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Messages - alexbrown64

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General Discussion / Re: Steve McQueen rates the bikes of ‘66
« on: Yesterday at 05:43:57 PM »
Here it is in all its techincolor glory... great read too. 


Honda / Re: New XR75 K1 1974 Project
« on: Yesterday at 02:13:55 PM »
Got up before the kids this morning and did a little prep on the body work.
The plastic mudguards got a rub back and then some plastic primer adhesive followed by some primer filler.
The tank and side covers got some dents removed, followed by a rub back and some etch primer followed by primer filler.

Now to find all the small imperfections and fix them up, followed by a good rub back and then some more undercoat, base coat, clear, decals and clear again... (2k clear to  make it fuel proof)


Honda / Re: New XR75 K1 1974 Project
« on: November 18, 2017, 09:44:11 PM »
Hey Mick, yep the centrifuge does work, as there is a lot of old crap built up around the edges.. but the later XR75's didnt have one. 
I will keep an ear out for the Chinese version of the special tool Matt.  The nut is all good and i can modify my special tool to fit a little better.  I would of got a proper tool, but didnt realize i needed one until i was almost ready to go.

Took two steps backwards today.  After some mucking around, i have to take the motor up to Pipe King and get him to repair the ally lugs that mount the footpegs.  It needs a decent repair job.  They are all stripped, broken and munted.  Hopefully Pipe King can do as good a job on the mounts as he does on his pipes.

Next one was the wheels.  The original spokes were cactus and i had to cut them off.  I got a set from Thailand that i thought would go nicely on the build. 
Unfortunately, either they dont know that there are inner and outer spokes, or they sent me all inners.  I tried to get a bit of extra bend on them, but the bend area also needs to be longer to get around the thickness of the hub.
I have dropped Vintage Avenue and email with the pic below. Pain in the arse. 
It can only go 3 ways... He sends me the correct bend spokes..... he gives me my hard earned dosh back...i get a new set of OEM spokes from Partzilla at $2 per spoke/nipple.



Honda / Re: New XR75 K1 1974 Project
« on: November 17, 2017, 07:06:04 PM »
Had a bit of time this arvo, so i hooked into removing the gear shaft. The gear shift had been welded on and the splines were knackered, as well as the oil seal blown.
First off was to remove the oil pickup filter thingy. You need Honda special tool #somethingorrather.. but to get around it, i just ground 4 notches in an old socket.  I also needed Honda special tool #costsalotamoney.  This is a an 2c piece that i jammed inbetween the gears to stop the rotation of the engine.  Its copper, so doesnt damage anything (except the 2c piece).
This all worked a treat and off came the oil thingy, the clutch, a few other doohickies and then the gear shaft just pulls straight up and out.

Thats as far as i got, as i am using some of my special ally welding wire to fix a broken footpeg mount using a propane torch.
We will see how this all works out when i try and fix it tomorrow morning with a hangover...

Pic below showing numerous Honda special tools and techniques....


Honda / Re: New XR75 K1 1974 Project
« on: November 17, 2017, 04:07:48 PM »
Got all my parts together and they have gone to the powder coaters together with my YZ125G frame.  All to be done with a zinc prime and gloss black powdercoat. (pic below is various G and XR components)

Working on the engine this afternoon.  Have to make a special tool to get the oil pump/cleaner thingy off, so i can get the clutch off...

Have all the parts now to rebuild the wheels, so hope to get them together over the weekend...


Yamaha / Re: YZ125G Build
« on: November 17, 2017, 04:03:53 PM »
Thanks guys, love doing the rebuilds, but they can be a nightmare sometimes when you run into problems.
Took all the parts up to Southside Powder Coaters in WA this morning.  They are going to do the G frame, XR75 frame, handlebars, spring, 2 sets pegs, airbox, brake arms and various other parts shown in the pic below. Thats blast, zinc prime, and gloss black final coat.. $300.  Thought that was a bargain.. pick up next Tuesday, so pics then..


Yamaha / Re: YZ125G Build
« on: November 16, 2017, 06:20:40 PM »
OK, after what seems like ages, we think we have the frame ready to go to the powder coaters.
Lots of work went into cutting out, fabricating, reinforcing and welding up the new tubes and gussets.
Frame has been prepped, and now needs a good sandblast, zinc dipping and a full, rich coat of gloss black.

Pic below of subframe gusset.  Both entirely replaced including crush tube, plate and 45* bend (with drain hole).  Peg tubes inserted the length of the subframe and all fully tig welded.

The same with the gusset below.  A strong back running internally the length of the frame, rusty sections cut out and entire new gusset fabricated and blended in, with new drain hole.

And finally the finished frame ready to get fresh paint after 37 years of neglect....

This is going up to Southside powder coaters tomorrow, together with the G's pegs, bars and other bits, and an XR75 frame and nickers nackers..
Thanks to my old Pa for helping with this and also all the guys on the forum here for ideas and advice...

More pics soon...


General Discussion / Re: Vale Bob Tait
« on: November 14, 2017, 01:17:33 AM »
Very interesting story Fat Toy, and condolences. Always a shock when somebody you know passes.
A 750 triple 2T would be an amazing build! Would be nice to see someone with the skills to take over the project.


Yamaha / Re: YZ125G Build
« on: November 12, 2017, 07:41:32 PM »
Cheers Mick,
I may add some weep holes to the tubes on this frame.  I will inject some rust converter into the holes and slosh it around to treat the inside of the frame.
I had to cut the subframe downtube completely off to do another repair. Cleaned the inside of the subframe tube, treated it with rust converter, fitted an internal stub tube and a piece of outer repair tube and fitted it all back together.
Also started fabrication on the gussets. Used a section of 12.7mm cut length ways and then gently bent into the correct curve for the gusset. Worked out well and much stronger than the original. Just need to plate the gussets, fit the seat and mark the mounting holes, drill them out and fit crush tubes..


Yamaha / Re: YZ125G Build
« on: November 11, 2017, 09:51:03 PM »
There were sparks flying everywhere this afternoon.
The rusted sections which were under the gusset were chopped out. New tube inserts were fitted the entire length of both horizontal subframe tubes and then plug welded.
One vertical subframe tube had to be cut and bent out slightly so that a tube insert could be inserted. It was then put back into position and tacked.

Next step is to make new fill in sections to replace the rusted sections that were removed. And also fab up some new gussets.


Yamaha / Re: YZ125G Build
« on: November 11, 2017, 04:09:59 PM »
Aaaaawwwww man, this is the never ending frame repair thread.

Since doing the main gusset repair, and seeing the dirt and rust trapped in behind it, i couldn't leave the rear subframe gussets without inspecting them.  I had previously repaired the outer subframe gussets, but it was on my mind what was behind them.
So this morning i cut the subframe gussets off.  I exposed lots of dirt, rust and some holes.  I have cleaned them up, inspected the area and come up with a game plan.  The first plan was to storm around in a huff and throw the frame over the fence...

Plan two involved having a measure up and seeing what could be done.  The subframe has an i.d of about 16mm.  The o.d is about 19mm give or take half a mm.

Good old Bunnings to the rescue again.  I picked up a meter of 19mm pipe and a meter of 16mm pipe for under $7 combined. This has a wall thickness of about 1.2mm which seems to be the same as the subframe tubing. Yes, it has a light coating of galv on them, but its easily ground and burnt off.

The plan is to cut out the rust holes as i did on the main gusset previously and make a repair patch with the 19mm tube.  The 16mm tube will be inserted down the subframe from the ends and welded into position.  I will have to cut the subframe in one section so that i can insert a new 16mm tube up and into it. 

I also now have in my possession a sheet of 1.6mm plate.  This will be used to fabricate the new gussets.  Some tube is on the way that can be inserted through the new gussets and tig welded to act as the seat mount points.

There is a bit of work involved, but as stated before, i dont think Yamaha intended the G to be still going 37 years later.  The gussets are a dirt and moisture trap, which will eventually eat out the tubes.  So now i can safely say i have inspected, cleaned, repaired and strengthened the gusset areas.


Yamaha / Re: YZ125G Build
« on: November 10, 2017, 11:18:17 PM »
Definitely not nice to have a crack in yer gusset... :o

I did a bit of work on the frame today. Cut the new crush tubes where the engine mounts up.  I put a bevel on the tubes so that my old man can tig them up with a nice semi v prep.

I decided i didnt like the repair i did on the rear gussets, so i am cutting them out again and have some new plate to put in.
I went to Bunnings today and picked up a D size argon bottle.  I will get everything prepped and tacked up so we can get it all tig welded in one hit. Still waiting on some 10mm tube to arrive (7mm i.d) for the tube that will go in the rear gussets ( the tube where the seat bolts run through).

By the time i am finished, the frame will be stronger than new and i would not think it would be subject to cracks. My powder coater dude blasts the frame, then zinc primes it, then nice thick gloss black powder coat to preserve the frame for another 37 years..


General Discussion / Re: Better than Tattslotto
« on: November 03, 2017, 06:38:59 PM »
Congrats if you won it pbm.  Very lucky dude...I woulda given my left nut to of won that holiday...

Yamaha / Re: YZ125G Build
« on: November 02, 2017, 01:02:47 PM »
Hey yz250h, glad to hear you will try to fix your old frame.
I will be home next week and start work on the frame after that.
Will use the tig rods that are compatible with chro mo and mild Steel. No heat treatment, just good fit up with no stress points. A bit of grinding, buffing and sanding and then off to powder coaters. Hopefully be better than new when finished. Updates soon....

Yamaha / Re: YZ125K Rebuild
« on: October 26, 2017, 03:16:39 PM »
I have the Yamaha map which shows peak curve at 28* for piston set at 1.88 btdc.
I have hpi map which shows peak curve at 30* for piston set at 2mm btdc.
I have contacted pvl. They want to know all my part numbers. I wil have to get back to them in a few weeks.

I did get it through Newmann as he had an account with Penton.

Perhaps curve could be wrong. Lots to measure up and a puzzle to solve. I will run lots of tests, take lots of notes and give everything over to an expert for analysis.

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