My new Project: R65

[Voyager]

You just need to get the new rubbers over the bottom lip of the hole, then it should all fit.

I would use a couple of flat metal strips (metal shoe horns would be good) as ramps then just lever the rubber up as the barrel is seated.

The collars move on the push rod tubes as well (they are, of perforce, tight) if some small adjustment is required.

Because of the angles they can't just slide together.

Bob.

 

[Humbug]

Its very high temperature aluminium paint. It comes in very small tins and is not cheap.

If you don't mind me asking, what make/brand is it and where do you get it from? Is it petrol resistant?

Thanks.

 

[Crapaud]

If you don't mind me asking, what make/brand is it and where do you get it from? Is it petrol resistant?

Thanks.

Apologies for not replying sooner. I'll take photo of tin and post up details tomorrow.

Cheers

Sid

 

[Crapaud]

This is the stuff I use on engines etc. As noted, its not as bright as my pics made out, it was the reflection of the flash.

I've got two tins and not sure which is the newest, one is marked Carplan the other Tetrosyl but appears to be the same.

Link to their website: http://www.tetrosyl.com/index.cfm?page=1

 

[patanga]

Made a good start on this project today.

Built an engine stand so I can safely work on the motor.

Thanks for all the advice above but I think I'll stick with the 650cc for now. If I find it too slow I'll always have the option to tune it at a later date.

Chassis wise the Africa Twin 750 front end arrived. I offered it up to the spare frame just to see how it will look:

Interesting post...... How did the AFRICA TWIN front end work out?.... Were many mods required to make it fit?

 

[Crapaud]

Africa twin almost fitted straight on. Only needed a couple of washers/spacers to sit tight.

My welder/engineer has taken away the entire frame, sub-frame, extended swinging arm and rear shock. He has constructed a large jig to ensure everything is lined up perfectly.

It will be my winter project.

 

[Padmei]

Did you get your barrels on properly?

 

[Crapaud]

Did you get your barrels on properly?

I admitted defeat and dropped them up to Sherlocks for his mechanic to do them. Got the engine back all sorted.

 

[(RIP) Tibs]

You should have said, I could have lent you my Big Hammer.
Have you done anything to Trigger since the WeeeKend? I've got a replacement bit for the carb that Steptoe broke.
I'll try and drop it off to you before we head off on holiday.
Tibs

 

[Crapaud]

You should have said, I could have lent you my Big Hammer.
Have you done anything to Trigger since the WeeeKend? I've got a replacement bit for the carb that Steptoe broke.
I'll try and drop it off to you before we head off on holiday.
Tibs

Not touched Trigger in months since you stripped down the instruments. Didn't know anything was wrong with the carbs. Been busy working on other bikes. Son's Fazer 600 needs new tyres, brakes, chain & sprockets, MOT etc so that is top priority at moment.

I should be around all next week so please call around anytime.

Sid

 

[(RIP) Tibs]

I'll drop by towards the end of the week for a catch up.

 

[patanga]

Africa twin almost fitted straight on. Only needed a couple of washers/spacers to sit tight.

My welder/engineer has taken away the entire frame, sub-frame, extended swinging arm and rear shock. He has constructed a large jig to ensure everything is lined up perfectly.

It will be my winter project.

Another question if I could please: Which Africa Twin model did the forks come from? (750 / 1000, year model etc). Has this been a common swap on Airheads?.... Have these been tested out in the field and if so how are folk finding them compared to the O.E. GS option? Thanks

 

[Crapaud]

Time for update.

To answer above question. Sorry not sure which model/year of Africa twin.

Finally got my frame and swingarm back from my welder chap. This might be one of the first airheads with a KTM back end on it. Of course I could have gone the Richie Moore or HPN route but I like to be different and not follow the crowd. Also I'm careful with my money and hate spending it unless I have to.

I might add up the total cost of this project at the very end but I don't want to spoil the process at the moment.

Some of you lot may well think my approach and result to the rear suspension is a total abortion but you can't deny that it is unique. The mountings for the top of the shock are very substantial as the frame has been braced where required. The swingingarm has been extended by 100mm (4 inches to the old timers) and a cross brace added to take a KTM copy bottom shock mount. We have made the top shock mount adjustable so that I can fine tune the ride height etc later.

All unneccessay frames mounts will be removed and the frame etc will eventually be powder coated in the blue similar to a HP2 frame.

My welder has spent a lot of time making up the required jigs so could reproduce similar frames if this project turns out successful.

I've taken a few general pictures but like Richie Moore, don't want to show very detailed pictures for others to copy as so much work has gone into this.

It is still very early days in this project but I'm looking forward to spending numerous hours on it over the winter.

 

[Kenny]

Great thread Sid, totally unique, keep up the excellent work

 

[Crapaud]

Took it all apart again today.

Just the bare frame in the stand. Carefully removed a few unwanted bits and starting to clean up the frame.

On inspection the back wheel has a tiny crack in the rim so I'll have to get a nice new shiny black rim laced up to match the new front wheel I bought. First pictures were taken with an old KTM wheel but that was replaced with lovely shiny new black wheel with stainless spokes. I tried to undo the spokes but got fed up. As I happened to have the angle grinder in my hand at the time (dangerous!), it was easier to use that. Will need to clean up rear hub and then take a trip to Devon Wheel Co (I think they are just down the road on the way to Sherlocks).

The more I investigate this, the more I realise that this may cost me a few quid over the winter. However, I won my long term battle today with the local Council about my imaginery house so they are due to pay me some money. Best idea is obviously to invest in into Airhead parts.

 

[(RIP) Tibs]

Best idea is obviously to invest in into Airhead parts"

That's frightfully kind old chap, I'll send you a list!

 

[Crapaud]

I spent a few more hours working on the frame today. I want to ensure that it is perfect before I send it to be powder coated. This meant hours of filing the various bits of metal that had been added for strength.

Next job was building the new rear sub frame. It might be nice to buy a Qtech unit but again I want it to be cheap and I want it to be unique. So I've started with an old sub frame from a KTM enduro. The beauty is that it is incredibly light but still strong enough for what I need. The bike will be a single seater enduro/rally machine so most of the time it will be ridden standing up. Also the shock absorber is mounted direct to the main frame so all the rear sub frame has to do is support the rear mudguard and the seat. The exhausts will mostly be supported by the main frame with only minimal brackets from the sub frame.

It is great fun looking around my large workshop to see what bits can be used. It reminds me of the TV show "Scrapheap Challenge". Far more satisfying that just writing out large cheques to other companies.

A covert photo:

 

[SeanW]

Hey Sid - I'm curious about the shock layout you've gone for. Was it designed on the basis of looks right /feels right, or something more scientific?

Suppose the thing that strikes me about it is that the shock's positioning makes it look like it is going to end up only working within a limited part of its possible travel. Ie it might only use 2 inches out of a maximum available travel of 4 inches. if the shock wasn't originally designed to only work near the top of its stroke, the ride might be a bit odd?

Though maybe it's a short travel shock from a bike with similar geometry? In fact looking at the position of the bump stop on the damper rod, that does look like a distinct possibility...

 

[Crapaud]

Hey Sid - I'm curious about the shock layout you've gone for. Was it designed on the basis of looks right /feels right, or something more scientific?

Suppose the thing that strikes me about it is that the shock's positioning makes it look like it is going to end up only working within a limited part of its possible travel. Ie it might only use 2 inches out of a maximum available travel of 4 inches. if the shock wasn't originally designed to only work near the top of its stroke, the ride might be a bit odd?

Though maybe it's a short travel shock from a bike with similar geometry? In fact looking at the position of the bump stop on the damper rod, that does look like a distinct possibility...

The entire bike is a bit scientific, a bit experimental and a bit Scrapheap Challenge ie using whatever bits I find in my workshop. However, most of the "found" bits are being replaced with purpose built stuff.

The shock was a left over KTM unit. However, it will be fully rebuilt with a heavier rated spring. It is being used at exactly the same angle as original. The top mount is adjustable to allow the mounting to be moved about 50mm to alter the angle and ride height.

Today I have cleaned up the rear wheel hub as that was in a bit of a state. New brake shoes will be needed.
Next job was designing and making up new foot rests. The old R65 ones were solid thick rubber ones totally unsuitable for off-roading. I managed to make new brackets which will take foot pegs similar to the ones on my R1100GS. There is something very satisfying about spending hours of your time cutting and filing metal to eventually end up with a unique new piece you have made yourself.

 

[k80matey]

Great thread, enjoying it a lot and looking forward to seeing it finished.

You mentioned earlier you might be selling some of the original bits that would be surplus to requirements? Looking for headlight brackets for my '77 R60/7 rebuild and think the ones from the R65 would fit.

Let me know if you have them and want to sell.

Ta.