La Puttana ------Build------ Ride her hard, Sell her Cheap

[Customize IT]

I got to rub the girls back today[backbone]!!!


I took measurement of rail!!!












Put .130 by 1in by 2in tube on mill!!!
Found center!!!















I then put 1in end mill in the mill.
The square tube was cut back the hole seen is not on the bike!!!
















Found edge and reset DRO to produce notch!!!


















Notched one side and then made measurement for rails!!!















I tack welded backbone to motor mount!!!




























With both sides notched!!!
Put the bar in and marked backbone!!!!
This bar needs to slide in frame too so not to effect the rear axle plates measurement!!!

























I then cut line with grinder and hand filed!!!





















Put square tube in and checked all measurements!!!



Frame rails straight with straight edge!!!





























Measurements the same side to side!!!!































Tube square with frame rails!!!































Tack welded and rechecked everything!!!!

Checked the neck angle was right!!!

Losened cones and retightned before check to make sure not pulled one one direction!!!

I also losened the motor mount bolt and made sure slid without any bind!!!

Within 1 tenth a degree is well enough for me!!!
































Checked the neck still centered with frame!!!




























Set back and looked at her!!!!

[Customize IT]

I was able to work on Ana today!!!

I started by choking the neck of the little girl!!!!




I took this piece of scrap left over from the rear bottom frame rail that was too short!!

I bent past 90 degrees!!!














Cut it off to aproxmite length by eye with grinder in vise!!
















I then put in the notcher!! This will not give me the angled notches needed but gives me a idea of what the angle is for grinding!!
You can not do this on other direction notch on bend!!!

















Another majic of tele moment This Took Forever to get the thing ground to fit!!!
Proabaly 100 trips back and forth with grinder to get it to fit!!!!



















Checked by eye centered and straight with frame with straight edge!!!




























Picture of it instaled and tacked in frame!!!!

Of course checked the neck afterwards!!! Blah Blah Blah!!! It had not moved!!!





















I then set about mounting her!!!! Engine Mounts!!!








I took measurement of front mount!!!!



















Then grabed 3/4in solid steel round bar!!! This is the point where camera battery died!!! So missed cutting and turning on Lathe!!
and a bunch of other things!!!
I was able to get charged before the other I done!!!














Cut to size put in with tape off mount bolt and tape to the frame and the use of the digital anglefinder to get straight!!!
Then welded in pretty solid because not mounted to frame yet so can not warp it!!!

I will finish welding when out!!! The plates will be trimmed too to a respectable shape!!
The mount should go up and twist out then by taken up the neck tell it can be totally removed!!!
If it is too tight I will weld a bar staight out on plate and use leverage to slightly bend out so this can happen!!!




















I used a fabrcators best friend to get the plates sizes!!
The floor is covered with trimmings and wasted tries!!!


















I could not find the other plates cardboard cutout but the battery is now charged and most of this is after the fact!!!

Here is idea of one side!!!















Plates made and ready for fitting!!!





























Fitting and happy with it!!!















Tacked togther!!!

















Used 1 7/16 bolt the same as plate size!!!
Not enough room for two here!! this space is tight!!!




















Made sure I did not drill my rotary table by moving it to center and locking the slides down!!!
Does not need to be on rotary table but it was on there so clamped it to it!!

















Locking slides!!

























Then clamped plates to drill in mill!!















Drilled!!!
















The two plates with holes!!!

























I then welded the nut to plate!!!















I scribed the plates locations relative to each other!!!
















I cut the two plates free with grinder!!!!
















I then cleaned the plates with sanding wheel!!!

















I did not like the look so thought I would hide that there is a nut there!!!























Debured both pieces on sides!!!















Showing a worked finished part!!! Sometimes you have to revert back to the hands on grinder eye and hand for parts!!!

You would have so much time in producing this with a cnc it can be done by hand much faster and look just as well!!!



















Put in frame and tacked!!!!







































Now set about mounting her backside!!!!




On this one because plate on far side in pic is not straight it was better to get dimension by putting it in and making a line!!!





















I then cut off with grinder!!!
I have a band saw just want to show that if you have a grinder a drill press and a welder you can make anything!!!
The mill and lathe just makes it easy and more accurate!!!!








Faced the bar down in lathe both sides tell fit!!!!















Measured of off the engine mounting bolt!!!



























Measured of off jig!! I some how did not get the digital anglefinder pics that more acureratly places bar square in frame.

The tape just gets you close to start!!!

























I then made cut outs seperate then placed together to see relationship to each other!!
If you want to make a semetrical part fold card board and cut the edges togther when unfolded it will be the same on both sides!!!

There was a pile of scraps and failed attemps on these too!!!


























I then layed the parts on the respected steel pieces to scribe for cutting!!!



















Went to mill to make the slot!!! This can be done with drill press just not as easy. When using drill press drill hole then cut to edge of plate with grinder to make the slot part!!!
I have a mill so I took the easy route here!!!
By milling now before cutting I am about to have more surface to clamp the plate down!!!















Found out the other endmill dull will have to sharpen latter with endmill grinder. Anyway good endmill and took .008 passes tell through the plate!!!

















Cut parts out with grinder and cleaned up with hard stone then flap disc!!



































The two pieces fitted and tacked!!


























Clamped to drill!! Make sure not to damage my table!!!!
















Drilled!!!













Repeated other hole!!!
























Plates/mountes

















Welded!!!















Hid nuts!!!!















Ground off welds!!! Then flap disc sanded and matched plate edges and debured!!!

















Finshed set bolted for install!!!




























Installed and tacked!! They will both be removed out this side of bike then followed by engine on this side!!!























The other side!!!





















Two more mounts to make!!! I had to go get a refill of gas bottle for welder!!!!

[Customize IT]

I got down to the underside of her mounting position last night.


I started by finding a piece of scrap that I thought would work and cutting cardboard to match!!!












I folded the templete to get the hieght and then cut it!!!













I then found anouther piece of scrap and welded togther!!
















Transfered the templete to steel!!!
















Cut off with grinder


















Ground!!!
































I then found size of drill needed. I did this the easy way. Took old spacer and just put drill bits in it from set tell found the one that fit!!!






















Drilled















Cut apart!!!
















Finished pieces!!!
















Clamped to frame and moved tell happy with how bolt came in and out!!!
Then tack Welded!!
























































Then took measurement for spacer that is needed to remove and have enough room to remove engine from frame!!!




















I then took measurement of old spacer diameter!!!



















I cut a piece of stock oversize to make spacer!!!



















I put in lathe and indicated it in!! Slowly turning chuck by hand and tapping shaft tell true with machine spindle!!!
Showing true!!



































Faced the shaft end!!!

















Then turned the diameter down to match the old spacer!!!





























Center drilled so drill bit starts correct!!!



















Installed back gear do not need to spin fast to drill!!! I do not want to wipe my drill bit!!!
























Drilled and then checked I went deep enough with mics!!!






























Beveled outter edge!!!

















Beveled inner edge!!!

















Put parting tool in and set it parrelell with the face cut. Easy way to get tool straight!!!
























Now to set tool hieght to part off!!!
This is really really really importantant!! Especially when parting off to have right!!





Used a straight edge and put between tool and shaft!!!













Tool too high!!!
Notice lean to right?















Tool dead center!!!
Notice straight up and down














Tool to low
Lean to left!!!




















The tool needs to be at center or like I have found I like to run just a little lower than center!!
You will know if too high it will chatter and make sqilling noises.
The tool will grab or break if too low!!!

My happy spot!!
Just a little under center!!!





















Set distance for parting tool!!!























Started parting off keeping the shavings cleared on apling cutting oil!!!
This is how I caught the part so not to damage machine ways!!!
Drill bit is way smaller than hole and can be any object you can insert that is not tight in there!!!!



































Put the piece in lathe and beveled other sides!!!





























Checked size. If wrong will have to keep working or throw away and start over!!!


















Finished part!!!
























I then put the stock bolt in to work on making shorter!!

I marked where the distance was!!!































First to work on threading!!!

I found the die needed beacuse my lathe does not do metric threads!!! I do not have gear sets!!!

















Measured the difference between the threads and shaft!!!
































Put bolt in lathe and indicated it in!!!















































Turned shaft down to thread diameter!!!

























Put in vise and threaded with the die!!!!




































Put back in bike and marked to cut shorter!!























Cut off with grinder!!!
I put the nut on so after cut I can back it off and it will deburr the cut so it will start again!!!


















Took to grinder and just barely took burr off!!
I like to hand file abit too!!!



















Put bolt in and tightned down!!!


























Now to finsh the top mount!!!


Made templete

















Transfered to steel scrap piece!!!






















Cut and ground!!















Finshed!!!















Put in to make sure right. I will not weld yet so other top moount can be welded easier. Then I will put it in and weld it!!!

This is the last piece other that 4 gussets to be made before frame can be welded!!
I will not make the gussets so I do not get impationt and weld them in before the frame cooled from welding!!!
That way there will be atleast this cooling period while I make them between welding and gussets!!!

[Customize IT]

She is now one piece!!!!!

I started by cleaning my work area!!

A long over due thing!!!

















I then cleaned my 20 dollar cheap chinese welding helmet!!!
I do not know how effectively???















I then set about tacking the frame!!
I started in the center and worked back then center to front!!!





















































I then started to lay down something that looked it might be able to be called welds???

I used same pattern center back, center foward, and what was done to one side was emedatly done to the other side!!




























































































































































































I then made gussets while it cooled!!!







Made templete and checked it fit both sides!!







































Tack welded some .250 steel plates togther and marked gusset then cut out with grinder and sanded then test fit!!!












































I then worked on lower gussets!!!
These took forever!!!
It was definally cool after these!!!



















































Tack welded the gussets. I ran down downtube and back bone first with tacks!!
Then welded following the same pattern!!




















































































































Frame welded [if you can call it that??] and waited tell cool!!!
It seemed like forever but, I wasted some time on the net while waiting!!






















I loosened neck cones!!!
























Said prayer to some great power and checked if the neck had moved!!!

IT HAD NOT YAAAA!!!






















Cut the engine temp mount off!!






















Removed engine!!!
























Set about welding everything I could not get with motor in!!!
I tighten neck cones before cutting the engine temp mounts out!!!

















































I left rear axle positioner in and took out jig then flipped over!!!

















Cut the downtube to length!!! I was using it to help hold everthing straight!!


















Welded the underside!!!
















































I had to cut the rear axle jig bolt out because of how I made it to have sproket on it!! I new this would happen when I made it!!
I then welded inside rear axle plates!!


















Said another pray to some higher power and grabed rear wheel!!



IT FITS LIKE IT WAS MADE TO BE THERE!!! LIKE A GLOVE!!!! PERFECT NO FIGHT AT ALL AND NO EXCESSIVE SPACE!!!
YAAAAA!!!!!!!




































Mid way point in plates!!!













I do not think I did too bad???
3 weeks to build a one off frame and being 1 guy???
Especially just a young redneck hick surronded by cornfields working in his garage that is only 10ft by 30ft with old used tools and never making a motorcycle frame before!! While working a full time job!!!
Lets just say I am HAPPY with it!!

[Customize IT]

Alright I am working towards the front end!!


I started buy finishing the frame by cleaning a the little slag from the welding off, touched the welds up [there was just a couple little place on the plates and one spot on front gussets that needed just a very little more welding to totaly complete all welds], and then welded the rear axle plates!!!

I used the turned part of the jig bolt to set the length!!!
































I then welded the nuts on end of the adjuster bolts!!
























The two plates finished!!!























I then marked the motor nounts and took the off!!!




























I took them off and finshed welding!!! Then cut off with grinder and then sanded the mounts!!



































































































Then took the oportunity because my friend had come over to help move the jig for some photos!!




































































I then bolted the motor back in!!!


















Then took off the lift!!!





















Then we moved the jig and the lift out so I can build the front end!!
I will be working off the ground now because to stupid to build a bike to fit on my lift!!!!
I guess it is a ground up build!!!
I think I could use this girder but it is not one I built so will be used for design ideas and sold!!!

[Customize IT]

Here is a better representation of front wheel postion and the limits I have when designing the girder for her!!!

That should be about 3.5 in of trail!!

I have to layout and do better measuring when I start it but, I need a chalk line to line everthing up and measure better. I do not have one right now will borrow one tommorow!

She is still almost exactly 9ft 6in long!!!

[Customize IT]

I went to the breakers today and found a couple things so I could keep going on this!!


I found the shocks that should work for the trees!!

They are off a Yamaha 250 and have 11.5 between eyelets!!!















They are 1in shorter than the ones on the other girder!!! This will allow me to use for the bike!!


The distance between the mounting bolts for other tree for girder!! 8 and 7/8in!!
























I also was abe to go and get the billet cut for trees!! There will no surface not machined on them!!!

























The front girders will be 8.25in wide to outside edges and will allow me in the future to put dual disc brakes on if I like!!!


Here shows how the shocks will mount on top tree!!!
























I also was able to find a fender for rear that with some work may fit the design???

[Customize IT]

Maybe you guys can help me out???

I am up in the air right now on the girder design???

Anybody got a favorite????



Staight both legs???
















Curved bottom leg????

















Both legs curved?????

[Customize IT]

I have been working on the trees!!!


I started by making sure my vise was square with table since I moved it!!!
It is not the best vise in the world but it does the task and I only paid 20$ for her!!!



















































I then found if I had a cut anywhere near square!! I got lucky and had one!!!
























I took my fly cutter and put a sharp edge on the cutter!!!
























I then went to my chart for speed of cutter!!! It is funny and not sure if the right way but with fly cutting I have found the feed rate for the desired material is about where the fly cutter speed should be. I then tune in the finsh from there slower usually faster but that gets me close!!
This was taken directly out of bridgeport manual!!























Fly cut one side off square sides!!!






















Flipped over and Fly cut parrellel side!!























Filed and checked measurements!!!
















































Checked square!!






























Fly cut other two sides and checked square all four directions top and bottom!!1

























































Checked the side dimensions the same!!




































Flipped on side and indicated it both directions!!!































































Cut edge and measured the cut made square!!





































































































Flipped over indicated and fly cut edge!!
Then measured!!










































































































































With that block squared I started working on the other!!
Fly cut all sides edges and checked with square then measured!!!



















































































































I fly cut this block to match dimension critical for girder because this is the side the linkages will be on!!!
































































I then indicated for both sides and cut both sides and mad exactly match the other thickness!!!





























































































































Two squared and matched blocks ready for layout for front end!!!

[Customize IT]

I just reread the handbook and it says either to press and weld [which is not possible being billet] or to thread bottom and set screw for bottom tree??????

It also recomends 5/8 bolts which is crazy big for linkages????

I am thinking 1/2 or 9/16 bolts???

It also say I could get by with running one shock??? It says the second shock just follows the first if not perfect match pairs?????

The shock I have is almost a perfect match to what it calls for????

There is no referance to fixing the top tree at all???

[Customize IT]

I have been calculating the links for my forks!!

It may need refined tellme what you think??

[Customize IT]

Here I have refined the links to be about perfect this also tells me distance of mounts for fork legs.

The legs follow neck angle and the trail is about 3.5!!!

I belive my shock will fit in there perfect too????

[Customize IT]

Thank You RueDOG for this calculator!!!!!



Here is what I belive to be my finalised linkages???

[krymis]

man o man you just made my morning. We need more people to post stuff like this. I like using the tubing on the top of the neck fixture to the axle fixture also. You do great work. Take a look at my front end rules of thumb. Build how you were going to then build one with those and tell me how you fair. I am trying to get input from others as i am the test bunny. What is the height from the bottom of the lower tube up to the top of the weld at the neck backbone intersection? What is the measurement from front of axle slot to intersection weld of backbone and neck? Centerline of crankshaft to weld intersection?

[Customize IT]

man o man you just made my morning. We need more people to post stuff like this. I like using the tubing on the top of the neck fixture to the axle fixture also. You do great work. Take a look at my front end rules of thumb. Build how you were going to then build one with those and tell me how you fair. I am trying to get input from others as i am the test bunny. What is the height from the bottom of the lower tube up to the top of the weld at the neck backbone intersection? What is the measurement from front of axle slot to intersection weld of backbone and neck? Centerline of crankshaft to weld intersection?

Thanks,

This would not be happening for me without people like Gary he has been great help to me!!

Can you post a link to the front end rules of thumb???
I am not locked into building it yet but have set guide lines of 3.5in trail, same rake as neck 45.5 degrees,and the enough room for shock???

Here is those measurements you wanted add 3/4in to the last two to get centerlines of the downtube bar.