I started this project back in 2015, there was a build thread on the old board but progress had been so slow I have not posted anything in a couple of years. I have been picking away and I am ready to post because I am actually almost finished. I hope to take it to Mark (M in SC) early this spring for tuning and actually be able to ride it this summer! I built the frame, swing arm, custom stem for R1 forks, front disc brake system, rear disc brake system, rear sets, tank, seat, tail section, pipes, silencers, manifolds, almost every single part of the bike. A huge thank you to Mark Hasse, Joe Spooner and Jim Hobbs, They all were a huge help and inspiration to helping me get this done.
Sorry for the way the pictures are posted, it's the only way I know how to do it..
Rear Sets and starting the pipes
Motor and finishing. Joe Spooner built the Engine, thanks Joe!!! :clap: :clap:
Brakes and almost done.
I did follow your project in 2015.
Work of Art!
Looks great, Danny! Glad you are getting around to finishing it. :clap: :whoop:
Looks fantastic!
Absolutely Beautiful!!
Can't wait for mine Danny! (Mike)
looks great Danny. :cheerleader: cant wait to see it in person.
amazing work.
Great work Danny, keep it up. Can't wait to see the final product.
Rob
:clap: :whoop:
very trick, I really appreciate custom builds
Rich
Looks great! :whoop: Nice to see progress from the old forum.
Looks great! It must be a deep sense of personal satisfaction too know you built nearly every damn bit of that bike! Well done.
Thank you everyone for your kind words! It has been a long time and a lot of work, I can't wait for it to be finished!
I was holding my breath on that one. Thanks for the renewed surge, love it.
Cheers, 50gary
What front wheel are you using Danny?
Looks lighter than a '76/'77 wheel and has the attachment capability for a 2nd disk.
I believe they are standard RD 400 wheels. They came from Mark, he can correct me if I'm wrong.
actually, xs400 wheels, 18" front with the dual disc drill pattern. (daytona style)
Hasd them on the lc for a long time, same exact wheels.
I am currently building a couple sets of Pipes for Jim so progress is slow but still getting a little done here and there. Manifolds are finished, (stainless with tube inside and out for sealing), they and the pipes are done and mounted for good. I also installed the turn signal lights, very small and mounted a little bit inconspicuous but I did not want them sticking out and facing front and back. They are insanely bright so I really don't think it will be an issue.
nice :cheerleader:
Danny, are you a welder, or maybe machinist by trade? Your workmanship is absolutely top shelf!
Yes, thank you. I owned my own company building race cars for over 20 years and I am now a manager for Pratt and Miller, Corvette race cars and military prototype vehicles. I don't get my hands dirty at work much anymore so building bikes and pipes fills the void when I have time. I met Mark (MinSC) along the way, working together about 8 years ago.
Superb craftsmanship, Danny!
I am a bit curious about your pipes. Are they of your own design, or something else?
Some years ago, there was talk of building replica Denco chambers for sale, is that still on the books?
I was stupid and impatient enough to buy a pair of Higgspeed SS chambers, but they were a big disappointment. In fact I am still using my beat up 1982/83 vintage Allspeeds instead.
And I still haven't got around to mounting the nice round tube swing arm you built for me, but hopefully will before summer arrives at 70 N.
I also have a small tip for you, and everybody else. Use flanged M8 nuts for the manifolds, either 10 mm hex or 12-point. That way there is plenty room for a socket or a ring spanner. Which a standard 13 mm hex M8 nut won't allow. Pretty sure ARP have some really nice 12 point nuts in M8, in some kind of special Hi-Temp material :)
The pipes are my own design, I combined a bunch of what I wanted and what I know and just went for it. We'll know soon how well they work!! Currently not for sale and more than likely will never be. I still don't build nearly enough of the Kawi pipes for Jim, so adding more to the line up probably isn't going to happen.
As far as the manifold nuts, one of the cars I built and raced many years ago, had M8 studs holding the exhaust on. The only nuts that ever worked were these copper lock nuts. And I'm talking about trying some very expensive jet nuts and all kinds... And, they have a 12mm head size so a 1/4" drive socket fits right on.
Quote from: 27 Cycles on February 22, 2020, 10:13:24 PM
The pipes are my own design, I combined a bunch of what I wanted and what I know and just went for it. We'll know soon how well they work!! Currently not for sale and more than likely will never be. I still don't build nearly enough of the Kawi pipes for Jim, so adding more to the line up probably isn't going to happen.
As far as the manifold nuts, one of the cars I built and raced many years ago, had M8 studs holding the exhaust on. The only nuts that ever worked were these copper lock nuts. And I'm talking about trying some very expensive jet nuts and all kinds... these copper lock nuts are all I use and will ever use and I promise you they work and never come loose. And, they have a 12mm head size so a 1/4" drive socket fits right on.
Gotcha!
I guess I need to calibrate my eye micrometer. Thought those nuts were 13 mm hex... Yes, copper nuts are good, on my Ducatis, the OEM M8 nuts are flanged copper nuts. Hex is 12 or smaller, so tool access is ok.
Sounds good!! Post some pics when you get the arm on!!
Quote from: 27 Cycles on February 22, 2020, 10:13:24 PM
As far as the manifold nuts, one of the cars I built and raced many years ago, had M8 studs holding the exhaust on. The only nuts that ever worked were these copper lock nuts. And I'm talking about trying some very expensive jet nuts and all kinds... And, they have a 12mm head size so a 1/4" drive socket fits right on.
I got a tech tip years ago from a fellow forum member on exhaust manifold nuts. VW used the correct id and threads with a thin wall, allowing you to easily put a wrench or socket to them. I've run them for years...
Mine:
(http://i239.photobucket.com/albums/ff131/aaaltered468/Yamaha%20Rebuild/5F2111AB-F8D6-41DF-AAA9-C072D7389426_2.jpg) (http://s239.photobucket.com/user/aaaltered468/media/Yamaha%20Rebuild/5F2111AB-F8D6-41DF-AAA9-C072D7389426_2.jpg.html)
One of many sources:
https://www.mooreparts.com/empi-43-6051-vw-bug-ghia-brass-exhaust-nut-8mm-1-25mm-11mm-hex-head-set-of-8/ (https://www.mooreparts.com/empi-43-6051-vw-bug-ghia-brass-exhaust-nut-8mm-1-25mm-11mm-hex-head-set-of-8/)
Such an awesome build, the engineering and execution are awesome.
Russ
Thank you very much Russ!
Got lights and blinkers!!! :whoop: :whoop: :celebrate:
:clap: :clap: :clap:
Another milestone reached :clap: :vroom: :whoop:
I am finished for now with the wiring. Once I run and ride the bike I will pull it all out and the loom will get some shrink tube and sheathing. The extra room on the mounting plate is where the ignition bits will get mounted.
very nice. is that a copper plate?
No, ha.. All of the aluminum pieces I made I am coating with Alodine. It always leaves a gold color, similar to gold anodize but different types of aluminum come out different shades of gold. That piece definitely soaked in some color. Look back at some of the finished side pictures and you will see my rear sets and brake caliper spacers are gold as well. Look closely at the crossover tube also, it came out really dark!
We used the alodine in the aircraft industry as a corrosion inhibitor, and to promote better primer adhesion. Nice use of the product. Again the build is incredible.
Russ
What is the purpose of the Alodine coating? It looks nice.
Alodine is a prep/primer for aluminum. I use it for a couple reasons. It is fairly inexpensive, I can do it myself and don't have to send parts out and, I like the finish color.
It also keeps aluminum in better shape over time than just leaving it bare.
Understood! Thanks for the info. It does look nice!
Small progress this weekend. Sprockets and chain, 520 conversion with sprockets from Economy Cycle!! Getting really close!!
thats one hell of a centerstand!
Looks great danny. :righteous:
Ha!! Had to build it on something!! You should see the sh$& show it takes to get the bike up and off of it! :dawg: :dawg: It has been great to build the bike up that high!!
I have decided I am going to build a center stand, that's actually up next!!!
I finished the center stand this afternoon. Mounting the front fender tomorrow and the bike is basically finished. Will purchase the HPI ignition soon.
:P
An outstanding build! Even if that great looking seat would kill my fat old a$$ in less than half an hour.......
The seat will get one more thin, soft layer of foam then a cover. But.. I figure I'm good for an hour. ;D ;D
If you have been racing bicycles or mountain/downhill bikes (which I think you may have), then your posterior should be more than able to cope :whistle:
Front fender is mounted and finished. When I get and install the ignition, the bike will be able to ride/test.
looks great. is it just one bolt on each side? :umm:
Yes, I was a little worried too and was going to make a second bolt somehow/where.. the fender is actually quite thick and so are the mounts. It's strong as hell and I don't see an issue. It's actually a Harley fender and no matter how thick you think it is... it's thicker..😁. You would hate it😀
A steel front fender? From H-D? That must be the latest in "wheelie control" 8)
My plan is to ride the bike for quite a while before paint, if any problems should arise and I'm sure they will, I will be able to fix/change! If there was another mounting area for the fender I would certainly use it, there just isn't anywhere for another tab without tapping into the fork bottoms and I just really don't want to do that unless totally necessary, so for now I feel comfortable with how it is.
A year or two ago landspeed racing, a guy put a front fender on his bike (a harley) and secured it but only in a couple spots, as you speed up the tires "grow" they get taller from the centrifugal force, the tire caught the fender, pulled it around under the tire, the tire became a skate and it threw him down at speed. If your racing at least take a little extra time to design your mounting points. food for thought.. Ed
Quote from: EE on March 23, 2020, 02:30:08 PM
A year or two ago landspeed racing, a guy put a front fender on his bike (a harley) and secured it but only in a couple spots, as you speed up the tires "grow" they get taller from the centrifugal force, the tire caught the fender, pulled it around under the tire, the tire became a skate and it threw him down at speed. If your racing at least take a little extra time to design your mounting points. food for thought.. Ed
Wow, that's scary!
Work is basically done. Needs paint and ignition to run, hopefully both happening this month! I built a center stand and a few other small detail parts to really finish it up.
Very nice, has a from the future look.
Quote from: RDFL on April 01, 2020, 09:41:31 PM
Very nice, has a from the future look.
Almost looks like it's out of Mad Max
I like it! Doesn't need paint, looks good raw! :metal:
Quote from: SoCal250 on April 01, 2020, 11:18:10 PM
I like it! Doesn't need paint, looks good raw! :metal:
Yeah I like the raw look too.
Quote from: Jspooner on April 01, 2020, 11:24:33 PM
Quote from: SoCal250 on April 01, 2020, 11:18:10 PM
I like it! Doesn't need paint, looks good raw! :metal:
Yeah I like the raw look too.
It looks great now, and maybe even better with a suitable paint job :toot:
But besides the great looks, I am really curious about the weight, ready to ride (i.e full tank of fuel) And also about power and power band :whoop:
id like to see where the weight is myself. I -know- mines at 243 with almost 2 gallons of fuel ready to ride. since its -basically- the same, id like to see where danny landed. Im going to guess 8-10 lbs heavier. (mags, inverted forks, etc)
looks great danny.
you know... they make a suitable paint....
(clear)
Love it. Great job. :celebrate:
Maybe, ? paint the tank only, same color as wheels, :vroom:
I really dig it!
Quote from: economan on April 02, 2020, 07:38:22 AM
Love it. Great job. :celebrate:
Maybe, ? paint the tank only, same color as wheels, :vroom:
Painting the tank only would ruin it in my opinion, I think it's all or none when doing a build like this.
Thanks guys! I also really like the raw look but I am going to paint the whole thing. My Dads old race boat is the inspiration for the paint job, also where the 27 comes from. The paint job will be very subtle and very 70's!!
Mark, I will be surprised if it's not at least 10 lbs. heavier than yours.
Well, I fired it up tonight, started on the second kick. I rode it around the block a little, still need to verify timing and a few other odds and ends. I don't know how to post video here, maybe Mark or Joe can if they have time. Thanks to anyone who helped!! :whoop:
I tried Danny. I don't know how either 😩. Maybe mark will do it.
you need to upload it to you tube and share it, or another hosting servcie.
i'll try to get it uploaded tomorrow.
btw, good work danny, sounds good. :metal:
Quote from: 27 Cycles on March 22, 2020, 08:19:36 PM
Yes, I was a little worried too and was going to make a second bolt somehow/where.. the fender is actually quite thick and so are the mounts. It's strong as hell and I don't see an issue. It's actually a Harley fender and no matter how thick you think it is... it's thicker..😁. You would hate it😀
The fender is steel, I would weld some flat stops to the fender brackets so the bolts can not rotate. This would capture the fender in position and the bolts
would only hold the fender on.
Cheers, 50gary
Well, 5 years and 3 months since I started and it's finally done.. it was worth the wait!!!!!
Mark, if you get a chance, please post the video, I'm never able to make it work. 😄
:clap: that is so cool.
here's the video. sounds pretty damn good. will check out in person this week at deal gap I hope.
Wow what an amazing looking bike. I really dig the tail, just everything about it. The shape and how the tail light fits in. Different than anything else. Also digging the centerstand. seems like a better solution to a side stand plus it gets the back wheel off the ground. Awesome bike, very slick! :clap:
I'm not sure what's more impressive, the bike or actually getting a potato to film a video. :dawg:
Nice!
Very different build, looks cool.
Well done.
I think my favorite part is the tail section, has a unique look to it. Well done indeed. Did you ever get some weight numbers, also front rear wt. distribution?
Cheers, 50gary
some pics i took from gap, and i got to ride it. handles great. seat isnt nearly as bad as i expected but man its cramped for me. danny seems to be OK with it, and thats all that matters. :patriot: :cheerleader: :cheerleader: :cheerleader:
(http://www.2strokeworld.net/wp-content/uploads/gap-all/gap-2020/gap-2020_2_2.jpg)
(http://www.2strokeworld.net/wp-content/uploads/gap-all/gap-2020/gap-2020_2_5-e1598029910988.jpg)
(http://www.2strokeworld.net/wp-content/uploads/gap-all/gap-2020/gap-2020_2_3.jpg)
(http://www.2strokeworld.net/wp-content/uploads/gap-all/gap-2020/gap-2020_2_7-e1598029982203.jpg)
(http://www.2strokeworld.net/wp-content/uploads/gap-all/gap-2020/gap-2020_2_8.jpg)
Nice pics :nana: That bikes just oozes trick racing custom machine. :metal:
Bummed I didn't get to see this bike, been hearing a lot about it.
(https://uploads.tapatalk-cdn.com/20200821/849095bc9fb4d27b7574bfe1a1cb5cde.jpg)
:righteous:
Thanks Guys, I appreciate all the kind words about the bike. Very nice to meet the guys and gals at the Gap and finally put some faces to names. Mark, thanks as always, I had a blast and it was totally worth the trip even though it was short lived.
The bike still has a ways to go, the seat isn't finished, it needs some more/softer padding and a cover, it's coming, 😎. I spent a lot of time on my riding position, it is how I like it, I like my knees up around the tank as I grab very hard with my knees and legs, I'm also a pretty small sized guy. I'm going to ride it and enjoy the hell out of it until winter and then I can tune and tweek... unfortunately here in Michigan I will have about 5-7 months..😎😎😎.
That thing is all sorts of cool! :nana: Awesome job! :bacon:
yea looks kinda mean!
:taz:
well done again, winter is certainly the time for tweaking and improving
Wow that looks so cool! Yeah in MI we have to wait it out for the long haul haha. Will the motor get paint?