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Guzzi 1100 custom build
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Points: 105 		Post Options Post Options   Thanks (0) Thanks(0)   Quote Buzzer Quote  Post ReplyReply Direct Link To This Post Posted: 25 Feb 2022 at 13:50
The finished results, apart from a good polish...  As I am going to use a Ducati rear calliper, I have also used a Ducati Master cylinder, and also used the same leverage ratio for the pedal...  here is a short video 
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Some time ago I was taught to gas weld Copper then tig weld copper cylinders ...went on to work for a place that sold specialist repair rods and Mig/Tig machines so learned to braize/weld stainless, Cast Iron, steel, Alloy and of course copper sheet.

BUT like any skill when you don't use it you loose quite alot of skill. Therefore to "get into" it again takes time and patience.

As an apprentice I also learned to solder to very high Telephonic standards but soldering now takes me time to complete.
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Points: 105 		Post Options Post Options   Thanks (0) Thanks(0)   Quote Buzzer Quote  Post ReplyReply Direct Link To This Post Posted: 22 Feb 2022 at 10:44
Originally posted by Simond Simond wrote:

I can run to the hundred quid for the welder, it’s whether I can afford the mountain of scrap that would be required for me to learn to use it…

Which is a roundabout way of saying, “the exhaust looks good”. :)

I know what you mean...  there are some great tutorials on YouTube though!

Next on the list is the new foot controls… I sat on the bike and decided where I wanted the foot pegs to be. This bike wont have rear-sets, I want to to be comfortable to ride! I then measured how long from the peg the brake and gear lever needed to be and set about designing some controls. It would have been easier to have had them water jet cut, but that’s a 3 hour round trip for me, and usually quite a wait, so I decided to mill them out instead. What has made a BIG difference to me is the acquisition of a band saw… Its great for cutting stuff like this out! I was so lucky to acquire it… my mate was throwing it out!

I made a couple of spigots to mount them on the frame which I will weld on. I have used a couple of Oilite bushes on the holes rather than run the alloy directly on the steel. the first spigot I made I realised I had counter bored it a bit too far and it would have been too weak… a case of measure twice cut once! I then bent them in the vice to get the correct crank angle to clear the exhaust.
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Points: 687 		Post Options Post Options   Thanks (0) Thanks(0)   Quote Simond Quote  Post ReplyReply Direct Link To This Post Posted: 20 Feb 2022 at 13:54
I can run to the hundred quid for the welder, it’s whether I can afford the mountain of scrap that would be required for me to learn to use it…

Which is a roundabout way of saying, “the exhaust looks good”. :)
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Originally posted by Ken-Guzzibear Ken-Guzzibear wrote:

Nice work the only item I don't have a welder .... but then rarely need to braize or weld things on the odd occasion I pop to a local fabrication shop and for a few beers can use their gear 

I only had a MIG for years, I do some consultancy work for a fabrication company so any TIG i just popped in there...  What I found though was making things like inlet manifolds I needed to have the TIG there on hand, hence I bought one in the end... its AC/DC so it does alloy and ferrous.  I have to say its brilliant!

The nice thing about TIG is you can also TIG braze with the right rods...  I have recently made some rear footrest hangers, which was my first ever go at brazing with it..

My mate has just bought a cheap DC TIG inverter so he can only do ferrous, but that's all he needs.  He paid less than £100 for it new, and I have to say its superb! he uses the small gas bottles with it that are around £16 each.
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Points: 9350 		Post Options Post Options   Thanks (0) Thanks(0)   Quote Ken-Guzzibear Quote  Post ReplyReply Direct Link To This Post Posted: 19 Feb 2022 at 12:57
Nice work the only item I don't have a welder .... but then rarely need to braize or weld things on the odd occasion I pop to a local fabrication shop and for a few beers can use their gear 
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Originally posted by Ken-Guzzibear Ken-Guzzibear wrote:

Nicely done on the zorst do you tig it?

yes, its all TIGed togetherSmile
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Nicely done on the zorst do you tig it?
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Pipe work  Thumbs Up
1100 sport corsa , Yam R1, guzzi 650tt rider
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Originally posted by Brian UK Brian UK wrote:

Beauty is in the eye of the beholder, as they say.

That is so True Brian Big smile

yesterdays job was to mock up the exhaust... I had ordered some 2" mandrel bends and straight pipe as I wanted that chunky look, and for the pipe to fit straight into the silencer with no reducer. From a performance aspect, the large headers are probably not I deal... but I wont miss a few BHP! I also wanted that angled swept back look (old School!!) The bends are 135, 45 and 30 degrees. It should all polish nicely as its stainless steel. This bike will have more forward mounted foot rests, hence I could kick up the silencers earlier...

I find making exhaust systems quite therapeutic, although sometimes I could do with a third hand. My wife used to help, but since I burned the back of her hand with the hot end of the filler rod, all help has been withdrawn!LOL
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Beauty is in the eye of the beholder, as they say.
Brian.

Better 5 minutes late in this world than years early in the next.
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The Ev /Cali long side stand was designed for Police use ( Some Harleys use exactly the same stand) It means you can operate it with a boot from the saddle and once deployed the bike will not be knocked over by the wind blast of a passing truck. 

The bracket is designed so it allows the bike to lean furthermore there can be an additional gismo that operates a secondary rear calliper to effectively add a park brake, used mainly on the Convert auto box. 




Edited by Ken-Guzzibear - 15 Feb 2022 at 18:41
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One thing I hated about the bike was the side stand… Just how agricultural is that bracket! I know its a great functional design, but its SO ugly!  so out come the angle grinder and it is no more!  In the loft (or as my wife calls it the spares department!!) i had a side stand off a 1994 Honda CBR 600…  it bolted straight on!  Just need to adjust the angle a little when the ride height has been set.  a job for much later on...

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Originally posted by R100CS R100CS wrote:

1929 those were the days things were made to last, not use once, throw away and buy a new next time.

yep, I replaced the miller a few years ago with a new one...  but went back to the old one within a month as the new one was so poor...

a little side track as I had a new facing cutter for my milling machine and wanted to try it! I took the top yoke off and removed the section where the ignition switch fits… and milled it flat. I then contoured the edge to blend it in. Those power files are a great piece of kit, something i bought thinking I may not use it much, but I use it all the time! Then into the blaster to clean it up, it can wait a while for polishing….
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1929 those were the days things were made to last, not use once, throw away and buy a new next time.
1st R100CS flattened by a truck
2nd R1150R modified
3rd V7iii GREEN
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