Dogbytes' R80 ST project

[Dogbytes]

Finally got the bits back to mount the rear wheel in the wheel building jig. It's a bit makeshift but it'll do the job. Steve's going to give me a hand with it on Wednesday evening then I can get the tyre on it. So on Thursday, hopefully, it'll be able to stand on its own two wheels for the first time in almost five years. Brings a tear to my cynical old eyes just thinking about it

 

[Dogbytes]

The modified driveshaft coupling fits a treat too.

 

[Dogbytes]

I was supposed to be welding the battery box but I couldn't resist the lure of the rear wheel... I've given it a go, without supervision(!) and I've got it to within .33mm of runout (that is +/- .16mm). That's on a 32 year old rim so some of it could be distortion of the rim itself or even differences in the powder coating thickness. I think it's probably okay but I'll run it by the expert tomorrow evening anyway.

Okay, back to that battery box...

 

[Dogbytes]

Clutch release mechanism question

Just been gathering together the bits of clutch release and, according to the diagrams I can find, there's a bit missing. The bit in question is the piston marked '3' in the diagram. I don't appear to have one. Do they all have them?

The bits I have got are in the pic. The thrust bearing races have the same markings but the internal diameters differ - 10.95/9.97mm, why?

Any insights gratefully received...

 

[ianboydsnr]

Just been gathering together the bits of clutch release and, according to the diagrams I can find, there's a bit missing. The bit in question is the piston marked '3' in the diagram. I don't appear to have one. Do they all have them?

The bits I have got are in the pic. The thrust bearing races have the same markings but the internal diameters differ - 10.95/9.97mm, why?

Any insights gratefully received...

Yes your missing a piston, though there were differences throughout production, look here

http://www.largiader.com/articles/throwout/

 

[Dogbytes]

Yes your missing a piston, though there were differences throughout production, look here

http://www.largiader.com/articles/throwout/

Thanks. I came to a similar conclusion and ordered one from Sherlocks. They only had a used one though. Hope it's the right one!

 

[Dogbytes]

On two wheels

On its own two wheels for the first time in almost five years.

I'll tell you what - it doesn't half feel light! Now, I know the bodywork, exhaust and a couple of other things are missing, but even so... Must borrow some bathroom scales.

 

[Neil W]

On its own two wheels for the first time in almost five years.

I'll tell you what - it doesn't half feel light! Now, I know the bodywork, exhaust and a couple of other things are missing, but even so... Must borrow some bathroom scales.

Absolutely love the look of a bike running on TT100 pattern tyres

 

[Dogbytes]

Absolutely love the look of a bike running on TT100 pattern tyres

TT100 GP. Not the cheapest but they're supposed to be good. I wanted something that looked the part too. Personally, back in the day, I was a fan of the K91 Red Arrow - even though my Kawasaki 500 would go through a rear one in 1500-2000 miles.

 

[charlie b]

Ahhh ... great progress John... good to see it outside the office at last

I'm sure it's light as a bag of feathers compared to your current daily ride..?

+1 for the TT100's - for me, THE tyre to use back in the day - good choice

 

[dr nosh]

Sorry for the lack of progress, 'Doc Martin' took a bit more time than they expected. However my lovely wife is off camping with her mates this weekend and I'm not invited - well, someone has to babysit the dogs. Anyway it'll be dog-walking and bike building for me.

So, to the pic, the metal bits are the driveshaft coupling but slightly modified (it was a prototype!) and the the carrier that'll mount the rear wheel on the wheel building jig to true and tension it (at long last!). The white bucket is a Zinc Passivate plating kit, from Gatero Plating, with which I intend to refinish some of the odd steel bits.

The unfamiliar stainless steel tooling on the 40" Snap-On roll can in the background? Well I retired that box and I use it as a kitchen cabinet these days.

I, (and plenty of others on here) will be interested in the results from this plating kit.

I'm at the stage now of also getting lots of small bits re-plated for my Montesa Cota project.

Having done everything else myself, (painting, making parts in stainless or alloy etc, etc) could be also satisfying to do the plating as well.

 

[Dogbytes]

I, (and plenty of others on here) will be interested in the results from this plating kit.

I'll be firing it up (the plating kit) in the next day or two. Watch this space.

 

[Dogbytes]

Ahhh ... great progress John... good to see it outside the office at last

I'm sure it's light as a bag of feathers compared to your current daily ride..?

+1 for the TT100's - for me, THE tyre to use back in the day - good choice

Thanks Charlie - it's a bit of a morale boost to see it resting on two wheels. Now I can get underneath it to plot the tortuous route of the exhaust system!

Battery box is nearly done, just got to fabricate an oil catch breather bottle, site the various electrical boxes, tweak various linkages, get throttle cables, clutch cable adjuster (fabrication job), oil cooler hoses, fluids, then over to CT for electrics. Close, so close...

 

[peepingtom]

Looks great you must be very pleased hope it starts up good for you it's always a nervous time !

Well it definitely is for me not being the best spanner man that walked the earth....

 

[Kenny]

Battery box is nearly done,

Looking splendid and an absolute credit to you .. although nice to know I had a s/s battery box before you

 

[Dogbytes]

Looking splendid and an absolute credit to you .. although nice to know I had a s/s battery box before you

Thanks for that.
BTW my battery box is aluminium

 

[Dogbytes]

When I built the rear wheel, I pulled the rim over as far as I could (not far, about 5mm)... Glad I did!

 

[Dogbytes]

Just figuring out where the electrics, such as there are, are going to live.

 

[Dogbytes]

It's not all glamorous, high performance stuff!

Today, for instance, I spent most of my time making a number plate holder.
It is nice, lightweight, 6082 alu alloy and I did have a couple of Dzus fasteners left over, so it detaches quickly leaving the back end nice and neat.

 

[Dogbytes]

and speaking of weight...

I tried to borrow some bathroom scales but, it turns out, no one I know has any. That'll be why we're all lardy-arsed bastards then. Anyway I went and bought some just to keep you informed...

Now, it doesn't have an exhaust system - except for the silencer. Also, Tunneruk has the bodywork, but that can't be too heavy. Pretty much everything else is there.

So, front? 73.1 kg. Rear? 79 kg. That's a total of 152.1 kg dry weight. 335 pounds, in old money.

I reckon I can keep it to 350 pounds dry when it's complete and with that I am very happy - I mean, the engine and gearbox account for a third of it!