Ascot Forum

First Generation Ascots => The Thumper Years: Modified To Full Customs => Topic started by: kansloos161 on August 19, 2013, 07:26:35 AM

Title: Dutch FT project
Post by: kansloos161 on August 19, 2013, 07:26:35 AM
Hi guys

As a great fan of the yahoo group I had to check this forum out as well. I do think a forum is better for ongoing threads like projects.

My name is Paul a 27 year old mechanical engineering student from The Hague in The Netherlands.
I've been riding motorcycles since I was 18 and they were getting faster and faster, last year however I bought a ft500 as a commuters bike to save my zx6r a little.

I've completely fallen for the little thumper and even take it out on the fun trips in the weekends instead of my zx.
As a fan of fast and good handling bikes I do want to improve the FT's suspension a bit and also change the looks a bit more to my liking.

Enough about me, it's FT time.
I've bought my yellow '82 as a non runner. It had been standing for about a year because the PO had trouble starting it. After the purchase I replaced the battery, did the starter maintenance as described at the yahoo.groups and did a full fluids and spark plug change. It immediately purred like a kitty.
I did have to replace the starter spring with a homemade ballpoint one but it functions perfectly.
How the Ft looked when I bought it:
(https://s17.postimg.org/sviylwl73/20121221_131951.jpg)
Ofcourse this is a project thread so what am I going to do with it.
I really wanted to change the front suspension, since I have a spare CBR900rr front end lying around, this is going in!
The steering stem is exactly the same as the FT's so no adjustment needed there.
Here is a picture of an original FT fork compared to the CBR:
(https://s13.postimg.org/a7g5dg5if/20130819_163317.jpg)
The front axle is 20mm thick while the FT's is only 15mm.
At first I plan to run the cbr forks with the ft wheel so I ordered some new wheel bearings for the FT wheel with the correct axle diameter. Later I plan to install spoked wheels.
I then made some spacers to centre the wheel correctly into the forks.

I really like the upright position on the FT so I want to keep the original handlebars, this means adepting the CBR top yoke, I've bought a couple of risers from a salvage yard to mount to the CBR yoke.
I've had to shorten the stuts of the risers and rethread them because they were really long and had a strange non-metric thread.

Ofcourse I strenghtened the original yoke with some thick steel plates.

This is were I'm at so far, as soon as I have time I'll try a mock up to check the ground clearance and see what kind of spacer or adjustment plate I have to make to mount the front brake caliper.

It's in!
(https://s2.postimg.org/e8hpplm21/20130820_154934.jpg)
I've had a couple of struggles along the way, for instance getting the original bearings out of the FT wheel was ridiculously hard.
(https://s15.postimg.org/oy1llgoaj/20130820_173646.jpg)
As you can see the front brake caliper isn't mounted to the forks yet, I haven't figured out how to do this just yet and if spacers on the calipers or the wheels would be a better option. I'm also thinking of changing to a 4 or 6 piston caliper. If I do that I don't have to bother with the stupid sliding bracket of the ft.

I took it for a spin around my block, the suspension is a bit to hard at the moment but I didn't have immediate problems with the ground clearance. of course I haven't ridden it hard or took it round a real turn but we'll see how it works out.

I've bought a BMW F650 rear wheel to fit in the bike as well.
And I bought a CX500 tank, a quick mock-up of how that would look on the bike:

I'll keep updating this first post.
Any comments, both on my project or faults in my English are welcome :D

Has been a bit quiet here sorry. I've been crazy busy with an internship and will be busy for the rest of the year probably.
Did make some time to fabricate a bracket for my brake caliper. The cb spoked wheel will have to wait till I have more time.
A quick picture of the (quick) bracket I bodged
(http://imageshack.com/scaled/640x480/849/mslb.jpg)
Next up is new seals for the forks

Got both my wheels now. so eventually these bad boys will go in the ft
(http://img43.imageshack.us/img43/7885/mwus.jpg)

update 4/10

Got the fireblade forks out of the bike to see if I could fit the spoked wheel and bigger brakes.

I had to get new bearings for the wheel and fabricate some new spacers.
Right now the wheel is perfectly centered between the fork legs. However the brake faces on the hub seem not to be completely centered.
Any thoughts on this?

well, time for pictures I guess  ;D
(http://www.picturehost.eu/uploads/a7da16a12d74738a475393102c602a68_20150410_150251.jpg)
the wheel centered with the new spacers
(http://www.picturehost.eu/uploads/42e19a08327bcf364d2e8958c7bdded4_20150410_150302.jpg)
nicely centered
(http://www.picturehost.eu/uploads/5057ad785255fae1c31b48e7052f057a_20150410_151133.jpg)
with disks in the forks
(http://www.picturehost.eu/uploads/cda3ffe9130edb8193aacf25e527053a_20150410_151155.jpg)
lookin good


cheers Paul
Title: Re: Dutch FT project
Post by: J6G1Z on August 19, 2013, 07:48:55 AM
Welcome to the board Paul. Sounds like you have a great project on your hands. I've heard that other Countries received Ascots in yellow & blue. Here in the USA we only had a choice between black & red. I saw a picture of a Canadian Ascot that had a dual disk front brake that was supposed to be original equipment. It would be interesting to learn of the various configurations & colors that different Countries received.

I'm looking forward to hearing more about your bike & seeing some pics.

J.
Title: Re: Dutch FT project
Post by: kansloos161 on August 19, 2013, 08:22:56 AM
Hi J.

Most of our Ascots are red or black as well, mine is the only yellow one I've seen so far. No blue ones as far as I know.
The color also gave it its current nickname, the banana.
Dual front disks on an Ascot is something we do not have here. The front wheel can be easily fitted with another disk but the forks do not have another mounting point.
I'm thinking of installing dual disks on mine since I have a spare disk and the CBR forks do have the mounts.

Cheers paul
Title: Re: Dutch FT project
Post by: kansloos161 on August 20, 2013, 10:25:05 AM
The fork is in!
Title: Re: Dutch FT project
Post by: J6G1Z on August 20, 2013, 02:23:29 PM
The fork is in!

Cool!

It looks like you have some rough working conditions. Are you working outside on the street? I like your flower pot/motorcycle stand. ;D  Dedication & motivation will get you through it. Looking forward to hearing a more detailed ride report.

Good luck
J.
Title: Re: Dutch FT project
Post by: mike on August 21, 2013, 05:54:08 AM
Ah... I live just round the corner from you and I've got an Ft500 on-going project too...
Title: Re: Dutch FT project
Post by: mike on August 21, 2013, 06:01:53 AM
heres another pic of mine
Title: Re: Dutch FT project
Post by: mike on August 21, 2013, 06:20:52 AM
Since buying it for 350 a year ago with just 20000 on the clock I have changed the cam chain, fork seals, steering head bearings. Cosmetically, I fitted a bottom mount bates style headlamp... fits very easily onto the steering lock lug once the steering lock is removed. I removed a big chunk of the rear subframe and fitted a short rear mudguard with BSA rear light and sawed off the back of the original saddle and stretched the cover back over which I think looks surprisingly good. The handlebars were also replaced as were the clocks for little stainless steel items found on ebay. New indicators fitted nicely onto the original rear bodywork mouting lugs. I too ride it more often now than my other bikes... it's a great little around town bike and perfect for short blasts up to the beach here in The Hague!
Title: Re: Dutch FT project
Post by: kansloos161 on September 02, 2013, 01:52:26 PM
Hi Mike,

great to see another Dutch FT'er here, did you read my post on motor-forum or are you a regular at the yahoo groups as well. If you need any spare parts let me know, I have about 2 whole ft's in spares.

I think I've seen your bike once or twice on the Elandstraat (right around my corner).
I like what you've done with it so far, more plans for the future?

For me the top priority now is to get the front brake reassembled. The distance between the original caliper mounts on the CBR forks and the brake disc is really big. I don't know if I should put a bracket between the caliper and the fork mounts or a (big) spacer between the wheel and the disc. I've also scored a couple of 4 cup calipers which I would rather install than making a bracket for the shitty original caliper. Unfortunately I do not have a lot of time and just as J pointed out I'm working in the street.

Cheers pau
Title: Re: Dutch FT project
Post by: mike on September 03, 2013, 06:13:53 AM
yes that would be me popping in Albert Schwein... I have some LEDs that I'd like to mount as odiot lights and wouldn't mind getting rid of side panels etc... Are you going to this Retro Wheels Festival in Scheveningen on 15/9?
Title: Re: Dutch FT project
Post by: kansloos161 on September 07, 2013, 02:46:50 AM
wow that is right around the corner, I did have some other plans which I might have to cancel now  ;)
Title: Re: Dutch FT project
Post by: mike on September 09, 2013, 07:48:47 AM
I should be there around 2.30 ish... not sure whether to take the triumph or the ft??? decisions decisions!
Title: Re: Dutch FT project
Post by: kansloos161 on November 11, 2013, 12:55:44 PM
I've been crazy busy and unfortunately enough not with the FT.
Did make a bracket for my front brake though so its rideable.

cheers paul

ps. Mike, I think I saw you passing by in september when you were on your way to that meeting. I was unfortunately not able to make it.
Title: Re: Dutch FT project
Post by: kansloos161 on December 09, 2013, 12:52:16 PM
bought some new wire wheels for the ft.
Don't know when ill have the time to install them but they will look nice.
The front hub has the same spacing as a lot of semi modern sportsbikes so I'm actually thinking of installing dubble big brakes!
Title: Re: Dutch FT project
Post by: Whata on January 27, 2014, 01:26:21 PM
Hey chanceless, werktuigbouw ftw  ;)

Nice work going on there  :)
I really like what you've done with the front end.
Though I'm curious how it will affect the bikes handling, as the shorter fork changes the rake angle.
If it turns out well, I might even try it myself   :)

Keep up the good stuff !

Wouter
Title: Re: Dutch FT project
Post by: kansloos161 on February 08, 2014, 06:49:03 AM
thanks wouter,

defenitely werktuigbouw ftw! almost done myself now so ill be calling myself in a couple of months :D
the ground clearence with the cbr forks is actually quite good. no complaints from me. I've still got the 19 inch front tire wich is huge, that helps a lot for ground clearance.
unfortunately my ignition switch developed a little issues so im looking for a new one or a way to mend it.
Title: Re: Dutch FT project
Post by: J6G1Z on February 08, 2014, 07:12:53 AM
What is the ignition switch doing, or not doing?

I've repaired one before & had to replace one before. The one that I had to replace was broken in half & & the top half was missing. I ended up finding another ignition switch, gas cap lock & a key on eBay for not a lot of money. Think it was in the $30 range. I just unplugged the old switch & plugged in the newer one & all was well.

On the one that I repaired. It wasn't making electrical contact when in the ON position. I took it apart & lightly cleaned the small brass contacts with some extra fine sandpaper & contact cleaner spray. I then took an ice pick & carefully made several indentations in each brass contact. This raised some of the material around the indents. I then lubed up each contact with a dab of dielectric grease & re-assembled the unit. It worked fine after that & is still working.

Good luck
J.
Title: Re: Dutch FT project
Post by: kansloos161 on February 13, 2014, 01:29:03 PM
i have excatly the same problem as you describe, no contact when the ignition switch is in the 'on'postion.
Traced it down to a faulty connection for the red wire, can't open the ignition switch though. Maybe I haven't tried hard enough ;)
how did you get it apart?
i've allready ordered a new one for 30 euros including a gas cap lock but having a (working) spare cant be bad.

cheers.
Title: Re: Dutch FT project
Post by: J6G1Z on February 13, 2014, 04:22:56 PM
I can't remember exactly which bike I repaired the switch on. I seem to recall bending a few tangs & the switch seperated into several sections.

There is a fusible link hidden in a plastic box by the battery that I recently discovered on my project bike. I haven't looked at the wiring diagram to determine where in the scheme that it falls, but you might want to check that out also.

Good luck
J.
Title: Re: Dutch FT project
Post by: kansloos161 on February 14, 2014, 09:12:55 AM
you mean That fusible link in the starter relay housing? That can cause problems aswell, Im well aware of that.
I've replaced mine with a normal car fuse.

I've removed the complete ignition switch to measure it and thats when I discovered the problem so it can't be anything else.

I'll try to get it open, its already busted so it can't get any worse :D
Title: Re: Dutch FT project
Post by: colosseumrat on February 20, 2014, 08:00:15 AM
Hi kansloos161,

I'm working on my custom FT as well. I was wondering what's the source of those nice spoke wheels that you intend to install.  :D :D

Cheers
Title: Re: Dutch FT project
Post by: hondapartsman on February 21, 2014, 02:46:37 AM
You have my greatest respect young sir, I at least have a small back garden in which I can park ( although access is a little difficult) and work on my bikes on a hard if slightly sloped standing. I'd not want to do all you're doing, but then maybe you have youth on your side. My older bones find working on bikes on ground level to be a bit of a strain these days, I dream of a garage, or even a big shed like I used to have. I must talk to my friend who owns a workshop and see if he'll be happy for me to do work there, sometimes. Anyway, I'll be watching to see how this goes. All power to you.
Title: Re: Dutch FT project
Post by: kansloos161 on February 26, 2014, 07:18:47 AM
@ hondapartsman
Thanks, so far I manage with the space in front of my house, I would really like to have a shed or back yard too, would really speed up the whole process and the fun in doing it.

@colosseumrat
The front spoked wheel is from a Yamaha xs650. I do not know if its the original rim. The front hub is great, it gives the oppertunity to install dual brakes and the hole pattern is very common.
The rear wheel is from a BMW r650 funduro. The BMW uses it the other way around (sprocket on the right hand side) but since the tire has to be replaced anyway that shouldn't be a problem
Title: Re: Dutch FT project
Post by: colosseumrat on March 03, 2014, 02:01:49 AM
@colosseumrat
The front spoked wheel is from a Yamaha xs650. I do not know if its the original rim. The front hub is great, it gives the oppertunity to install dual brakes and the hole pattern is very common.
The rear wheel is from a BMW r650 funduro. The BMW uses it the other way around (sprocket on the right hand side) but since the tire has to be replaced anyway that shouldn't be a problem

Thanks a million for the sharing. I wish you good luck and I hope to see you around in NL or at Rust swap meet, in May in Amsterdam.
I'm based in Amsterdam.

Cheerio
Title: Re: Dutch FT project
Post by: Whata on March 09, 2014, 01:46:43 PM
Hey cool I'm going to the rusty swap meet aswell   :)
Title: Re: Dutch FT project
Post by: colosseumrat on March 18, 2014, 04:55:19 AM
Hey cool I'm going to the rusty swap meet aswell   :)

Than let's meet up! :D
Title: Re: Dutch FT project
Post by: Whata on March 28, 2014, 12:24:21 PM
Yes sure thing  :)

I'll be coming on my black V-twin Ascot and a friend of mine on a Yamaha XS360, who has a pretty thick black beard for his age (if he doesn't shave it  ;) ).. for recognition
Title: Re: Dutch FT project
Post by: kansloos161 on August 19, 2014, 07:47:33 AM
Well I haven't replied in quite some time but I've still got my ascot.

I'll try to work on it this week again, unfortunately the work will be limited to getting it running again since it wont start.
I suspect a faulty cdi wire or something like that. Ill get my multi meter out and find out tomorrow.

I plan to change my steering stem bearings to conical ones and to do a valve clearance check aswell, maybe also do the airfilter mod and change the jetting.
Hopefully ill get it running by the end of the week.
When I have some more time (and money) I want to start work on the spoked wheels, I have want to buy new brake discs and calipers for this so it will have to wait a bit.
Title: Re: Dutch FT project
Post by: J6G1Z on August 19, 2014, 08:38:43 AM
Hang in there. Those long term projects are often forgotten. Just keep plugging along at your own pace & post up any progress that you make. Build posts are very motivational.

Make sure you perform that jetting change. Nothing gives you a better bang for your money than replacing those two jets. Might as well pick up a 16 tooth countershaft sprocket to take advantage of the newly released power after re-jetting.

Good luck
J.
Title: Re: Dutch FT project
Post by: plasticadam on August 29, 2014, 02:53:05 AM
I completely support J's comment - hang in there kansloos. My project started in December - supposed to be finished by May - unlikely to complete before October now. And I have the luxury of an overcrowded garage! Sometimes it seems that every time you get one thing working again it throws up a fault in another.
Worst thing is that this is all for the wife - and she wants her new bike ;D
Title: Re: Dutch FT project
Post by: kansloos161 on October 23, 2014, 01:07:10 PM
Although my work is taking up most of my time, it does have it's benefits.
I have a buck or two to spend on my ascot!
I already had the xs650 spoked wheel which I am planning to install, but I didn't have any nice brakes yet...

Tada:
(http://s29.postimg.org/46r7bjstj/2014_10_22_22_44_29.jpg)

These are dual yamaha fzr1000 320mm brakediscs that fit the hub perfectly.
I've also ordered a set of nice ducati multistrada brembo brake calipers to complete the setup.
Now I just have to find time to install all my goodies...
Title: Re: Dutch FT project
Post by: J6G1Z on October 23, 2014, 01:14:55 PM
Very nice!!!

That will look sweet on the front.

J.
Title: Re: Dutch FT project
Post by: Luke on October 23, 2014, 01:25:34 PM
x2! That looks sweet!
Title: Re: Dutch FT project
Post by: kansloos161 on October 24, 2014, 04:10:37 AM
indeed 2 discs :D

coupled to these calipers:
(http://s14.postimg.org/hc9a9ryvl/2014_10_24_12_49_25.jpg)
Title: Re: Dutch FT project
Post by: J6G1Z on October 24, 2014, 06:06:18 AM
Ooowie!!! Those are sexy!

Now you need one of these: http://www.brembo.com/en/bike/Racing/Racing/Pages/Master-Cylinders.aspx  LOL!
Actually I used the front master from a Ducati Monster on my FT/CBR hybrid. It has the "coffin" style of box shaped fluid reservoir & even has a mirror mount in the correct location with the correct size/thread for the Ascot mirrors.

You will definitely stop just fine with just one of those disk brake assemblies on the front. The dual disk is just icing on the cake.

J.
Title: Re: Dutch FT project
Post by: kansloos161 on October 24, 2014, 07:04:46 AM
Hahaha i'm sticking with the spare cbr900rr master cylinder that I have. although the radial brembo one is a sure bit of bike p*rn.

One disc would defenitely be powerfull enough but I like the looks of the double disc :)
Title: Re: Dutch FT project
Post by: J6G1Z on October 24, 2014, 09:11:27 AM
Dual disks look more balanced.

J.
Title: Re: Dutch FT project
Post by: kansloos161 on November 02, 2014, 06:07:48 AM
just a quick mock-up of the discs and calipers on the front wheel.

(http://s27.postimg.org/9aip9l7ab/2014_11_02_14_33_02.jpg)
(http://s29.postimg.org/jz3oeuzaf/2014_11_02_14_33_13.jpg)

me likey!
Title: Re: Dutch FT project
Post by: J6G1Z on November 02, 2014, 06:24:01 AM
Those Brembo calipers are pure sex!

If they are as an impressive improvement as one of their master cylinders, you will be very happy every time you use them.


J.
Title: Re: Dutch FT project
Post by: AndreLindholm on March 21, 2015, 07:59:40 AM
Those wheels will look great on the bike! Have you mounted them yet?
Title: Re: Dutch FT project
Post by: WTF304 on March 21, 2015, 06:37:52 PM
That's some real beauty.... keep your chin up, take your time .... can't rush perfection.
Title: Re: Dutch FT project
Post by: Slyphon on March 24, 2015, 02:32:04 PM
Is the CX500 tank a direct fit? I purchased a CB750 Super Sport tank last summer, but the tunnel is a slightly different shape and narrower. It will take a bit of work to get it on there.
Title: Re: Dutch FT project
Post by: kansloos161 on March 31, 2015, 09:41:20 AM
haven't been online for a while and haven't done anything to the bike unfortunately.
I've been to busy with work and I don't have a garage to work in. (I'm really done with working on the street so I think I'll have to start looking for one)

Regarding your questions:
@J6G1Z: I have a fireblade master cilinder and lever so will fit that with the ducati brakes... she will probably stop on a dime than.

@AndreLindholm: No I haven't gotten round to fitting the wheels yet. If I start with the fitting 'll  defenitily post every progress here.

@WTF304: thanks. Really want to take more time to work on the bike though, there is rushing and there is no progress....

@Slyphon: the tank is not a direct fit. The tunnel of the cx tank is way wider than the ascots. This is an easy fix by replacing the rubber pieces that hold the tank with wider ones or something like that.

thanks for posting guys.
Helps me to remember that I should start working on the bike again.

regards,
Paul
Title: Re: Dutch FT project
Post by: WTF304 on March 31, 2015, 11:47:31 AM
You've got time and money in it, it would be nice to enjoy thE fruits of your labor. Should be a real head turner when she's all done.

Just keep picking at it
Title: Re: Dutch FT project
Post by: kansloos161 on April 10, 2015, 06:31:22 AM
thanks guys,

The replies on this topic made me realise I had to work on the bike again.
Got the fireblade forks out of the bike to see if I could fit the spoked wheel and bigger brakes.

I had to get new bearings for the wheel and fabricate some new spacers.
Right now the wheel is perfectly centered between the fork legs. However the brake faces on the hub seem not to be completely centered.
Any thoughts on this?

well, time for pictures I guess  ;D
(http://www.picturehost.eu/uploads/a7da16a12d74738a475393102c602a68_20150410_150251.jpg)
the wheel centered with the new spacers
(http://www.picturehost.eu/uploads/42e19a08327bcf364d2e8958c7bdded4_20150410_150302.jpg)
nicely centered
(http://www.picturehost.eu/uploads/5057ad785255fae1c31b48e7052f057a_20150410_151133.jpg)
with disks in the forks
(http://www.picturehost.eu/uploads/cda3ffe9130edb8193aacf25e527053a_20150410_151155.jpg)
lookin good

regards Paul
Title: Re: Dutch FT project
Post by: Lefty on April 11, 2015, 02:56:54 PM
WOW, that's cool as hell!
Title: Re: Dutch FT project
Post by: kansloos161 on April 16, 2015, 04:47:05 AM
just bought a set of cb700sc rear shocks as was recommended in the ' race bike' thread.

Title: Re: Dutch FT project
Post by: WTF304 on April 16, 2015, 07:40:54 PM
Looks like you're bike is going to have a nice balance of old and new styling. That setup looks real good, what forks are those ?  .... i had thoughts about finding a nighthawk front end to use for dual disc brakes, the forks are the same diameter and the front wheel is the same style .... forgot what year it was the one i was looking at.
Title: Re: Dutch FT project
Post by: kansloos161 on April 17, 2015, 01:13:57 AM
Thanks,

The front forks are from a CBR900RR Fireblade from 1996. So they are more than capable of keeping the little ascot on the road.

regards Paul
Title: Re: Dutch FT project
Post by: kansloos161 on April 18, 2015, 10:17:49 AM
Bought a new headlight today.. its biiiiig!!!!  8)
(http://s10.postimg.org/8t8d07zkp/20150418_190409.jpg)
Title: Re: Dutch FT project
Post by: ex119x on April 18, 2015, 12:48:58 PM
just bought a set of cb700sc rear shocks as was recommended in the ' race bike' thread.
I thnk you will like the shocks. I have mine set on the next to highest spring preload and middle on the damping. That is for race use and I weigh about 120 K. If you are lighter and riding on the street I would start on the softest settings for damping and preload.
Title: Re: Dutch FT project
Post by: kansloos161 on April 20, 2015, 01:39:25 PM
just got these bad boys in the mail
(http://s9.postimg.org/6e53g50in/P4160236.jpg)
Title: Re: Dutch FT project
Post by: WTF304 on April 20, 2015, 10:41:58 PM
That's a monster light .... what that come off of ? .... might look real good with an HID ...
Title: Re: Dutch FT project
Post by: kansloos161 on April 20, 2015, 11:53:04 PM
Its definitely BIG! it's quite old too.
It says made in Japan on the glass. if I were to guess I would say it comes from a suzuki gsx1100e or something similar.
Title: Re: Dutch FT project
Post by: kansloos161 on May 06, 2015, 12:02:47 AM
Changed the fork seals of the fireblade forks yesterday.
(http://s17.postimg.org/l3qy4ioxr/20150505_142546.jpg)
(http://s22.postimg.org/c22ceiexd/20150505_155026.jpg)
(http://s23.postimg.org/6rgioljwr/20150505_184326.jpg)

next up are the stem bearings and fabrication of spacers and bushings to fit the brakes to the wire wheel.
Title: Re: Dutch FT project
Post by: kansloos161 on May 12, 2015, 01:30:36 AM
altered my top and bottom yoke today.
Got rid of the steering stops on the bottom yoke and the hole for the ignition switch in the top yoke.
Ill paint them later today.
(http://s24.postimg.org/5zqprwwad/20150511_184946.jpg)
Title: Re: Dutch FT project
Post by: triguyracer on May 12, 2015, 11:03:38 AM
Question about the cb700sc shocks been looking on ebay and see there are quite a few for sale,most list them as 15 inches eyelet to eyelet.My stock ones are 13 inches,am I missing something when I look at ones to buy,did they use diff ones on some models that where shorter or longer ?
Title: Re: Dutch FT project
Post by: kansloos161 on May 12, 2015, 11:12:15 AM
they are longer than the stock ones, don't know exactly how long. Ill measure them later.

I've finished painting the yokes!
(http://s16.postimg.org/kswgod485/20150512_184336.jpg)

(http://s21.postimg.org/4vjhknm3b/20150512_184400.jpg)
Title: Re: Dutch FT project
Post by: WTF304 on May 12, 2015, 12:14:39 PM
It is possible..... the one's i put on mine were from a CB550 nighthawk same year as my FT .... fit fine just had to swap 1 bushing from the FT stockers to the CB's. If anything those should fit it and if there was any difference between the CB's it would have been due to position and weight, only sense i can make from that. Had to but some M16 washers from homedepot cause the width of the eye's were shorter to space the tops like they should be but the bottom eye's were exact.
Title: Re: Dutch FT project
Post by: ex119x on May 12, 2015, 11:07:46 PM
The shocks from the 700 Nighthawk are substantially longer. The point is to change the steering head angle. Stock it is raked out too far and gives lazy handling. By raising the rear end and going to a slightly smaller front wheel you are rotating the entire bike and decreasing the steering head angle to a more sportbike like angle. I haven't measured mine, but I should. That in combination with the straight in line forks from a CBR instead of the stock leading axle forks makes the front end very responsive. I like a steering damper at that point because the bike can feel a little twitchy at times.
Title: Re: Dutch FT project
Post by: kansloos161 on May 15, 2015, 03:20:13 AM
just got word from the guy who made my spacers!
(http://s22.postimg.org/h6brbvqht/DSC_2584.jpg)
he also made my day :D

the shocks are 37 cm long (center eye to center eye) so about 14,6 inches

this was a rough measurement though.

looking forward to your topic patrick4wd!
Title: Re: Dutch FT project
Post by: kansloos161 on May 19, 2015, 09:14:50 AM
i've test fitted the spacers and bushings.
Looks good!:
(http://s21.postimg.org/3y1q021tj/20150519_174753.jpg)
(http://s9.postimg.org/besbmvf1r/20150519_174805.jpg)

ofcourse I couldn't resist to put the wheel in the front forks.
(http://s3.postimg.org/wi4elov1f/20150519_175642.jpg)
(http://s16.postimg.org/v1933yv1h/20150519_175703.jpg)

Fortunately the caliper runs free from the spokes (forgot to measure)
One of the claws hits the claw mount on the forks while the other one fits behind it. I can try to solve this by making the right bushing a bit smaller or I'll solve it with the adapter plates for the claws which I'll have to make anyway.

Any tips on cleaning a spoked wheel? tried with WD40 and some sanding linnen but that doesn't sort the wanted effect.
Title: Re: Dutch FT project
Post by: thumb on May 19, 2015, 09:42:53 AM
spent quite a few hours over the years cleaning rusty spokes and lacquering them ,only for them to rust up with the year again
Have a look at these on the Evil bay search "spoke skins"
Title: Re: Dutch FT project
Post by: triguyracer on May 20, 2015, 09:28:27 AM
steal wool works good,I have 3 of the xs650 wheels and forks with alloy triple clamps that I use on my vintage dirt trackers.A drill with a fine wire wheel works good also,1000 or 2000 grit sandpaper works, a bit of grunt work but will work well 
Title: Re: Dutch FT project
Post by: kansloos161 on August 17, 2015, 05:43:20 AM
I've made some time this weekend to work on the little thumper:

First I swapped the original head bearings with conical ones
(http://s10.postimg.org/wje0t8ma1/IMG_20150814_155224.jpg)
(http://s1.postimg.org/yctzodcgf/IMG_20150814_164331.jpg)

The conical head bearings for a FT fit nicely on the Fireblade stem. It's incredible how easy a set fireblade forks can be fitted this way.

Together with the fireblade forks, the XS650 wheel, FZR1000 discs and Multistrada calipers my frankenstein bike looks like this:
(http://s14.postimg.org/5twexkp0h/IMG_20150814_170452.jpg)
(http://s10.postimg.org/u7b2srg09/IMG_20150814_170624.jpg)

I have to fabricate some adapters for the calipers to fit to the forks.
(http://s30.postimg.org/8czkesjgx/IMG_20150814_171327.jpg)

The next day I test-fitted the BMW F650 rear wheel
(http://s16.postimg.org/gsr0iz5g5/IMG_20150816_143706.jpg)
(http://s3.postimg.org/eqqgi9kj7/IMG_20150816_144522.jpg)

I've also removed the rear to see what I would want to change:
(http://s12.postimg.org/yuk7nox31/IMG_20150816_145308.jpg)

I'm still in doubt about the BMW rear wheel.
The hub is quite wide, this gives some issues with chain allignment. It also rubs on the brake caliper mount (easy grinder fix though)

Both the rear sprocket and the brakedisc are a different diameter as the stock FT so that might give some issues aswell.

I'm also thinking that a 18 inch wheel might look a bit better...

Does anyone know a bike with a 18 inch spoked rear wheel with discbrakes? preferably honda because those are like lego's :D

cheers Paul
Title: Re: Dutch FT project
Post by: WTF304 on August 18, 2015, 02:22:45 PM
Man that looks sweet .... i like how it looks, keep at it.
Title: Re: Dutch FT project
Post by: triguyracer on August 19, 2015, 09:08:17 AM
You might try looking for a used late model motorcross or dual sport bike that uses a disk on the rear there are many to chose from.Your build looks great
Title: Re: Dutch FT project
Post by: Kornfed on August 01, 2016, 07:39:11 AM
Curious about the progress.
Did you finish the bike?
Title: Re: Dutch FT project
Post by: kansloos161 on March 27, 2017, 08:34:17 AM
After many many moons of inactivity I decided to give the project another go this weekend.
Where the bike was still technically ridable in the past I figured that if I'm going to do it, I might as well do it right and really disassemble it.
Warning the pictures are quite horrific, the bike has been under this cover for over a year.
(https://s29.postimg.org/w0bh78fs7/IMG_20170326_122329.jpg)
(https://s29.postimg.org/qz7uryz47/IMG_20170326_130512.jpg)
(https://s30.postimg.org/ner07bli9/IMG_20170326_170921.jpg)
The bike was surprisingly easy to tear down. Took me about 1,5 hours from the first to the last picture.
Plan is to do the engine first. I'm not going to give it a complete overhaul but just do some basic maintenance (valves, camchain etc), freshen up the paint and all new stainless steel bolts.
After/in parallel I'm trying to source and fit a Honda nx650 or transalp rear spoked wheel.
Eventually the plan is to turn it into a nice little bratstyle bike to blast around the city on.

I'll keep you guys posted on any progress
Title: Re: Dutch FT project
Post by: J6G1Z on March 27, 2017, 06:36:21 PM
Holy cow Paul! Those are some tough working conditions. Glad to see that you're still at it. Keep up the good work.

J.
Title: Re: Dutch FT project
Post by: kansloos161 on March 28, 2017, 08:41:48 AM
Yep,
Thats one of the reasons that progress has been very slow.
Every time I disassembled the bike I had to make sure I was able to assemble it again within the day.
Unfortunately a real garage is almost unobtainable here in Amsterdam.

I've taken the engine inside now so I can work on it during the evenings in my living room.

This project will never be a fast paced one but nonetheless I hope to eventually have a nice little bike that I can enjoy.
Title: Re: Dutch FT project
Post by: J6G1Z on March 28, 2017, 11:08:08 AM
Do you have a back porch, balcony, or maybe even a bath-tub?  ;D

You wouldn't be the first guy to build a bike in his living room.

Good luck
J.
Title: Re: Dutch FT project
Post by: kansloos161 on April 03, 2017, 12:51:53 PM
I do have a balcony and since the weather today was very good in the early evening I decided to work on the engine a bit.

Armed with a ton of de-greaser, a copper brush, some steel wool and a lot of toilet paper I tried to clean the very dirty engine.

I realized quite quickly that Honda did not design the engine with cleaning in mind, way to much unreachable nooks and crannies.

This is how bad it was:
(https://s9.postimg.org/66ftuutov/IMG_20170403_174724.jpg)

(https://s17.postimg.org/bkgrsemwf/IMG_20170403_183748.jpg)

After some scrubbing (who ever had the idea to make these large crevasses where chain grease builds up?)
(https://s8.postimg.org/dtspn8045/IMG_20170403_180313.jpg)

The eventual some what clean result
(https://s28.postimg.org/vc00enowt/IMG_20170403_190526.jpg)

Goal of today was not to get it shiny clean but clean enough so I can have it in my living room without receiving to many complaints ;)
I you guys have tips how to better clean it, especially in the small corners and in between the cooling fins they are more than welcome.

I also removed the rev cable mounting. Ill probably fabricate some sort of plastic insert and than cap it using a small steel plate using the original bolt hole
(https://s30.postimg.org/fbfvc8ltd/IMG_20170403_184722.jpg)

Unfortunately I also discovered that I am not the first to tinker with the bike, I found a large array of different screws, nuts and bolts with this being the absolute winner:
(https://s2.postimg.org/3td8t7xo9/IMG_20170403_184728.jpg)

After cleaning its time for ordering parts!
The FT has a strange angled inlet manifold to help clear the battery tray but since I'm not using this anymore I wanted a straight inlet.
In one of the old Yahoo message board files I found a post about the possibility to use a Harley inlet manifold for which you only needed to oval the mounting holes a bit.

I ordered it and got it in the mail some time ago
(https://s30.postimg.org/ai1rmhls1/IMG_20170403_204556.jpg)
However the carb mounting hole is slightly smaller than the original carb (42 vs 44mm) after some persuasion it does actually fit.
I am a bit worried about the original bracket that holds the throttle cables but I'll test that later.

Next part is deciding on how to paint the engine.
I'm leaning towards this look
(http://i764.photobucket.com/albums/xx287/postyrob/IMG_1365.jpg)
so silver/polished side covers and cam cover, black cilinder, cilinder head and polished cooling fins.
Title: Re: Dutch FT project
Post by: J6G1Z on April 03, 2017, 01:46:46 PM
I've used the foaming oven cleaning spray before. It is becoming difficult to find in the USA though. If you find some & try it, make sure you wear protective clothing, gloves & eye protection.

It looks like you might have a lot of rain in your area. Raw aluminum will not stay nice looking if it is exposed to moisture. It will turn chalky white, or worse. If you want a nice silver type of appearance, look for a Powder Coating shop. Here are a couple of wheels that I had powder coated.

J.
Title: Re: Dutch FT project
Post by: J6G1Z on April 03, 2017, 02:27:45 PM
Here is something else you might be interested in.

https://www.z1enterprises.com/bolt-set-ft500-ascot-82-83.html

http://www.ukbolt.co.uk/448-qty-kit-honda-ascot-activa-atlas-aviator-stainless-engine-frame-allen-bolt-65886-p.asp

Title: Re: Dutch FT project
Post by: kansloos161 on April 05, 2017, 03:22:42 AM
Thanks for the tips.
I'm still a bit in doubt if I should use galvanized or stainless bolts since the stainless can react with the aluminium engine and seize.

I did continue on the bike yesterday.
First I did a quick check if the carb would fit on the engine with the short Harley inlet.
Conclusion... inconclusive. With just the inlet manifold it doesn't fit. With the original spacer between the cilinder head and the manifold it almost fits. Problem is the bracket that supports the throttle cables. This will have to be altered in order for it to fit. (also taking into regard that the throttle cables themselves have adjusters on them making the fit even tighter)

You can see the fitment issues in the pictures, also clearly visible is that the time standing still under the cover took its toll on the carb.

(https://s16.postimg.org/vex119mat/IMG_20170404_182245.jpg)

(https://s3.postimg.org/m7gggjg2b/IMG_20170404_182253.jpg)

(https://s21.postimg.org/8bud9dh13/IMG_20170404_182307.jpg)
Seeing the carb in the state that is was made me decide to try to clean it a bit.

Some bolts did not completely agree with my effort though
(https://s12.postimg.org/je3b4wyi5/IMG_20170404_190006.jpg)

(https://s12.postimg.org/nwy5g2uxp/IMG_20170404_190000.jpg)
Some light encouragement with a impact driver solved that issue

The eventual exploded view of the carb
(https://s22.postimg.org/bv44poskx/IMG_20170404_191621.jpg)
And after some thorough cleaning
(https://s15.postimg.org/sv5syjs2z/IMG_20170405_075758.jpg)

(https://s10.postimg.org/p8oqf42nd/IMG_20170405_075835.jpg)
I'm probably going to spray paint the rusted brackets and replace all the bolts.
When I was disassembling the throttle and choke stems (what would be a more appropriate English word?) I found some completely disintegrated seals. I couldn't really identify what they were made of. Looked almost like some kind of rope-like material.
Any of you know what kind of material this has been since they definitely need replacing?
Title: Re: Dutch FT project
Post by: J6G1Z on April 05, 2017, 10:25:40 AM
That cleaned up well. I think I might have left the butterfly attached & cleaned around it. See if you can stake those two screws in place from the backside. If not, clean the threads real well & use some stout Lok-Tite thread locker. Wouldn't want those screws to back out while the engine is running. Pretty much guaranteed that they won't end up in the air-cleaner side.

Here is the only FT500 carb rebuild kit that I know of: https://www.randakks.com/ft500-ascot-randakk-master-carb-overhaul-kit.html
They also offer a book on how to rebuild & modify the FT500 carb. Here is their site link: https://www.randakks.com

The FT500 carb is a nice piece. It has an accelerator pump that feeds a squirt of fuel into the carb every time you twist the throttle. I use that feature to prime my bike prior to starting.

Another option would be a 36mm Mikuni. Some have used the 34mm & modified bikes have used the 38mm. If you go that route, you will need a 90 degree throttle cable mount on top of the carb to clear the frame.

About stainless steel fasteners & aluminum...  Whenever I work on a bike, I use an anti-seize paste on all the fasteners upon reassembly. I cover the threads, the shank & the backside of the screw or bolt head.
https://www.permatex.com/products/lubricants/specialty-lubricants-anti-seize/permatex-anti-seize-lubricant-2/
http://www.antiseize.com

I wish that all the bike manufacturers used anti-seize during initial assembly.

Here is another bit of information that you might find helpful: http://ascot500.com/index.php?topic=128.msg460#msg460

Good luck
J.
Title: Re: Dutch FT project
Post by: kansloos161 on April 14, 2017, 02:11:16 AM
Took some time to work on the engine last night

To get the engine ready for paint I wanted to remove both side covers and the valve cover.
This did go pretty smooth up to the point that I got to the valve cover, a couple of the bolts needed a bit of convincing and a bit of thread came loose. The worst one actually snapped of halfway in the threads :(.

I'm going to freshen up the threads with a screw tap and try to remove the broken peace.
Time for some pictures:
Left side
(https://s11.postimg.org/6z9ow2gs3/IMG_20170413_201141.jpg)
Left side engine cover
(https://s21.postimg.org/d672auinb/IMG_20170413_201148.jpg)
Right side
(https://s21.postimg.org/xnlybewdj/IMG_20170413_203102.jpg)
Camshaft looks pretty ok, the lobes are not worn down or anything although they have a bit of marking on them.
(https://s3.postimg.org/dy63tfhfn/IMG_20170413_211745.jpg)
Thread that came out of 2 of the bolt holes
(https://s7.postimg.org/hko1l531n/IMG_20170413_211701.jpg)
Bolt that snapped
(https://s15.postimg.org/h23v5xu3v/IMG_20170413_211924.jpg)
Title: Re: Dutch FT project
Post by: triguyracer on April 14, 2017, 07:32:52 AM
Try using a left handed  drill bit , many times this will remove a broken bolt without damaging the threads in the head, doesnt work all the time but will work many times, also using some heat from a hand held torch will help swell the alloy from around steel bolt and help free up the bolt so it will come out 
Title: Re: Dutch FT project
Post by: kansloos161 on April 20, 2017, 12:13:24 AM
Had some time during Easter holidays to work on my engine

I tried to clean the engine as much as possible. Looking back I should have left the side and rocker covers on and powerwashed the engine. Now I had to slave using degreaser, wirewool, old toothbrushes, Q-tips and my Dremel to try and get all the grit and grease off.
(https://s8.postimg.org/gh5fu7w85/IMG_20170417_163837.jpg)
How the engine looked after some thorough cleaning (yes I worked on it on my living room table)
(https://s3.postimg.org/ha9x37wg3/IMG_20170418_111338.jpg)
After cleaning I had to mask everything. I figured out a fast and effective way to mask small parts using cling foil! Works very well
(https://s16.postimg.org/4dq0c3g79/IMG_20170418_115528.jpg)
After giving the engine a first coat of primer
(https://s12.postimg.org/e6dgj1hgd/IMG_20170418_164241.jpg)
All the silverware after its first coat of paint
(https://s3.postimg.org/8tn0f3pz7/IMG_20170418_185236.jpg)
All painted pieces.
(https://s23.postimg.org/qbvupvd17/IMG_20170418_195733.jpg)
A quick mock up of the engine
(https://s22.postimg.org/ykx5k8vu9/IMG_20170420_221800.jpg)
The other side
(https://s2.postimg.org/xsbo73lo9/IMG_20170418_225224.jpg)
And a before and after compilation just for the fun of it

I've used motip wheel spray for the engine (VHT is better but that is not sold to consumers here in the Netherlands) I'm not disappointed by the results so far although I think that, especially for the amount of work I put into it, with a bit more prep and a better working environment the result could have been even better.
I deliberately did not mask all the bolts as some of them were quite rusty and I didn't want to replace them because that would mean I had to disassemble the whole engine.
Title: Re: Dutch FT project
Post by: J6G1Z on April 20, 2017, 11:17:35 AM
That looks real nice!

When it comes time to start the engine, you might consider gently heat cycling the paint. Start the engine & then shut it off as soon as you feel warmth. Let cool completely & then repeat several times while allowing the engine to become warmer each time.

It will probably stink like paint fumes for a while until all the solvent is cooked out of the paint.

J.
Title: Re: Dutch FT project
Post by: kansloos161 on April 21, 2017, 06:31:14 AM
Will definitely do that.
The paint I used is not an official heat resistant paint so it will smell quite a bit I think. I've seen it used on many (air-cooled) engines though so it can handle the heat.
I've added a picture of a mock-up of the other side of the engine in the previous post.
I'm now ordering stainless steel bolts but I ran into a small problem. Honda uses 6mm bolts for almost everything but somehow they decided to use 7mm bolts for 2 of the 13 bolts in the valve cover. 7mm bolts are very hard to find so that's a small issue. (Can't have 2 ordinary bolts while I replaced all others with nice stainless steel ones...)
Title: Re: Dutch FT project
Post by: kansloos161 on May 01, 2017, 06:37:18 AM
The mailman came to my door again

(https://s8.postimg.org/l4hvy7p0l/IMG_20170_170606.jpg)

Some small original Honda parts (tacho cable delete and oil filter) and a whole shitload of stainless steel bolts.

I've spent yesterday evening prepping all covers for reinstalling. Had to remove a lot of old gasket, sand the surface area, determine which bolts go where (have an Excel file with pictures if someone is interested) clean up the threads of some of the mounting holes etcetera.

A rather tedious job but it atleast means I'm getting closer to assembly which is always nice.

I've also replaced all bolts in the carb and found a way to mount the throttle cable bracket without it hitting the cilinder head.

I'm going to sand the cooling ribs on the cilinder and head tonight so hope to be able to post some pictures of that soon.
Title: Re: Dutch FT project
Post by: kansloos161 on May 01, 2017, 01:37:41 PM
The result of sanding the cooling ribs and mocking up the engine again:
(https://s11.postimg.org/pyxskajpv/IMG_20170501_214829.jpg)
The other side
(https://s9.postimg.org/jjjuctwtb/IMG_20170501_212809.jpg)
I also ovaled the mounting holes on the harley inlet manifold to use is on the FT
(https://s11.postimg.org/45cki6br7/IMG_20170501_220448.jpg)
This puts the carb nice and close to the cilinder (and now the carb sits straight so it's easy to mount a big open air filter)
(https://s4.postimg.org/qbbnjjiot/IMG_20170501_220642.jpg)
You do have to alter the throttle mounting bracket a bit though (you need to grind away a bit at the bottom so it can tilt a bit further)
(https://s23.postimg.org/gonxp0bcb/IMG_20170501_221420.jpg)
I still have to tidy up the bracket itself ofcourse

Next step is get some liquid gasket and then close the engine for real.
Title: Re: Dutch FT project
Post by: kansloos161 on May 07, 2017, 01:10:56 PM
Unfortunately I ran into the exact problem that a lot of FT's have.
Stripped cilinder head cover boltholes :(

When pulling them to the prescribed tension 3 of them snapped through.

This are the culprits:
(http://i67.tinypic.com/1ph5yu.jpg)

I probably have to get a Helicoil thread repair set and rework most of the threads.

To relieve some agression I got my grinder out and started working on the frame.
Removed some small brackets that I didn't need anymore and cut the back of the frame
(http://i67.tinypic.com/svja08.jpg)
cut up frame
(http://i67.tinypic.com/2roonfc.jpg)

The bike looked as follows with the cbr900rr forks and xs650 front wheel, standard rear shocks and rear wheel.
(http://i67.tinypic.com/2h54aye.jpg)
Next I mounted the longer shocks and the BMW wire wheel that I still had.
(http://i67.tinypic.com/nv8a2s.jpg)

How the seeting position will roughly be.
(http://i67.tinypic.com/2prih7b.jpg)

A day with some ups and downs. Glad with the look of the bike with the wire wheels and the shocks. Not so glad with the stripped bolts ofcourse
Title: Re: Dutch FT project
Post by: kansloos161 on May 12, 2017, 02:13:54 AM
Was able to work on the bike yesterday

When removing the head bolts to take the cilinder head off, 2 of the bolts got rounded. Had to actually chisel them to oblivion in order to get the head off.
The first one was relatively easy, the second one however..
(https://s2.postimg.org/fmagl9auh/IMG-20170510-_WA0004.jpg)
Eventually it gave in and with only small damages in my fresh paint the head could be removed.

There was a lot of sud on the valves
(https://s7.postimg.org/3ncy4g84b/IMG_20170510_173644.jpg)
They cleaned up pretty nice though
(https://s27.postimg.org/nhkhh8fzn/IMG_20170510_205347.jpg)
The piston looked pretty good, not a lot of sud here.
(https://s21.postimg.org/5mqxmcsfr/IMG_20170510_173731.jpg)
After cleaning I also checked the cilinder and you can still see some honing marks (not a lot though)
(https://s28.postimg.org/8ihb3tsul/IMG_20170510_205806.jpg)
To get to one of the holes in the cilinder head I had to drill the hole a bit bigger in order to reach the threaded part with the cutting tool. This meant drilling very close to the camshaft seats..
(https://s10.postimg.org/mjrmtv361/IMG_20170510_195941.jpg)
The Helicoils went it quite smooth so i'm not dissatisfied with the results
(https://s12.postimg.org/k57sv7crx/IMG_20170510_221448.jpg)

I've ordered some new flange nuts for the cilinder head (plus some other parts I needed) and when I get these I can start to rebuild the engine (again)
Title: Re: Dutch FT project
Post by: kansloos161 on June 06, 2017, 03:04:10 AM
It's been a while since I posted something here but I've made a bit of progress
Started out by working on the tank.
That got pretty dirty after spending 2 years under a cover outside
(https://s11.postimg.org/l8retop6b/IMG_20170513_120346.jpg)
Fitst cleaned it a bit
(https://s24.postimg.org/imdk2bujp/IMG_20170513_123351.jpg)
(https://s28.postimg.org/5xk6lqu59/IMG_20170513_121535.jpg)
The holes on the side are only used as mounting holes for the side panels, since I won't use side panels these can go.
First marker out where to cut.
(https://s28.postimg.org/jzq7lppfh/IMG_20170514_124708.jpg)
And eventually without the holes
(https://s22.postimg.org/h5hynwu75/IMG_20170514_125745.jpg)
For now I won't paint the tank. This will be done in a later stage.

I went to Japan for holidays (got a bit of inspiration while there too) and when I came back I had some parts waiting for me
(https://s10.postimg.org/cmupxebzd/IMG_20170530_121541.jpg)
I also received my new cockpit. A cheap one from china but it looks ok and I could take the risk for the money
(https://s22.postimg.org/w2g58hysx/IMG_20170603_120527.jpg)

Among these parts were some new exhaust studs, the former owner used low quality bolts from a DIY store so I was pretty lucky I did not have to put helicoils in these boltholes.
(https://s29.postimg.org/qiv69gnav/IMG_20170530_130145.jpg)

Now I was able to install the cilinder head using my nice brand new headnuts. You can't order the copper rings anymore so I had to heat treat them myself in order to reuse them
(https://s11.postimg.org/r1k5iznyr/IMG_20170530_131653.jpg)

After this I could fit the camshaft, camchain sprocket and camchain. Quite a shitty job and I was a bit anxious that it might be off by one tooth but it seems to have gone right.
The real test was refitting the headcover cause this would test my new helicoiled boltholes. Fortunately this was a succes!

Cleaned, greased and tested the solonoid assembly and closed the rest of the engine. Time to work on the rest of the bike
(https://s22.postimg.org/kd8attbz5/IMG_20170530_190209.jpg)

I decided that I was completely done with working on the bike in front of my house so I disassembled what was left and put the bike on my balcony.
Here I fitted the aluminium handle bars that I had bought some time ago and also fitted the (very large) headlight
(https://s9.postimg.org/q5dh4f1m7/IMG_20170605_182208.jpg)
(https://s4.postimg.org/4f509ffzh/IMG_20170605_182153.jpg)
I still have to lower the headlight a bit more judging by the pictures.
I'm also not very satisfied by the mounting brackets but since I'm using fireblade forks which are very thick there are not a lot of options here.
I've also test fitted the battery and it seems like I can get away with a small battery compartment just below the seat.
Good news since I want to keep the frame part as empty and clean as possible.

I also measured the spacers for the rear wheel but I ran into some issues here. Although I measured from the wheel rim to the rear swing arm on both sides and the distance is equal. It still looks like the wheel is offcentre, it might be that the swing arm is not symmetrical. Does anyone have a tip how to properly space your wheels?
Title: Re: Dutch FT project
Post by: J6G1Z on June 06, 2017, 08:13:57 AM
Does anyone have a tip how to properly space your wheels? 

You might have to wait until the engine is mounted so you can check sprocket alignment.

J.
Title: Re: Dutch FT project
Post by: kansloos161 on June 07, 2017, 01:57:32 PM
Sprocket alignment is only one of the issues.
I want to make sure the wheel at least is centered in the frame, I'll worry about the sprocket later.

I was thinking of hanging something like a plumb-line from the middle of the frame and try to determine the center of the wheel of of that.

Got to working on the electrics today btw:
To be diagram
(https://s12.postimg.org/yr95mxx4d/met_cockpit.jpg)
And I have to fabricate that using the below bowl of spaghetti
(https://s16.postimg.org/clk6lxewl/IMG_20170606_184946.jpg)
Title: Re: Dutch FT project
Post by: kansloos161 on June 28, 2017, 09:17:24 AM
time for some updates:
testfitted the engine and made a cardboard template for the battery box
(https://s30.postimg.org/8z96dn0v5/IMG_20170613_183517.jpg)
(https://s9.postimg.org/ptzn8z8nj/IMG_20170619_155500.jpg)
roughly test fitted my new cockpit
(https://s15.postimg.org/k6q8mrbm3/IMG_20170619_154144.jpg)
(https://s17.postimg.org/b0ek4pkvz/IMG_20170619_154152.jpg)
Alligned the rear wheel
(https://s18.postimg.org/m73p14n0p/IMG_20170621_194006.jpg)
Also installed the front brakes to determine where the brake calipers are going to be and what kind of brackets i need to fabricate. After bleeding the brakes for hours I finally got them up to pressure.
Unfortunately the brake fluid leaked on my tripple tree :( i didn't properly close the reservoir.
My bad and I will just have to redo this when I get the frame painted or coated
(https://s15.postimg.org/lh330m1iz/IMG_20170627_165628.jpg)
(https://s15.postimg.org/5lb5y2uvv/IMG_20170627_165936.jpg)

got some stuff in the mail too:
Wiring loom parts:
(https://s10.postimg.org/5y0uqzbt5/IMG_20170619_160318.jpg)
New jets although the pilot is the wrong one :(
(https://s24.postimg.org/cbh84soid/IMG_20170619_131702.jpg)
frame rear loop and steel for the battery box
(https://s7.postimg.org/vixbocmsb/IMG_20170628_170914.jpg)
Title: Re: Dutch FT project
Post by: greenjeans on July 03, 2017, 06:12:11 AM
Really starting to look good! 
Title: Re: Dutch FT project
Post by: kansloos161 on August 01, 2017, 01:18:44 PM
Thanks!
I really like the look too and really enjoy doing everything on it myself.
Today I was able to rent a welding machine (last time I did some welding was almost 10 years ago and I never properly learnt it)
First I prepared everything for welding.
I made the battery box and determined where all the electronics can go.
(https://s1.postimg.org/aq10absqn/IMG_20170719_181339.jpg)
First welding job was the hoop as the subframe extension.
I deliberately did not post a picture before I cleaned up the welds ;)
(https://s2.postimg.org/krdptzxqh/IMG_20170801_103751.jpg)
Next step was to attach the batterybox. I started out by spotwelding it
(https://s4.postimg.org/63npczzwt/IMG_20170801_121618.jpg)
After welding the parts between the spotwelds I cleaned up the rear. I'm pretty stoked about the result although it is far from perfect.
(https://s2.postimg.org/dyruq649l/IMG_20170801_144237.jpg)
I also welded some brackets in the batterybox so I can attach the electronics in there.
(https://s2.postimg.org/etazgt0cp/IMG_20170801_160716.jpg)
This is how it looks from the side, you can also see the bracket for the contact switch just in front of the batterybox.
(https://s1.postimg.org/h7w6knl4f/IMG_20170801_162407.jpg)
Although I am pretty happy with the result (as I did it all by myself) it does pose a bit of a problem.
My welding (and grinding) skills are not sufficient to get rid of all the imperfections. I was planning to have the frame powdercoated but now I have to use some bondo to get it tidy and this means no powdercoat. It does mean that I might be able to do another thing myself... spray paint the frame :).
Title: Re: Dutch FT project
Post by: J6G1Z on August 01, 2017, 04:10:06 PM
Here is something that might be helpful: http://www.dotheton.com/forum/index.php?topic=23719.0

Keep up the good work.
J.
Title: Re: Dutch FT project
Post by: murdo on August 03, 2017, 01:09:45 AM
Looking good.
Title: Re: Dutch FT project
Post by: Lefty on August 07, 2017, 02:48:05 PM
Wow, looking good! I haven't been on this site for a good while.
Nice job, looking forward to the finished product👌😎
Title: Re: Dutch FT project
Post by: kansloos161 on November 02, 2017, 02:45:42 PM
It has been a while but I've been able to do some work on the bike :D

I wasn't really satisfied with the way my welds looked so I decided to try a special Bondo that is heat resistant.

I've bondo-ed the parts between the underside and the frameloop and between the batterybox and the framerails
(https://s1.postimg.org/7dcpq8zzm7/IMG_20170829_200857.jpg)
(https://s1.postimg.org/4btl374atr/IMG_20170829_175815.jpg)

I altered the original footrest holders to accept modern footrests
(https://s1.postimg.org/7r6e2xy51b/IMG_20170916_125420.jpg)

I managed to source the rear brake and mounting plate of a BMW funduro (I already had the complete rear wheel). I was able to install all this without to much alteration.
(https://s1.postimg.org/3bnyxovtgv/IMG_20170913_154029.jpg)

I also made a bracket for my cockpit but I don't have a good picture of it.

The oversized headlight I have was painted (rat)black by a previous owner. I used some steel wool to clean it up and I have to admit it looks pretty good. I'm actually contemplating to keep it bare metal (put some clearcoat on it though)
(https://s1.postimg.org/8c3ab2lnmn/IMG_20171029_151636.jpg)
(https://s1.postimg.org/5a7e9upw1r/IMG_20171029_151615.jpg)

I had my frame and some loose parts coated.
Unfortunately something that I already anticipated actually happened. The underside curled up due to the heat and seperated from the frameloop.
I'm probably going to put some black kit or something in between to make sure no moisture can get in between.

The normal camera on my phone died so I had to take all these pictures with my crappy selfie camera so the pictures do not do the coated parts justice. In real life it looks better!

(https://s1.postimg.org/4a1s4ckmfj/IMG_20171102_192710.jpg)
(https://s1.postimg.org/9b6ma2iz3j/IMG_20171102_192739.jpg)
(https://s1.postimg.org/59umvoqgen/IMG_20171102_192733.jpg)

The parts that I bondo-ed (looks rough in the picture is actually very smooth and looks better than expected)
(https://s1.postimg.org/3ryz1kw8fz/IMG_20171102_192833.jpg)
(https://s1.postimg.org/10pwtiqetb/IMG_20171102_192815.jpg)
The rear part that unfortunately seperated a bit.
(https://s1.postimg.org/5yb51iy9cv/IMG_20171102_202632.jpg)

Time to start the rebuild!
Title: Re: Dutch FT project
Post by: J6G1Z on November 03, 2017, 07:56:57 AM
Way to keep at it.

By any chance have you mocked up the final ride height & kick-stand length? I had to shorten my kick-stand so the bike wouldn't tip over to the opposite side.

J.
Title: Re: Dutch FT project
Post by: kansloos161 on November 06, 2017, 04:31:17 AM
I did a mock-up before and due to the shorter front forks but longer rear shocks it works out. (as you can see later in this post)
Because it is build-up time!

Although I live on the 3rd floor I've started to assemble the bike (in my livingroom). This helps me to determine what I still need to do/order.

steering stem with new dust seals (already had the tapered bearings):
(https://s1.postimg.org/7117i3k7rj/IMG_20171105_130302.jpg)
Complete tripple tree assembled including my new dashboard
(https://s1.postimg.org/5s0kiadtrz/IMG_20171105_131636.jpg)
Rear swing arm mounted.
(https://s1.postimg.org/19bathkfq7/IMG_20171105_152358.jpg)
Engine in.
(https://s1.postimg.org/6wglboavof/IMG_20171105_163407.jpg)
Mock-up without wheels
(https://s1.postimg.org/7ew5sm2chb/IMG_20171105_164832.jpg)
And this is how she sits in the living room now.
(https://s1.postimg.org/17xj6medxr/IMG-20171105-_WA0007.jpg)
(https://s1.postimg.org/4kt0f5udxb/IMG-20171105-_WA0008.jpg)
(https://s1.postimg.org/7ql9s9pirz/IMG-20171105-_WA0009.jpg)
It looks far more complete than it actually is.
I still need to do the complete wiring loom and make all the spacers for the front brakes and rear wheel.
Most of the stuff that I assembled now probably has to come of the bike a couple of times but I'm very pleased with the (intermediate) result
Title: Re: Dutch FT project
Post by: J6G1Z on November 06, 2017, 06:46:15 AM
That is a nice looking "Shop" you have there!


J.
Title: Re: Dutch FT project
Post by: kansloos161 on November 06, 2017, 12:38:13 PM
Hahaha yep.
Have to make due with the room that I have.

Bike looks a lot better with handlebars mounted.
(https://s1.postimg.org/2bq2prnhnj/IMG_20171106_183559_01.jpg)

Funny how much difference that makes.
Title: Re: Dutch FT project
Post by: J6G1Z on November 06, 2017, 06:20:49 PM
I was fixated on the size of the headlight & the spotless "Shop".

Didn't even notice the bars were missing.  :-[

J.