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Author Topic: Project Assembly  (Read 18347 times)

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Ji Gantor

  • Guest
Re: Project Assembly
« Reply #105 on: May 24, 2009, 06:50:46 pm »
This is my home made plate shear I made.
It is cutting the 25mm wide x 3mm thick alloy seat connection plate.

Ji
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Ji Gantor

  • Guest
Re: Project Assembly
« Reply #106 on: May 24, 2009, 06:54:07 pm »
Shape the plate and drill two 5mm diameter holes.

Ji
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Ji Gantor

  • Guest
Re: Project Assembly
« Reply #107 on: May 24, 2009, 06:57:19 pm »
The front seat pan connection plate sits directly over a chassis tube so the bolts have to be countersunk into the alloy plate.

Ji
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Ji Gantor

  • Guest
Re: Project Assembly
« Reply #108 on: May 24, 2009, 06:59:53 pm »
Line up the plate onto the pan and drill the holes through the plastic pan.
Test fit.
The seat foam will be glued on top of these bolts so there will be no access so I have used nylocks and a drop of loctite.

Looking good.

Ji
« Last Edit: May 24, 2009, 07:02:42 pm by Ji Gantor »
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Ji Gantor

  • Guest
Re: Project Assembly
« Reply #109 on: May 24, 2009, 07:05:21 pm »
Because these bolts are unserviceable I used stainless steel.
Use a cut off wheel on a Dremel and shorten the bolt ends.

Ji
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Ji Gantor

  • Guest
Re: Project Assembly
« Reply #110 on: May 24, 2009, 07:07:07 pm »
Test fit the seat.

Looking good.

Ji
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Offline maicomc490t

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Re: Project Assembly
« Reply #111 on: May 24, 2009, 07:42:05 pm »
Hey Ji

Stuff going to work tomorrow - stay up all night and finish the bike - it is shaping up to be a beauty. It's great to see someone with such a passion for getting the job done right first time.

All very interesting and entertaining - we are expecting a full description of re-tiling the floor too you know !!!

All good

Dave Mac  ;)
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VAPOUR (AKA HYDRA / HYDRO / AQUA / WET) BLASTING AND GENERAL ENGINEERING 0416074750 (or) [email protected]

DUCATI Parts wanted esp 450 R/T and other early models inc V-twins

BULTACO M49 parts wanted

Ji Gantor

  • Guest
Re: Project Assembly
« Reply #112 on: May 24, 2009, 09:28:50 pm »
Hi maicomc490t,
Thanks for the kind words.

I have to work tomorrow or I will not be able to buy more S/S bolts for the project.
I also have to purchase a rubber strip that finishes the rear guard, hopefully I will be able to purchase both items tomorrow and may be I might get a chance to fit tomorrow night.

The two rear guards are not easy to fit as they are very 3D. I spent an hour today with little to show for it.

The floor tiles are those really big ones 600x600 porcelain. They are so heavy it is not funny. You use a suction cap to lay them on the adhesive. The floor has to be level within 1mm over 5 metres or you see the slope in the reflection. I am not looking forward to that job. But I am sure once it is done I will be happy. Happy I don't have to do it again.

Ji
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Ji Gantor

  • Guest
Re: Project Assembly
« Reply #113 on: May 25, 2009, 02:01:05 pm »
The air box strut is attached to a spacer and a rubber boot.
The steel spacer has a 9mm internal bore.
The bolt that came out of mine was an M6.
I cannot find this bolt in the parts manual so I will assume that it is an M6.

Ji
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Ji Gantor

  • Guest
Re: Project Assembly
« Reply #114 on: May 25, 2009, 02:03:35 pm »
I have to make an internal bore spacer for this bolt.
I have placed a 10mm diameter alloy bar into the lathe and deep drilled it.

Ji
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Ji Gantor

  • Guest
Re: Project Assembly
« Reply #115 on: May 25, 2009, 02:06:12 pm »
That is a 6mm diameter drill bit that has bored the bar out by 60mm.
The spacer only needs to be 55mm long but you have to allow for facing and parting.

Ji
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Ji Gantor

  • Guest
Re: Project Assembly
« Reply #116 on: May 25, 2009, 02:08:55 pm »
Turn the outside diameter down from 10mm to 9mm.
Remember to go past the length you need for facing and parting.

 
Ji
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Ji Gantor

  • Guest
Re: Project Assembly
« Reply #117 on: May 25, 2009, 02:11:39 pm »
Next we part the spacer off.
Face the ends so they are square and place a small chamfer on the leading edges so the spacer will push in easy.

Ji
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Ji Gantor

  • Guest
Re: Project Assembly
« Reply #118 on: May 25, 2009, 02:14:51 pm »
Test fit the new spacer.
Fits like a glove.

Ji
« Last Edit: May 25, 2009, 02:19:03 pm by Ji Gantor »
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Ji Gantor

  • Guest
Re: Project Assembly
« Reply #119 on: May 25, 2009, 02:16:42 pm »
Slide the new M6 bolt into the spacer and the job is done.
That was a great little lunch time job, oh well back to work.

Ji
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