Rolling wreck bajaj
First the brake pads for sarahs car turned up. so i did those.
Thne i began to think “A pm55 is cheap if you can provide your own silencer” so i must find out the pcd, the silencer bwlow is off an aprillia rs250
This rd350 turned out to be a bit of a dog underneath everything, 250 barrels (rebored and ported) house hold wiring zip ties and broken bolts along with dead mains, then again is is 30 years old.
So finally got started on the bajaj, mounted up the fuel tank, must sort a knob of some sort to turn the tap.
then whipped the body off to get at more cables.
so far the front brake is in and the handbrakes. the clutch is also in but the sheath needs shortening/attention before it’ll work, choke is done, throttle I was about start with but then i ran out of time.
Whats left? gotta cut a chunk out of the body for the cables to pass through and a small section out of the frame to allow the starter handle to work. Find some bolts to hold the body on and lastly engineer hydraulic rear brakes a foot gear change and, of course, a seat.
Why a runner blows up.
The root cause was the water pump not being turned any more, weather it was the bolts falling out of the oil pump causing the wheel not to engage the pump or the wheel wearing out then the bolts falling off the oil pump I’m not sure which happened first. Parts are on the way anyway from http://www.psntuning.co.uk/ should be here next week.
rotax 123 barrel on runner 180 cases? i wish
I Will get this thing rolling tomorrow, i must!
In anticipation of fiddling with the carb i’ve put back in the standard 15.5g (i think there that weight anyway) rollers, slower ratio changes make it easier to diagnose problems.
Moar two-strokes
Got a few thing done over the last couple of day, even cleaned a bike!
Massive tuk tuk bars on an nrg.
Gasp nrg bars on a tuk tuk!
Old bars didn’t want to let go of the cable with out a fight, realised the cable was mangled by this point but had to show it who’s boss!
Vintage dt400 supplied brake lever.
May weld the bars on with a little more pull back, also need to notch the stem a bit deeper, couldn’t get the tuk tuk to the garage (camper van in the way) and the rain scared me off taking the electic grinder to the tuk tuk.
Worried about the cbr’s engine oil’s life if I do to many short trips to FAS, so decieded to take out the runner 180, no engine oil to mayonnaise in this engine.
Cleaned it in the hope it might help with starting. It worked!
Went to the new kinsale hillclimb on the runner, chased bigger bikes the whole way there 🙂
Three Wheeled Shenanigans
Cad course is working out great for me, found a guy their who own his own engineering shop, i’m designing a supercharger for the runner and the tuk tuk 🙂
In the last month or two i have actually done something, niki’s intruder chain for one was quite a bit worn out.
Head is off the gpz500, gasket looked okay, hmm
Found this in the garage, nice pipe eh?
Manly carbs stick out sideways. folding pegs for heroic corner action.
Oil cooler for the massive engine, not sure what size but it has to be at least 125 hope fully 150cc
And a top box, it has to have a top box lol
Sarge spent 3500 euro and this pile of shite.
neither of em can actually fit in the sidecar..
i nicked the seat 🙂
5 wheeler?
5 seater!
I’d like to meet the man who design this steering damper, then do something horrible to his right arm.
Wherer to start with the slagging? the front.
front brakes siezed. (sarge didn’t notice)
steering damper only works going right. (design fault)
steering damper limits lock. (design fault)
no reverse.
engine puking rusty coolant all over it’s self. (sarge didn’t notice)
rear air shocks have been replaced with hagons from a kiddies tricyle (not a millimetre of suspension travel,sarge didn’t notice)
the chair suspension is off a trailer, indespension, no damping at all.(design laziness)
rear brake (the only brake) requires you to lift your entire leg up to reach it and then stand on it and hope you don’t lock up. (pain in right leg, sarge thinks he’s having a heart attack)
over sized rear tyre rubs drive shaft.
gearchange design is so cave man, harley would be proud.
engine shake’s like a bastard under 2000 when you open up the throttle.
engine barely pull’s first gear, new clutch soon.
can’t see out the windscreen.
the wiring.
neither of them can properly fit on the bike, the drivers back rest actually squashes sharon right into her own back rest, and the back of sarges back rest is just a rusty pointy bolt.
I’m sure i could extend this list by alot, but the vitriol is running out.
Whats it like to drive? painful, the steering is direct like a go kart, but is stiffer to correct it to the right thanks to that fucking steering damper, so one arm hurts more then the other, neck hurts from craning it to look over the screen. your whole body is knocked left to right by the chair, can you imagine trying desperately to hold the bars straight, while the their swaying (not turning) violently? it’s like a permanent tank slapper. I’d love to see what a properly done sidecar might handle like, if my tuk tuk manage’s to out handle this thing i may revise my statement about all sidecars designers mothers.
So sarge again has blown a chunk of some one elses money on a pile of shite, what the hell could i have done with €3500? in six months i could have turned it into 10,000 easily provided i didn’t get distracted by building a twin engined hayabusa unicycle. topped with an inflatable duck.
Welding tan
I can’t take a pic but my left arm is like a fecking lobster and stinging like a bitch, however the tuk tuk is very very nearly done, now does any one have a copy of octopussy? can’t for the life of me find any clip of the tuk tuk chase scene, I swear it had a z1 engine stuffed in.
Turned it right way up to continue the welding.
CAD Cardboard Aided Design, think i’ll get myself killed if i tell that joke in CAD class..
Very dead headlight, gone now.
Should have built this patch first, cos I’m after dropping it in there now, magnet ought to fish it out later
rail’s welded to gether very nicely although you can’t quite tell in these pics.
Dragged out the cb1100r to tidy some stuff away, noticed how similar out red frames are…
Played with some of the jago parts, think i’m supposed to take out the roll bar bushs and then replace them with the HD one’s in the bag, probably won’t until the the standard ones are worn/soft.
Found these rear master cylinders off the cbr6, should do perfect for the tuk tuk’s brakes, the plan is to make two pedals rather like a tractor so i can brake independently each wheel, ought to help getting around corners 😀 If they push too much fluid for the drum slave cylinders one master cylinder will do, too old for skids and slides any way 😛
Sold the starlet, needed space for the tuk tuk. All thats left of my starlet is the gear knob, it shall live one in the jago!
More new bajaj frame
but first a dog.
And now the tuk tuk again:
Need to bend over the first bit I taked on, glad it wasn’t fully welded.
Much grinding (in fact most of the day) got me to this point.
A little bit more grinding and voila!
It’s quite off, tried moving it with a brush handle but no luck, need something more manly like a fork leg.
And that’s where I left it for the day, was very hot and sweaty after all that 😛
tuk tuk frame part 3-ish
Chopped out more of the old frame, bit difficult to get in there but I got it it the end.
Decided to take a risk and chop the other side too, it hasn’t fallen down. tomorrow will finish the other frame rail then next week it’ll be all welded together.
ebayed 8″ drum came finally!
New crossmember, arrived from a IrishEscortClub member, just the suspension top mount to find now.
More tuk tuk frame work
But first, a puppy!
Okay, with Frosty’s help we got it upside down and level, don’t have to worry about the front end being on straight now.
Decided to put the new rails just here, didn’t like the angles i’d have to cut  if I went from the end of the frame rails. This way is better engineering.
The bit i cut out was recycled into a patch.
An easy weld for once, the holed piece of metal in front of my patch is structurally unimportant, Your going to here that alot with this build, structurally unimportant.
Stopped there because I ran out of cutting disc’s dammit.
Tuk tuk, new frame.
First up a test peice to help me guestimate the angle I need.
Angle turned out to be quite shallow, didn’t figure on the fact that the head stock its self is inclined back.
Quick break to do Frostys brakes and a cv joint boot on his fiesta diesel van. took a pic of this hanger because i wonder if i could fit these calipers to the escort mk2 legs.
And a tack weld later, next week we’ll be sorting two more bits to split into a Y back to a more solid part of the frame and then it’ll be final welding. Sort some brakes and some brake lights and it’s off for a spin 🙂
Taking the handle bars off a tuk tuk.
But first i had to fix nikis puncture.
tyre off the rim because he drove it here like that.
screwed! also the gearbox seal was leaking because a plastic bag got caught up in the chain and wrapped around the shaft, then melted through friction and worked its way into the seal. just took the plastic out it seems ok, not a problem if it isn’t because the it can be replaced with out splitting the cases.
Over to sarges and the tuk tuk is covered in fags. great.
Friction steering damper :) that’s not staying.
Took nearly an hour to do this, to get the cables out the inner had to come out first then the outer had to be pulled the other way, not an easy to work with design but very repairable. The electrics! built like home plugs you have to undo little brass screws and pull out the wires, madness, again great for easy fixing but pain in ass if you can’t remember where which wire went . I just chopped then all off this bike is either getting dash switches or a completely new set of handle bar off a normal moped, this means I’d have to sort a foot gear change and handle bars that had cable brakes. I’ll be able to adjust the brake level up and down then and it’ll be a million times less complicated and lighter,and proper dog leg levers. On the other hand the standard bar setup does work and its all aluminium which mean i  could polish it up..
