Friday, April 13, 2018

Project XTracker: Rebuilding the forks & shaving lugs

I tore into the front forks to change the fork seals. Once I opened them up I figured I should change the bushings and other seals & o-rings too. 3 trips to the bike shop later I finally have the right seals. When I picked up the donor front end from the salvage yard it was marked 1992 GSX-R 750 so I bought seals to fit. Turns out these forks are off a newer model because the '92 would have had 41mm lower legs and these ones are 43mm. From what I can gather off the interwebs they are most likely 1996. A note for all you builders make sure you check the parts and verify sizes before ordering parts to save headaches like me trying to force a 41mm seal onto a 43mm shaft...

To get the forks apart I had to make a spring compression tool to access the nut to separate the top cap from the dampening rod. There is a 'special' tool you can get from Suzuki for this but I opted to make one. The spring spacer tube has 2 opposing holes so I dug around the garage and found that my tap die holder has to handles with tapped ends that fit the holes. I cut 2 pieces of steel angle, drilled and tapped holes for the handles and welded them together. Voila... worked like a charm.

I also wanted to shave the unused brackets from the fork lugs. Since I'm only running a caliper on the left side and no front fender there are a bunch of ugly extra brackets. Once I got the lower fork leg apart and cleaned up I ran it though the band saw a couple times, then smoothed things out with a flap wheel on an angle grinder I cleaned it up more with a hand file, ran a wire wheel over the entire lug and buffed with a scotch brite pad. That seemed to produce a fairly even finish. We'll see how it looks after some time. I may need to polish the cut areas further to blend better and clear coat them. I'm pretty happy with how they turned out. It'll look way better.

No turning back now...

After some flap wheel action

Monday, April 2, 2018

Project XTracker: Rear brake line clamp

I added a clamp for the rear brake line to keep it away from the chain. I'm using one of the extra clamps from the front brake line. I cut a small piece of steel, tapped a hole and welded it to the frame.

Thursday, November 30, 2017

Project XTracker: Tail light

For my tail light I'm using an adhesive backed flexible LED tail light with signals off ebay here. Since I'm using the minimalist drag specialties momentary push button I needed to use the motogadget m.relay+ to take the momentary signal and create a prolonged signal pulse. pretty slick unit. I finished up the mount. I originally wanted to integrate the LED into the rear hoop but its a pretty small diameter and I didn't think it would fit and still look good. So I went with a bending a piece of 1"x1/8" flat bar to mount it right under the rear hoop and welding it to the frame. I think it fits the minimalist/ low profile look and is visible and easy to replace (since it is a $2 china ebay part...).

Wednesday, November 15, 2017

Project XTracker: Number plate

A number plate is key for setting off the look of a classic street tracker. The number plate was one of the first things I bought for the project. Its an aluminum number plate that is 10" x 12" with a bead rolled edge that I picked up off ebay here.
The headlight is an Optilux mini LED light bar (H71020411) that I scored from one of the suppliers at my day job.
I really wanted to be able to flare the opening for the light so that it wasn't just a straight cut out. Since it wasn't a standard size to use a dimple die and I'd need to fine tune the opening size I needed to figure out a maual method. I saw a post in a hot rod forum where a guy did it manually using some flat bar with a slit cut in it to fit the material thickness. I tested it on a scrap piece of aluminum and seemed to work ok. I used a scale print out of the CAD model I've been working off to locate the mounting holes and the location of the cut out on the number plate. I cut it using a dremel tool and a cut off wheel - multiple cut off wheels as they wear out quick and break.... For the corners I cut them straight across then used the dremel again with a rotary sanding bit to sand back to the marked out lines. Then started flaring making multiple passes around the opening bending a short angle each pass.

Wednesday, November 1, 2017

Project XTracker: Number plate mounts & front brake line routing

I finished up machining the aluminum number plate mounts that incorporate front brake line clamps on the left side. I got my brake cables from Apex Brakes - good price & quick service but the banjo bolts they came with were coarse thread pitch vs the fine thread in the caliper & master cylinder. Luckily I had some extras to use.
I'm really happy with how the mounts fit up and how the front brake cable routing & clamps worked out. Now to sort out the number plate and the headlight cut out...

Project XTracker: It's RUNNING

The 12V conversion regulator came in earlier this week from Vintage Spoke so I got down to some more wiring. I got everything wired except for the the rear tail light. I decided to check if I did it right and see if it had any spark. Sure enough it did so before dinner I fired it up for a few minutes. Started 3rd kick too. The short exhaust has a nice bark to it but luckily isn't too loud. Jetting likely needs a little fine tuning since I replaced the airbox with a K&N filter and the new exhaust.

I also ordered a rear brake master cylinder reservoir (Ebay) that came in this week. Needed one with the outlet on the side to reduce height and fit under the top frame rail. 

Monday, October 23, 2017

Ontario Provincial BMX Finals 2017

The family made the trek to Nepean (Ottawa), Ontario for this years Provincial finals BMX race weekend. We decided to make it a bit of a family road trip. We booked a hotel with a water park and planned to do some sight seeing. Here's the video from our weekend adventure:

The track was great. They had the berms paved the week before the event and were super smooth and fast. We raced Friday night before the finals Saturday. Cam missed the transfer to his main by one spot and I managed to win my class which consisted of a couple other 17 & 18 year olds to made a full class.
Saturday was another great day. Cam made his main and rode well. I only had 2 other guys in my class so we can 3 motos for total point for the overall score. I went 2-3-1 for 2nd overall on the day. 
I had the 35+ cruiser title wrapped up before the weekend. I was the only rider to do enough of the previous provincial events (4) to be qualified for the championship ranking. 

Jumping the 2nd straight triple

I love this pic of Cam

Jumping into turn one leading Moto 3

Thursday, October 19, 2017

Project XTracker: Progress

Here's how its looking currently:

I machined up a nice little washer to use on the seat pan/ fender mounting. I'm going to make more for the front number plate mounting too. Also planning to fill the extra hole in the fender.

Tuesday, October 17, 2017

Project XTracker: Pipe Finished

I dropped the bike off to Trevor Daley at One Speed Chop Shop last weekend and he worked his magic with is TIG welder to get the stainless steel pipe welded up. He also made a mount for the muffler. He added a nice touch with using a dimple die around the hole to add some strength to the bracket - these details are why I went to Trevor...
I can't wait to pick it up later this week, finish up the wiring and hear what it sounds like!
Give him a follow on instagram @onespeed116

 Muffler mounting springs tucked around the back side