Dogbytes' R80 ST project

Front tire is about two sizes too big so weight saving doesn't seem a priority - probably weighs 5 more for than the right tire.
Looks OK though.
 
Front tire is about two sizes too big.

Really? What would you have suggested I fit?

And no, it was just a light-hearted comment. Saving weight wasn't a priority - otherwise I'd have left that starter motor off. Actually, if weight, or lack thereof, had been a priority I'd have started it ha different bike! Still weighs under 160kg dry though.
 
Still a bit puzzled by the tyre size comment. The tyre fitted is a 100/90 x 19 Dunlop TT100 GP which is the size, if not the make, that I always used on it.

I've got one more bit of exhaust to make - it goes from the exit of the Y-piece and into the silencer and it's a pain! Not the making of it - just the measuring of the angles involved.
 
Exhaust is 99% done. Just a little filler plate and loops and springs to fit (haven't got 'em yet). I'm 85% happy with it but I've learnt a lot!

Here are a couple of quick 'preview' shots...
 

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Things are a pain sometimes. The last joint I had to weld yesterday was part of the 2" diameter tube from the Y-piece to the silencer. It was always a tight fit but it went in well enough. Unfortunately the welding process and the heating thereof relieved some stresses in the mandrel bent section and now it will fit but hits the footrest hanger and the front of the silencer touches the tyre. Arse! If I'm lucky I may be able to heat it with a gas torch and tweak it otherwise I'll have to cut it again and adjust it.
 
I think that it's the black rim that makes the front tyre look so big. Great work, looking good.
 
I think that it's the black rim that makes the front tyre look so big. Great work, looking good.

Could well be, I suppose I'm used to it by now. Anyway, glad you like it. :)

You've got some nice roads, up where you are, would suit this bike very nicely - I might have to put it in the back of a van and head up there at some point.
 
Back to it

Ill people in the house have prevented much progress of late but I'm back to it now.

Unfortunately I've missed my opportunity to have Chris 'Tunneruk' do the electrics, he is deservedly very busy. The various bits arrived yesterday, so I'll get onto it.

In the meantime I've been knocking off some of the odd mechanical details. Today I've finished the rear brake linkage and an eccentric-cam pedal stop.
 

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Ill people in the house have prevented much progress of late but I'm back to it now.

Unfortunately I've missed my opportunity to have Chris 'Tunneruk' do the electrics, he is deservedly very busy. The various bits arrived yesterday, so I'll get onto it.

In the meantime I've been knocking off some of the odd mechanical details. Today I've finished the rear brake linkage and an eccentric-cam pedal stop.

Remember what I said fella, if you get stuck I'm happy to 'find' the time to sort it for you, I've overcome my biggest hurdle now (Full resto of a 1976 Honda SL125 in two weeks :eek: ) so I can accommodate if need be.
 
Remember what I said fella, if you get stuck I'm happy to 'find' the time to sort it for you, I've overcome my biggest hurdle now (Full resto of a 1976 Honda SL125 in two weeks :eek: ) so I can accommodate if need be.

Much appreciated, Chris. I'm sure there'll be questions! There's hardly anything of it - it's just that I haven't used this ignition system or this instrument pod before. As usual, the instructions aren't that instructive!
 
You should put up a better fight than that, they're easier to fend off when they are ill.

They sneaked up on me! Mother-in-law broke her hip and was brought here to convalesce by wife - who then got a cold. Very serious apparently - and they complain about us and man-flu! :rolleyes:
 
Much appreciated, Chris. I'm sure there'll be questions! There's hardly anything of it - it's just that I haven't used this ignition system or this instrument pod before. As usual, the instructions aren't that instructive!

No worries fella, you know where I am if you need me mate ... :thumb
 
Thought the battery box looked a bit plain so I drilled some holes in it. It would have been a damned sight easier with a mill, of if I'd got the water-jet guy to do it when he cut the plates out. A tank cutter and a battery drill is a messy way to do it.

The red bit underneath is an Anderson connector to hook the booster battery up for starting - preserving the bikes battery for ignition related tasks.
 

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Dilemma...

I've planned, all along, to have the electrics, such as they are, under the tank. For no particular reason other than that's where they usually are. The seat hump area was going to house the engine oil breather bottle (to be fabricated from alu plate).

Now that I come to do it, I rather think it would be nice for the electrics to be in the seat hump area - for ease of access, etc. However that leaves me with the dilemma of where to put the catch tank. I suppose I could make one to fit under the tank - but the accessibility issue raises its ugly head again. Perhaps (I'll have to do some careful calculations, mocking up and laying out) they could both fit under the seat.

Like I said...
 

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C'mon people, what's all this about?

I mean, it's only got two bloody cylinders! I'm really glad I decided to lose the lights.
 

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Wiring the horn can get quite complex ! :D

Hey, if I could have got away with one of those squeezy rubber ones, I would have! :D

Something like this would've done fine. (Just an excuse to Google 'Hooters' really...)
 

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It makes perfect sense to mount the electrics under that huge void you have there, the weight is negligible, the access is almost instant and there's plenty of space to do a really nice job of laying it all out.

Also, never underestimate the convenience of being able to test / fault find the electrics while being able to fire up the motor without removing the tank ;)

I'm genuinely gutted that I'm not doing it for you :tears
 

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