New build coming...Rover

[Lucky 1]

I would not put a motorcycle together with All - thread unless it was a desert repair.

[shinyribs]

I agree 100%. Not the stuff engines should hang on!  Thanks for the shout HB lol . And thanks for the help Lucky

[Lucky 1]

I worked on the rear Fender mount today. I made good progress.
I will need a rear fender brace also.
Rear Fender- Panic Cycles.

Here is what I have so far.




The rear tire is a 130/80-17 Avon Road Rider

[shinyribs]

I like that fender,has a nice profile to it. Just asking,but are there any tire growth concerns you need to take into consideration? Looks awful close to the tire,but they look good that way Good work Lucky

[Lucky 1]

The wheel is pushed all the way forward right now.
I will space the fender away from the tire a safe distance.
I plan to have a hoop that goes over the rear of the fender
and that hoop part may also house the tail light.

[Lucky 1]

This mornings project...

Brake reaction tab fabricated and welded into position.

[Hellbilly429]

I personally like narrow fenders on a bike, are you gonna cut that fender up and do anything with it or leave it as is and just paint it?

[Lucky 1]

I am going to leave it as it is but it will have a rear mount sort of like a sissy bar but no upper part.
Just support for the fender.

[Hellbilly429]

Gotcha, one of those nice low sissy bars that just wraps around the fender, I dig it

[Lucky 1]

I worked on the fender mounts for 1/2 the day.
I had a Doctor and dentist appointment.
Should finish up tomorrow.

A lot of small parts to make.
Photos of the mess tomorrow.
Photoshop sketch below.



Update of Photoshop sketch.

[Lucky 1]

I finished the fender this morning. It is now noon. Wow time flies!
There is a 1/8 thickness flat bar under the fender that is not visible.
The side struts are 1/2 square tubing.065 wall.
The tabs on the frame for the lower strut mounting are 3/16 thickness.
I may weld mounts on the side struts for turn signals but I cannot make
up my mind about that right now.
I will wait until later. I do lights last.
Photos:

[shinyribs]

Not a complaint,honest question. Why not use the support tab on the axle plate?

[Lucky 1]

That is a very good question.
Hold on a sec.

When I started I tapped all of the holes in the rear axle plate to 5/16.
The holes were all drilled to 1/4 inch so it was a natural.

But when when I went for the simple connection, it looked all wrong. It looked like the
rear wheel was the front wheel going backwards. Only front fenders have support struts on that angle.
"Like.... where have I seen that angle before?"

Here is what it would have looked like. (Photoshop sketch)


It is easier to choose when seeing the two versions side by side.
Also the shorter strut is much stronger.

When painted it would get even more attention.

[Lucky 1]

The next thing I wanted to check was the upper rear engine mount plates.
I wanted to see if they fit.
Unfortunately they do not fit. The holes are not lined up (holes will not reach), but it could be because the front lower mount holes are not right.

 What I need to do is re drill the front lower frame mount bolt holes to see it it will make the upper rear mount plates fit any better. Right now only the bottom rear mount bolt holes have the right bolt in it.
I might remake those upper engine mount plates if needed.

[Lucky 1]

OK...I can deal with those lower front engine mount holes when I take the engine back out of the frame.
If I try to do it now I might break a expensive drill bit or worse.

Now working on the seat mounting and all those parts.

[shinyribs]

I see what you mean on the fender strut now.Good call dude. Whats up with all the engine mount tabs being wrong? Is the frame that far outta whack,or is because its a 77-78 case? Man,that kinda sucks that you gotta do that much work on a "ready" frame! Have you talked to the people who built it? They might have some insight on it.Maybe they offer longer upper ears for these cases? Thats just strange

[Lucky 1]

As far as the engine mount bolt holes...The front bottom mount holes on the frame were too small for the Honda bolt to be used. I have a piece of all thread in it now.
I think it may have been jigged up with all thread. Not sure. The rear upper mount plates are very nicely cut and drilled but they do not quite fit and I think it is because the front bottom mount is not right.
The upper mount holes were only off by about .020 or so. But I do not like to POUND in bolts.

What happens is that if you had all of the correct bolts in the engine and you tacked the mount plates in position then removed the engine. The engine will come out alright, but after you fully weld each mount plate the welds shrink about 2% per inch. (Elongation rate)

If you left the engine in the mounts and fully welded the mount plates(even just the outside) you would never get the engine out because as the welds cool the frame shrinks.
Also the engine cases would get extremely hot and cause damage to the engine.

It is a common problem in manufacturing. They use quick release pins in welding fixtures for that reason.

Shrinkage from welding is always something to be factored in.
It is easily rectified by re drillling.

[Lucky 1]

Today, Thursday (Sept.,27th) I finished making the spring
 seat mount and hardware, and got the seat mounted.
I will post photos tomorrow.

The fender had to come first, then the seat, to make sure
the seat would clear the fender.

[Lucky 1]

These are the photos of the seat hinge and support.
I had a hinge but needed to make the "T" shaped bracket.
That one single screw in the front part of the seat pan holds the pan down in the front.
This seat is VERY comfortable. It is the 3rd one I have made. I make it from a tractor seat.
I call it the Pizza seat. Shaped like a slice of pizza.

The hinge is hidden.




Then I started working on the Battery support tray.
I want to keep it simple, but try finding a plastic battery box
 for a motorcycle battery! No one seems to make one.

I was thinking of  other applications but still have not come up
 with a nice battery box made in plastic for a motorcycle size battery.

[shinyribs]

I used to own a Polaris Scrambler four Wheeler. The battery was mounted outside the frame in a plastic box. I think it was an '05? Can't remember, but you might shop there.