Unofficial Royal Enfield Community Forum

Royal Enfield Motorcycles => Bullet with the UCE engine => Topic started by: wokka on September 05, 2011, 08:22:38 pm

Title: Build update
Post by: wokka on September 05, 2011, 08:22:38 pm
Right, rather than continue a thread started in the wrong section  :-[ Lets continue it here.

For the late commers:

Gday All,
I'm an Aussie expat, living over in Dubai, and figured i'd drop in to say hi

Well it took eight and a half years, but I've finally convinced the Handbrake it's a good idea for me to get back on 2 wheels.

A shattered wrist and twice fractured spine ruled out a crotch rocket, so I went looking for something a little more comfortable with a bit of character.
Sport tourers don't do it for me, and considered going down the Ulysses/Adventure route for a while but never really fell in love with them, a trip out to Classic Cycles in Al Quoz, and I ended up deciding on the C5 military Bullet.

First pic:
(http://i52.tinypic.com/5yvrsj.jpg)

A quick chat to the owner Nelson, and next thing you know, we're talking mods....

Drop the pillion seat and already it looks better
(http://i53.tinypic.com/fkuxxj.jpg)

A few bits and bobs are now on order,
(http://images-cdn.ecwid.com/images/84333/2505424.jpg)
Side mount tail light
LED turn signals
bar end mirrors
15" rear rim and 140/90 tyre
tractor type seat
Megaphone exhaust

and now it's time to hit it with the grinder, get rid of some excess steel....


TBC
Cont....

And now the spanner and grinder work begins.......


No pillion seat, no need for pillion pegs:
(http://i234.photobucket.com/albums/ee261/wokkawokkawokka/bobber%20build/th_P8220242.jpg) (http://s234.photobucket.com/albums/ee261/wokkawokkawokka/bobber%20build/?action=view&current=P8220242.jpg)

Get rid of that front guard and headlight chrome:
(http://i234.photobucket.com/albums/ee261/wokkawokkawokka/bobber%20build/th_P8220243.jpg) (http://s234.photobucket.com/albums/ee261/wokkawokkawokka/bobber%20build/?action=view&current=P8220243.jpg)

Bobbed rear guard, 140/90 15 tyre and rim to replace the 100/90 18 stockers easiest way ever to lower a bike! (Only mocked up, gotta sort lines and fitment yet)
(http://i234.photobucket.com/albums/ee261/wokkawokkawokka/bobber%20build/th_P8220245.jpg) (http://s234.photobucket.com/albums/ee261/wokkawokkawokka/bobber%20build/?action=view&current=P8220245.jpg)

Quick mockup of the seat with a little help from my old mate
(http://i234.photobucket.com/albums/ee261/wokkawokkawokka/bobber%20build/th_P8220247.jpg) (http://s234.photobucket.com/albums/ee261/wokkawokkawokka/bobber%20build/?action=view&current=P8220247.jpg)

And now the new stuff


With bringing my screaming bundle of joy into this world, and a week long religious holiday for Government departments (including the post office) spanner time has been a little low.

Was standing out the front of the post office this morning, hopping from foot to foot waiting for them to open, and got the indicators I ordered and a sheet of paper that told me I could pick up the numberplate bracket and replica model A tailight from another post office across town, but the sonamabitch was still shut today.

I went back to the garage and started unwrapping the stuff that came back from paint, got too excited and only remembered to snap a pic when I had nearly finished the lot

(http://i234.photobucket.com/albums/ee261/wokkawokkawokka/th_IMG00023-20110905-1303.jpg) (http://s234.photobucket.com/albums/ee261/wokkawokkawokka/?action=view&current=IMG00023-20110905-1303.jpg)

(http://i234.photobucket.com/albums/ee261/wokkawokkawokka/th_IMG00022-20110905-1302.jpg) (http://s234.photobucket.com/albums/ee261/wokkawokkawokka/?action=view&current=IMG00022-20110905-1302.jpg)

(http://i234.photobucket.com/albums/ee261/wokkawokkawokka/th_IMG00021-20110905-1302.jpg) (http://s234.photobucket.com/albums/ee261/wokkawokkawokka/?action=view&current=IMG00021-20110905-1302.jpg)

Original 120/90/18 rear is back on, will stay there till I run in the first 1000km.

I'll take the time breaking her in to start chasing up a few more bits and bobs. Power commander, Trials style top yoke with inbuilt guages, Smiths replica speedo in Km/h, brown braided leather grips and possibly brass switchgear and levers.
I'll fabricate a set of solid struts, but as she'll be my daily rider, I'll only put them on for bike shows or slow cruising nights

Headlight is definately going, but trying to decide to go bigger, smaller or dual.

I want to see how she handles the mountains they call speed bumps here before I decide how far I drop her, with 5" clearance, 2" should be safe, but we'll see
Title: Re: Build update
Post by: Ducati Scotty on September 05, 2011, 08:56:17 pm
Looks great.  Where did you get that seat?

Scott
Title: Re: Build update
Post by: wokka on September 05, 2011, 09:15:49 pm
Looks great.  Where did you get that seat?

Scott

Straight off the shelf at the dealer, it was exactly what I wanted.

You now feel like you are part of the bike rather than perched on top of it, time will tell if it's comfortable, but it's definitely wider than stock and the lip at the back stops that sliding off the back feeling I got from the stocker
Title: Re: Build update
Post by: Ducati Scotty on September 06, 2011, 02:18:05 pm
We don't have those at the dealers here in the US.  I'm really happy with my stock seat now that I ditched the stock foam and repadded it but that tractor seat looks great!

Scott
Title: Re: Build update
Post by: wokka on September 11, 2011, 08:08:39 pm
Update:
(http://i234.photobucket.com/albums/ee261/wokkawokkawokka/bobber%20build/DSC_0197.jpg)
(http://i234.photobucket.com/albums/ee261/wokkawokkawokka/bobber%20build/DSC_0199.jpg)
(http://i234.photobucket.com/albums/ee261/wokkawokkawokka/bobber%20build/DSC_0208.jpg)
(http://i234.photobucket.com/albums/ee261/wokkawokkawokka/bobber%20build/DSC_0234.jpg)
(http://i234.photobucket.com/albums/ee261/wokkawokkawokka/bobber%20build/DSC_0190.jpg)
Title: Re: Build update
Post by: Ducati Scotty on September 11, 2011, 11:58:46 pm
Looks great!  I love a minimalist bike.  I really like the matched helmet too.

Scott
Title: Re: Build update
Post by: FiRE Comms on September 12, 2011, 12:00:28 am
Woka,

I'll be heading through your neck of the woods here in the next couple of months... mind if Iook you up?

chris
Title: Re: Build update
Post by: Ice on September 12, 2011, 03:41:06 am
Man that things Bitchin'  8) !
Title: Re: Build update
Post by: jartist on September 12, 2011, 04:03:08 am
 :o :o THAT THING IS SO FRIGGIN' COOL!!!!! :o :o
Title: Re: Build update
Post by: wokka on September 12, 2011, 10:08:45 am
Thanks guys, still a long way to go, I'm thinking about solid mounting the saddle, fixing a 21" to the front, dropping the front 2.5-3" and the rear 2" then trials type top yoke, dual headlight kit, older style bar switches/micro switches etc.

Woka,

I'll be heading through your neck of the woods here in the next couple of months... mind if Iook you up?

chris

No problem Chris, email me on leigh.pattinson@gmail.com and we'll work something out
Title: Re: Build update
Post by: The Garbone on September 12, 2011, 01:27:31 pm
That bike is really sharp... Love it..
Title: Re: Build update
Post by: oldairplanenut on September 12, 2011, 03:36:58 pm
I really want a seat like that. Any idea where I can get one in the US?
Title: Re: Build update
Post by: wokka on September 12, 2011, 05:36:11 pm
I really want a seat like that. Any idea where I can get one in the US?

Let me see if I can find where the dealer gets them from.

Had a few people ask about it
Title: Re: Build update
Post by: BrashRooster on September 13, 2011, 12:32:04 am
Man that things Bitchin'  8) !

+1 and in non internet social media pop lingo........ yeah what Ice said!
Title: Re: Build update
Post by: GlennF on September 13, 2011, 11:45:15 pm
Coming together really well.

Another random styling thought is black headlight mesh like this Sydney-side SR500 ...

(http://www.pipeburn.com/storage/07_07_2011_yamaha_SR_500_monkey_02.jpg?__SQUARESPACE_CACHEVERSION=1310302285287)
Title: Re: Build update
Post by: wokka on September 14, 2011, 10:19:40 pm
Hmm, got me thinking now,

was originally going to go for something similar to these but mounted lower
(http://www.hitchcocksmotorcycles.com/http://assets.hitchcocksmotorcycles.com/pictures/category5503/large/Trailblaster-headlight.jpg)
Title: Re: Build update
Post by: Ducati Scotty on September 15, 2011, 12:19:37 am
What about stacked projector beam headlight like on the Sachs Madass?

http://www.google.com/imgres?q=motorcycle+projector+headlight&um=1&hl=en&tbm=isch&tbnid=2inkvbK7t186cM:&imgrefurl=http://motorcyclephilippines.com/forums/showthread.php%3Ft%3D208842&docid=ZRDR1ub_aZc6rM&w=651&h=600&ei=LzZxTuPBNOHq0gGZ8rWrCg&zoom=1&biw=1786&bih=816&iact=rc&dur=451&page=3&tbnh=137&tbnw=150&start=72&ndsp=36&ved=1t:429,r:2,s:72&tx=66&ty=61

Too modern?

Scott
Title: Re: Build update
Post by: GlennF on September 15, 2011, 11:52:33 pm
Hmm, got me thinking now,

That would work as well :D

By the way, here is an interesting link to a blog from a guy making a bobber out of his former Enfield trike :D You will note its an iron bullet with a modified hitchcock rigid frame kit. I particularly like the solution to the age old battery problem locating it low in front of the rear wheel.

http://bobthebullet.blogspot.com/

(http://2.bp.blogspot.com/-XxuU3ZKt704/TmzpGMgbZyI/AAAAAAAADB8/xRxqOAHwMWU/s400/BIW%2BShot.jpg)

(http://3.bp.blogspot.com/-lkF3nrWsAbk/TmzpFx4R02I/AAAAAAAADB0/rOaqUSkLfso/s400/Battery%2BTray%2B2.jpg)
Title: Re: Build update
Post by: wokka on September 16, 2011, 08:22:46 am
What about stacked projector beam headlight like on the Sachs Madass?

http://www.google.com/imgres?q=motorcycle+projector+headlight&um=1&hl=en&tbm=isch&tbnid=2inkvbK7t186cM:&imgrefurl=http://motorcyclephilippines.com/forums/showthread.php%3Ft%3D208842&docid=ZRDR1ub_aZc6rM&w=651&h=600&ei=LzZxTuPBNOHq0gGZ8rWrCg&zoom=1&biw=1786&bih=816&iact=rc&dur=451&page=3&tbnh=137&tbnw=150&start=72&ndsp=36&ved=1t:429,r:2,s:72&tx=66&ty=61

Too modern?

Scott

Ya, A little too terminator
Title: Re: Build update
Post by: AgentX on September 16, 2011, 04:28:29 pm
Cool bike...I think it looks great and you needn't get too way out with the design.  Personally, I like the casquette on this one.

For a mad max look, though, if you wanted to mount a single light, maybe mount it off-center, or do side by side large and small lights using traditional style headlamps.  Such as the 5" and 3" models from Dime City (link (http://www.dimecitycycles.com/cafe-racer-parts/vintage-universal-cafe-racer-caferacer-bobber-brat-chopper-custom-motorcycle-parts/vintage-universal-bobber-brat-chopper-custom-motorcycle-parts/other-bobber-brat-chopper-motorcycle-lighting.html))...

(One on each fork stanchion, using custom brackets for bottom-mount lights?)  If that'd fit...
Title: Re: Build update
Post by: Ducati Scotty on September 16, 2011, 06:28:47 pm
Ya, A little too terminator

Well then I think there was a Buell with dual headlights like you posted but tiwth the addition of a screen/guard on the front.  That might do.

Scott
Title: Re: Build update
Post by: wokka on September 17, 2011, 05:26:08 am
Arrgh Too many options!!!!

 :D
Title: Re: Build update
Post by: wokka on December 24, 2011, 06:10:39 am
Progress has been pretty slow, with parts taking over 8 weeks to arrive, but we're finally getting somewhere

First shot of the 8' stretched swingarm:
(http://i40.tinypic.com/1qribk.jpg)

Was originally going to move the shock mounts back 4 inches, but then saw these atv shocks lying in the corner in my mates workshop so we threw 'em on for a giggle...

Well bugger me, they fit, they actually work on that angle (on flintstone power around the shop) and they are about 400 ways adjustable including height, damping and rebound

(http://i43.tinypic.com/104lydx.jpg)

Riding position is much more comfortable, especially for a 100kg 6'3" bloke

(http://i39.tinypic.com/28t9m5k.jpg)

(http://i43.tinypic.com/fo27q0.jpg)

With those rear shocks on, it's got me thinking again about a set of gold USD's on the front,
I'll probably bend up a section of steel in the same profile as the toolboxes and hide a smaller battery in there and delete the electric start

Title: Re: Build update
Post by: The Garbone on December 27, 2011, 01:34:26 pm
Looking real good.. Love the saddle...

Title: Re: Build update
Post by: wokka on January 09, 2012, 08:48:24 pm
I don't know if it's just me and my ADD, but I keep changing my mind on this build.

Just got back from my first test ride with the 8" stretch at stock height and the mini 12" hotdog muffler (using the stock air filter as I'm still trying to work out where to put the new airbox) and it surprised the hell out of me, still tipped in well, cornered well and the rear suspension is actually quite responsive, if a little firm.

I was riding down a street in the industrial area, a little too quick and weaving to get a feel for how she turns in when I got a flash from the boys in blue (well, they wear green over here) so I slowed down and pulled up at the next lights, wondering what he was going to ping me on, the side mount plate, the loud exhaust, no front or rear fenders, speeding etc. he looked the bike over from his car, gave me a smile, a thumbs up and a "Mabrook" which translates to "you are blessed" and is used as a congratulations and then tried to race me off the lights.... Some times I love livin in the sandpit!


Now I'm liking the nacelle or headlight surround or whatever you want to call it, and it's got me looking for brass light trims and dial surrounds, I'm also trying to find amber lenses for the running lights and will delete the front LED turn signals and re-run the flasher unit to use the running lights instead.
Also thinking about flipping the bars to lower the look even further.

I'll head out for a ride to the stables in the next coupla weeks and see if I can find a saddlier (?) who can do some emboss and braiding work for the seat

Anyway, ramble ramble, thats enough for tonight
Title: Re: Build update
Post by: Ducati Scotty on January 09, 2012, 08:52:39 pm
Nice!

Keep the nacelle if you can, it's the signature piece of the whole bike.

Scott
Title: Re: Build update
Post by: GlennF on January 10, 2012, 02:45:33 am

Now I'm liking the nacelle or headlight surround or whatever you want to call it, and it's got me looking for brass light trims and dial surrounds, I'm also trying to find amber lenses for the running lights and will delete the front LED turn signals and re-run the flasher unit to use the running lights instead.
Also thinking about flipping the bars to lower the look even further.

I'll head out for a ride to the stables in the next coupla weeks and see if I can find a saddlier (?) who can do some emboss and braiding work for the seat

Anyway, ramble ramble, thats enough for tonight

Going steam punk ?? If you are intending to do a lot of smallish brass items may be worth investing in something like this ...

http://www.caswellplating.com.au/plug_N_plate.html


also ...............

Amber pilot lights ...

http://www.ebay.com.au/itm/NEW-ROYAL-ENFIELD-PAIR-ORANGE-PILOT-LIGHTS-CHROME-RIMS-/250749230504?pt=UK_Motorcycle_Parts&hash=item3a61d19da8

brass pilot light rims ...

http://www.ebay.com.au/itm/ROYAL-ENFIELD-NEW-BRASS-PILOT-LIGHTS-RIMS-PAIR-/260784233886?pt=UK_Motorcycle_Parts&hash=item3cb7f39d9e

Title: Re: Build update
Post by: wokka on January 10, 2012, 04:37:56 am
Going steam punk ?? If you are intending to do a lot of smallish brass items may be worth investing in something like this ...

http://www.caswellplating.com.au/plug_N_plate.html


also ...............

Amber pilot lights ...

http://www.ebay.com.au/itm/NEW-ROYAL-ENFIELD-PAIR-ORANGE-PILOT-LIGHTS-CHROME-RIMS-/250749230504?pt=UK_Motorcycle_Parts&hash=item3a61d19da8

brass pilot light rims ...

http://www.ebay.com.au/itm/ROYAL-ENFIELD-NEW-BRASS-PILOT-LIGHTS-RIMS-PAIR-/260784233886?pt=UK_Motorcycle_Parts&hash=item3cb7f39d9e



Nice one, thanks mate
Title: Re: Build update
Post by: St. Beardface on January 27, 2012, 03:48:22 am
nice, just ordered a pair of the amber pilot lights.

you have an amazing project going. your bike was the inspiration for what i've done so far on mine.

keep up the good work.
Title: Re: Build update
Post by: wokka on March 03, 2012, 09:07:52 pm
I'm stuck, I've been flipping back and forth between swapping to a mono shock rear or keep the twins....

I would mount from one of the swing arm braces to the bar that runs under the seat after I beef it up a little.

I drop it in next week, looks like I'll just flip a coin
Title: Re: Build update
Post by: Ducati Scotty on March 03, 2012, 09:27:43 pm
I think a mono would really strip it down and go further toward the minimal aesthetic you seem to be pursuing BUT you'll probably need to seriously beef up the swingarm.

Scott
Title: Re: Build update
Post by: wokka on March 03, 2012, 10:25:09 pm
you cant really tell from the pics, but the rear is pretty damn strong, I threw it in a sliding jig, cut the arms from the stock swingarm at the pivot tube and the axleplates, stretched it 8" and welded in solid bar and two radiused tube crossbeams, one close to the tyre, and one halfway between that and the pivot.

running up to 85mph, she's still solid and there's not even a hint of shifting left to right

I don't particularly want to go to box section, or brace with another hoop unless I really have too, but the last thing I want is for things to go tits up at speed
Title: Re: Build update
Post by: wokka on June 07, 2012, 10:14:15 am
I must admit, I've debated posting this for the last week or so, but I figured bugger it

ok, I know the Bullet isn't a crotch rocket
I know she sits happily at 65mph
I know if I wanted a faster bike, I should have bought something else etc.etc.

But.....
I am convinced she is capable of the ton

On the flat, in it's current form (front and rear fenders removed, 12" slightly baffled exhaust, 8" stretch) I can easily hit a gps verified 87 and then run out of puff. With a slight downhill, I topped out at 92, hitting the limiter

Next weekend, I am starting a mild teardown which when complete will consist of another inch stretch in the swing arm, monoshock conversion, power commander, custom header pipe, filter, 19T front sprocket, electric start removal, tool box removal, lithium 6a battery, tyres as well as some cosmetics

Now with the PC, filter, exhaust and a dyno run, I am expecting around a 20% hp increase, and hoping for slightly more.

Doing the maths, a 19T front will only bump up the gearing by 5.5% changing the rear hub was on the cards for a while, but I eventually decided against it, what that leaves me with is tyres

I'm now caught between a 130/90 18 Shinko 230 tourmaster or something similar, or swapping out the rear for a G5 19" wheel and running a 4.25 19.
Both of which on paper will get me to the 100 mark, with the 19 slightly in front (unconfirmed until I get real world dimensions)

the 19T and tyres together give an overall gearing change of around 15%

Wish me luck, Call me crazy or whatever

Title: Re: Build update
Post by: wokka on June 19, 2012, 08:16:54 pm
It seems the gods are against me,

Me and the missus recently got made redundant after 4 years, right at the start of the quiet season. So the ton will have to wait until we pick up some more work.

(http://i46.tinypic.com/33nzti0.jpg)

Strip the RH casing ready to install the 19T which like the muppet I am, I left at home
(http://i50.tinypic.com/t51sma.jpg)

The new brains, however the quick disconnects supplied with the PCV don't match either the domestic market or the euro spec bikes over here
(http://i47.tinypic.com/2pr65qh.jpg)
Title: Re: Build update
Post by: GlennF on June 19, 2012, 11:50:33 pm
commiserations on the redundancy, all the best on getting a new job soon
Title: Re: Build update
Post by: Fogrunner on June 19, 2012, 11:58:23 pm
Wow, great build!! Don't know if I'd have the guts, yet...
Hope you find something soon!!
Good Luck!!
Title: Re: Build update
Post by: wokka on June 26, 2012, 10:47:44 pm
Got a bit further in.
I traded a shock rebuild for a stainless straight pipe exhaust system
Fit a Twin air oil filter as a crankcase breather
Stripped the old airbox off
Cut the new seat pan


(http://i50.tinypic.com/wtev7p.jpg)

(http://i46.tinypic.com/6pne3d.jpg)
Title: Re: Build update
Post by: Fogrunner on June 26, 2012, 11:29:28 pm
Nice!! How's it sound with the straight pipe? Loud as hell?? Or major thump??
Title: Re: Build update
Post by: wokka on June 26, 2012, 11:40:13 pm
Nice!! How's it sound with the straight pipe? Loud as hell?? Or major thump??
Both

tomorrow will be the big test, I took her for a quick spin, but the pcv was set way too rich. I could feel a hell of a lot more tourque just waiting to be let off the leash.
once she's dialed in on the dyno I'll know where I sit
Title: Re: Build update
Post by: GlennF on June 26, 2012, 11:44:49 pm
You might need torque cones if its a straight pipe
Title: Re: Build update
Post by: wokka on June 28, 2012, 08:04:27 am
had the dyno run last night, but the powercommander is faulty >:( the rpm's spike up to redline randomly, feeding way too much fuel and fouling the plugs

Strangely enough, the stock ecu is rich enough to handle the filter and straight pipe

I have a sneaking suspicion that the intake length/ filter position is not allowing the required amount of air to get to the motor
Title: Re: Build update
Post by: Arizoni on June 28, 2012, 08:26:50 pm
As I recall, others have noted the fuel injected bikes like to have a straight length between the air filter box and the throttle body.  Probably provides a laminar flow instead of a turbulent one that will choke the system.
Title: Re: Build update
Post by: ace.cafe on June 29, 2012, 07:19:53 pm
Does that Power Commander allow you to eliminate the rev-limiter function of the ECU?
Is it programmable to do that, or just over-rideable? Or neither?

I
Title: Re: Build update
Post by: barenekd on June 29, 2012, 10:51:42 pm
I've been trying to keep out of this thread, but your swing arm
is going to do some serious harm to your body. It is just too thin to have any bending strength even it were solid steel. If you leave the shocks mounted at the ends of the swing arm. The worst force you have on them is twisting when you are in a turn. but even that will cause metal fatigue and you would have a good chance of the arms breaking at the pivot.
If you had left the stock shock on in the original mid mounted position, the arms most likely would have broken right behind the shocks. You need some vertical stiffeners on them to beef them up. That's why most modern swing arms are rectangular tubing at exceed 2" high or more. With the length you have extended you swing arm, you have added an incredible amount bending and twisting force to those small tubes.
I don't know how you are planning to mount a monoshock. But I would recommend you mount it like the Vincents and old Yamaha Scramblers of the 70s with a triangulated section that makes the swing arm look like a hard tail. That design would give you a massive increase in bending and twisting strength.
Don't wanna try to tell you how to built your bike, but don't wanna see you hurt yourself unnecessarily.
Bare
Title: Re: Build update
Post by: gremlin on June 30, 2012, 06:55:09 am
.....your swing arm is going to do some serious harm to your body. It is just too thin .....

+1
+1
+1
Title: Re: Build update
Post by: hortoncode3 on June 30, 2012, 12:03:33 pm
I love to see all the activity here, some of it far beyond where I would dare to go but still a few ideas I'll capture and use..the de-chromed headlight ring for example. I will get around to paint mine Olive but still hung up on the whole paint matching issue..no one around here has been successful so far! (It is Vermont, perhaps I need expert help from a more urban area)  Love the mesh screen over the headlight too. Bar end mirrors..that's next if I ever find a catalog that definitively states it'll fit a G-5...!
Title: Re: Build update
Post by: wokka on June 30, 2012, 01:15:34 pm
Does that Power Commander allow you to eliminate the rev-limiter function of the ECU?
Is it programmable to do that, or just over-rideable? Or neither?

we didn't get that far in ace, the rpm spike put an end to the run before we even really began

I've been trying to keep out of this thread, but your swing arm
is going to do some serious harm to your body. It is just too thin to have any bending strength even it were solid steel. If you leave the shocks mounted at the ends of the swing arm. The worst force you have on them is twisting when you are in a turn. but even that will cause metal fatigue and you would have a good chance of the arms breaking at the pivot.
If you had left the stock shock on in the original mid mounted position, the arms most likely would have broken right behind the shocks. You need some vertical stiffeners on them to beef them up. That's why most modern swing arms are rectangular tubing at exceed 2" high or more. With the length you have extended you swing arm, you have added an incredible amount bending and twisting force to those small tubes.
I don't know how you are planning to mount a monoshock. But I would recommend you mount it like the Vincents and old Yamaha Scramblers of the 70s with a triangulated section that makes the swing arm look like a hard tail. That design would give you a massive increase in bending and twisting strength.
Don't wanna try to tell you how to built your bike, but don't wanna see you hurt yourself unnecessarily.
Bare

I appreciate the concern Bare, I am a member of quite a few other forums and I am one of the first to jump on something I don't feel is safe or right.

The longer shocks mounted at the axle vs the stockers halfway down the arm took most of the vertical/bending forces out of play, I was concerned about the chance of the swingarm twisting so asked  a supplier to put it through a structural analysis and it came up well within limits. (the rails on the swingarm are currently 36mm round bar)

The monoshock is a totally separate beast, and I'm going through a few different configurations.
The triangulated setup you are talking about was my first choice, but chain clearance is proving an issue, the swingarm rails would have to have 2 bends to get around the chain, and I would much prefer to keep the whole thing as straight as possible.

The current preferred option is borrowed from the atv world and will use a 0.160 wall 32mm DOM tube as the main axle arm, and then a full length underslung triangulation in 24mm DOM that will be boxed to the main arm, this will make the highest stress point in the swing arm (the lower shock mount) 80mm tall and the minimum height at the pivot tube and axle plates 56mm. The pivot tube will also be gusseted to the arms as will the lower shock mount.

None of this will go through until I have the calcs back, and who knows, maybe I will have to bin the whole idea. But I'm a glass half full kinda guy
Title: Re: Build update
Post by: barenekd on June 30, 2012, 05:49:01 pm
Quote
Bar end mirrors..that's next if I ever find a catalog that definitively states it'll fit a G-5...!
The Napoleon mirrors will definitely fit a G5 with the stock bars. You just remove the rubber mirrors mounts and stick the bolt through the bar end weights (do not try to use bar end mirrors without them, the vibration is terrible) and screw them into the existing threads in the bars.
I would suggest one get slightly longer bolts to do this with, though. The bolts that come with the mirrors only are long enough to engage 4 or 5 threads. If you ant to change bars, you can to back to the mirror factories original rubber mounting, but, again, get a bolt long enough to allow you to use the weights.
Bare
Title: Re: Build update
Post by: hortoncode3 on July 01, 2012, 12:20:10 pm
Thanks for the info! Now, any suggestions on painting chrome?
Title: Re: Build update
Post by: wokka on July 01, 2012, 09:30:44 pm
A brillo pad and lots of elbow grease
Title: Re: Build update
Post by: Desi Bike on July 02, 2012, 12:25:05 am
Maybe acid etching? You need to break though the shiney top layer. A light sanding won't cut it. Once you get a chip or scratch it will peel.
Title: Re: Build update
Post by: AgentX on July 03, 2012, 07:26:12 am
Keep the twin shocks!

They look great.  Just moden and edgy enough while still reminiscent of the classic lines.
Title: Re: Build update
Post by: AgentX on December 13, 2012, 01:22:08 pm
Bump--what's been happening with the bike lately??
Title: Re: Build update
Post by: wokka on December 13, 2012, 01:49:48 pm
Currently sitting in Qatar customs, hoping to pick it up before christmas

There's a few threads floating about alluding to whats going to happen next
Title: Re: Build update
Post by: Ducati Scotty on January 11, 2013, 07:32:12 pm
Wokka, did you ever get enough seat time to determine the long term comfort of the tractor seat?  It's cold enough in my part of the world that I now have to admit I'm off the road for a while so I'm starting on my winter projects.  Tractor seat is on the list if it's comfy for long rides.

Oh, and you've got me thinking about getting a second fender and plate mount for summer time.  Just strip it down to the essentials when the weather is warm and the sun is shining.

Scott
Title: Re: Build update
Post by: wokka on March 10, 2013, 07:28:39 am
Wokka, did you ever get enough seat time to determine the long term comfort of the tractor seat?  It's cold enough in my part of the world that I now have to admit I'm off the road for a while so I'm starting on my winter projects.  Tractor seat is on the list if it's comfy for long rides.

Oh, and you've got me thinking about getting a second fender and plate mount for summer time.  Just strip it down to the essentials when the weather is warm and the sun is shining.

Scott

Scotty,

I have had about 13000 km on the seat, including over 1000km on a weekend and it is quite comfortable, but its too big for the direction I am taking with the bike now.
One thing to look for is the guage of the pan, I found mine to bend at the back over time, which was a real pain. The welds for the mounting studs also failed after about 6000km and had to be redone.

Progress has been slow, as I am waiting for insurance to come through for some cosmetic damage that happened on the ship over here. But I have test fit a lot of the brass parts I bought in india. Some of them required a bit of clearancing with a dremel to fit.

I wasnt happy with the varying patina that different parts had, so I hit them all with a brillo pad, then gave them a vinegar vapor bath (with a vinegar wash to give the process a kick start)

Came out ok I reckon

Before:
(http://i50.tinypic.com/x5uvlc.jpg)

After:
(http://i45.tinypic.com/15s2e7m.jpg)

Title: Re: Build update
Post by: ace.cafe on March 10, 2013, 11:22:02 am
We are working on a programmable ECU which might work out for you, so you could keep the EFI and have it do what you want it to.
I should have it in my hands very soon.
Title: Re: Build update
Post by: Ducati Scotty on March 10, 2013, 08:25:33 pm
Many thanks for the update!  I'm planning on getting one of those for my bike.  I does look a bit big but I'm really after something super comfy.  Thanks for the note on the bending and broken mounts.  I'm guessing I shouldn't go for the cheapest one out there after hearing that.

Scott