:32 am    Post subject: Reply with quote

The chain runs from the top of the front spocket to the top of the rear sprocket, and of course the rear sprocket is relatively large, so your chain run shouln't put that much tension in to the top of the swingarm at the pivot... Having thought about it, is that why you're happier now?

Just wanted you to knwo we're reading the posts and interested in what you're doing... Very Happy
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