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Lynrd
| | Posted on Wednesday, April 02, 2014 - 12:57 am: | 
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Oops...one problem. X1s apparently didn't have a clock, or wiring for a clock in the harness. I'll have to decide if I want the clock bad enough to add the wiring for it.
Headlight, Start, and Kill all wired! Headlight/Fairing mount is just waiting for the bulb to arrive in the mail so I can make sure the bulb is oriented right before I finish attaching the bucket. It really has come out nice, if a bit over-engineered... |
Phelan
| | Posted on Wednesday, April 02, 2014 - 08:49 am: |
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It's just two wires and a fuse. I say go for it. |
Lynrd
| | Posted on Friday, April 04, 2014 - 10:45 pm: |
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Moonshot weekend!
There always seems to come to a time in a bike build when the subject is on the ragged edge of transforming from a 'motorcycle shaped object' into a 'Motorcycle'. Gloria is there.
As a Art School graduate, I firmly believe in the motto "If it was not for the last minute, nothing would get done". I work best with a deadline. This Monday is Flat Track Night at ASBN - and Flat Track Night would be a great time for this "SR-1200" to make her debut from the garage.
She won't be 100% together - I need to sort out the rear caliper, and I haven't even started the seat cover - but I am pretty sure I can have a running Fuel Injected S2 on display...she'll just probably have to make the trip in the Van of Love.
So - "Moonshot Weekend": a personal tradition that usually happens shortly before some big show or Rally. All other tasks are laid aside and I will be locking myself in the garage tomorrow morning, knocking out the remaining "First build" one at a time.
The Gelcoat is already in the mold and will set overnight. I hope to be executing this plan tomorrow:
-Complete the Fuel pump installation in the tank
-Finish the dash cover - transfer the gauges and idiot lights
-Connect and install the horn.
-Source and install Clutch cable
-Fab and install the ignition switch plate and switch
-Finish the last of the wiring - Regulator and oil pressure switch
-Lay the 'glass for the tail section, including forming the taillight mount panel and inner panels.
-Cut and install oil lines.
That will leave Sunday for refinement of whatever I am not happy with from the above list, and initial tuning.
Beer and cigars are well stocked. Moonshot weekend begins NOW! |
Phelan
| | Posted on Friday, April 04, 2014 - 11:26 pm: |
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Nice! I'm diggin' the progress. Let me know how it works out putting the fuel pump in the stock tank. I'm planning on converting my S2 to fuel injection at some point as well.
BTW I found your email in my junk folder today, so I moved it and replied. I definitely need that windshield!  |
Lynrd
| | Posted on Sunday, April 06, 2014 - 11:51 pm: |
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Sooooo close....
Ran out of material for the dash mount. And I overlooked the exhaust hanger stuff. I feel a sick day coming on...
Fuel pump is installed. Looks like the low fuel light isn't lighting, but it runs when the key turns on. CEL is behaving normally per the manual. I haven't started it yet.
Most of the list above is done. Some easy stuff light tightening the mirrors and hooking up the taillight remains.
First tailpiece is out of the mold. Looking pretty good, needs a bit of gelcoat touch up, but it fits as it should. Like Greg's #13 bike, I pulled this one out of Kevlar.
No pictures yet...but maybe some tommorow... |
Lynrd
| | Posted on Tuesday, April 08, 2014 - 12:40 am: |
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And...she did NOT make it to ASBN Flat Track night.
Probably for the best - next month she should street legal and moving under her own power. There were a lot of incredibly cool bikes at Flat Track Night - my favorites were a Champion framed Triumph unit construction Bonnie, and a very cool XR-750. My primered "SR-1200" motorcycle shaped object may have been outclassed by the field this go around...but she'll get there.
I was stymied, at the end, by a front wheel that seems locked up. I spent so much time on everything else, I didn't really go over that - she has been rolling, but now with brakes and everything installed - something is wrong...I didn't discover this unit it was time to load in, so a quick change of plans, and Rhonda was, of course, ready and eager to make the trip to Fremont.
So, I am out from under the self imposed deadline now... but eager to get her to the next level.
Gauges are on, but I want to make a second dash panel as there are a few refinements to be made there.
A little bit o' wiring, rear brake and taillight...fab the exhaust hangers, and a license plate backing plate....and add fluids. Maybe pushing that button tomorrow night... |
Lynrd
| | Posted on Wednesday, April 09, 2014 - 12:11 am: |
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Well, if anyone is following along - the problem with the front wheel was that one of the caliper bolts was slightly too long - it was hitting on the carrier bolts for the early 9 pin cast iron caliper. Correct size is 3/8-16 x 1"...now I could roll her outside for some snapshots.
Here is how she sits this evening.
She has turned out to be a super skinny thing...perfect for that California lane splitting. With the exhaust tucked inside the frame, the air cleaner is the only thing that extends past the frame. I adapted some Delrin frame sliders into the olde gas tank cover mount holes and where the rear passenger pegs would go if I believed in passengers.
I'm not sure on the fairing - I'm thinking maybe an old Ducati style.
She cranks and turns, has tried to hit, but it hasn't lit. Sadly, the tank is leaking a bit at the fuel pump wire hole.. Maybe I should not have re-used those olde seals. I am not looking forward to sticking my hand back in the tank to reseat the pump - I tore the crap out of the skin on my hand getting it seated last time.
I get out the ECMSpy cable out, and downloaded the program for a peek into the situation. Now I'm waiting for the registration to go through so I can install the right database so I can find out if there are any error codes being thrown.
For the seat, I am going to do a snap-on style solo cover like the old XLCR Solo saddle. There is a leather shop right around the corner from me - I believe I will go talk to them tommorow
The ethic for this build has been, and will continue to be...no modification to the frame - keep the bike so that it could still accept the stock S2 bodywork.
(Message edited by LYNRD on April 09, 2014) |
Cheese
| | Posted on Wednesday, April 09, 2014 - 08:55 pm: |
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I love the idea of an old ducati SS fairing, or maybe a dunstall half fairing. there is something about those backswept half fairings that just look right. |
Lynrd
| | Posted on Thursday, April 10, 2014 - 11:03 pm: |
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Bingo - those are two of the three I am considering.
Here is the Ducati...
Here is the Dunstall
and the third option is the "Knoscher".
What I am disliking in the current one is the squared off look below the headlight, and it looks just a bit massive. I think the stronger horizontal lines of one of these half fairings would improve that a lot.
The differences are subtle, but anyone have any thoughts on aesthetics here? |
Jon
| | Posted on Thursday, April 10, 2014 - 11:30 pm: |
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Looks good. I prefer the Dunstall due to the cut out at the top of the wind screen. Seems to be more rider friendly. |
Jolly
| | Posted on Friday, April 11, 2014 - 07:27 am: |
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The project is really coming along nicely! Lots of custom work and time in the seat pan/ tail, it's really going to look great with paint on it!
I agree as well, the current fairing is just too boxy for the bike and it becomes the focal point.
I think all three options look good but the Ducati appears to offer the most room for handlebar options.
You need something that compliments the "street tracker" tail without looking as if you changed design approach halfway back from the front of the bike. |
Lynrd
| | Posted on Friday, April 11, 2014 - 12:34 pm: |
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Glad you said "Handlebars" - The bars are S2T style and therefor a bit taller than most of the bikes I am showing. THe headlight location is completely fixed - as in "welded in place"...I could move it if I have to, but it would be a drag.
Now I am thinking either the Ducati or, probably, the Dunstall Quarter fairing:
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Lynrd
| | Posted on Saturday, April 12, 2014 - 02:00 pm: |
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Or...I could just use the inside of the current one as a starting place and then build a form of what I am after. Lead times at Airtech are several weeks, and I can go through the whole form/mold/piece process in less time for less money.
I believe I am going to go that direction.
Thankfully the bike does not need the fairing to run - the headlight mounts pretty much like stock. , and the one on it can serve temporary duty until I have what I envision. |
Cheese
| | Posted on Tuesday, April 15, 2014 - 06:20 am: |
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I think the half fairings will tie in nicely with the frame, and will cover the fairing mount nicely. Your headlight is far enough out front that it doesn't look like the fairings will interfere with the bar. It looks like you ready made mounting points on your fairing mount for the part of the half fairings that run towards the back of the bike. Just my 2 pennies. |
Lynrd
| | Posted on Saturday, April 19, 2014 - 11:42 am: |
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My concern is more the relative height handlebars to headlight, the length from the headlight to where it should terminate on the top - and mostly the expense and lead-time of getting one that is not quite right from Air-tech - then modifying it anyway. I'm going to do some 'glass work today anyway - I have the second set of bodywork from Rhonda, her racing colors, and I believe it's time to fix that stuff up.... Since I will have all the materials out...well, why not?
But...that's not the big news. The big news is - I COMPLETED THE TITLE TRIP. Through some combination of experience and luck, that mess ended better than I hoped - not only is Gloria titled as a 1995 Buell S2 Thunderbolt - she did NOT end up with a "Salvage" branded title. The title is clean!
At the CHP, I was asked two questions by the inspecting officer that I think had an impact on this. Of course I just answered honestly, but these were the right answers.
Question 1: "So, you plan on riding this?" - my answer "Oh, hell yes!" Had I said "No, I am building it to sell" or any variation of that , that would open up a can of worms as I am NOT currently a registered manufacturer or even a dealer.
Question 2: "Where did the frame come from?" - this was the big one - I answered honestly - "Someone pulled the engine from this frame to build a stupid chopper, and I bought the frame off of them since they did not need it". If I had answered "They crashed it, and I bought it off of the owner after the insurance paid them off" or any variation of that - it would have been the salvage branding and salvage inspection.
The CHP did run the numbers through NICB database as part of the inspection, and the numbers came up clean, The DMV had run them previously, but I think they only check within California.
One other point that turned out just right - Since I have not painted the frame, it still had all of the factory Federal Certification stickers and emission labels on it. The inspecting officer had no problem filing out his section of the inspection form.
Now that I am through it, I want to write a separate post in the Knowledge Vault on the process - but I cannot finger out what section it would go in. Thoughts? |
Jolly
| | Posted on Saturday, April 19, 2014 - 12:12 pm: |
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CONGRATS ON THE TITLE! I know that in the end, since you probably plan on keeping the bike for a very long time, that it probably didn't matter, but it sure is great news to receive a clean title! perseverance, patience and tenacity through the red tape wins!
WELL DONE! |
Phelan
| | Posted on Saturday, April 19, 2014 - 03:01 pm: |
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Grats!!! I actually just got my new title in the mail today. One thing I noticed is that Texas doesn't track mileage after 10 yrs of age. They just mark mileage as exempt. On that note, I've added over 800 miles already since I got it legal last month  . |
Lynrd
| | Posted on Monday, May 19, 2014 - 09:58 am: |
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Funny story - I started working on the fairing. I decided I would make a fairing plug and pull molds from the same since I have a pretty clear vision of what it should look like.
I went for a new fangled spray on mold release instead of my tried and true turtle wax. The stuff did work really well on that acrylic screen - in came out perfectly smooth...but absolutely did NOT release the gelcoat from the ABS plastic fairing (I went to the inside to capture the shape around the headlight opening to build up for a fairing).
I went through all the gelcoat and first layer of glass work - then tested the release...tested it again...tried harder...harder...HARDER...OHMIGOD THIS IS REALLY ON THERE....CRAP!
picked up the phone, called Airtech, placed an order for a Ducati 900SS fairing...They said four weeks...
I haven't thrown that plastic fairing in the dumpster yet...but I probably will. I didn't break it, but that 'glass and gelcoat isn't going anywhere.
In the meantime - I finally got the last fuel leak chased down and stopped. I believe it is time for Gloria to climb in back of the Van of Love and go visit Fireman Jim... |
Lynrd
| | Posted on Monday, May 19, 2014 - 09:33 pm: |
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on a more positive note...she started and even sort of idled for a few seconds today....even before going up to JT&S... |
Phelan
| | Posted on Tuesday, May 20, 2014 - 10:09 am: |
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YAY!!! |
Lynrd
| | Posted on Wednesday, June 25, 2014 - 08:43 pm: |
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quick update - I dragged her up to JT&S, and Jim has her idling. That was really all I was after right now - to know that all the bits and pieces accumulated for this thing were going to work together. Jim re-routed a fuel line and did some ECM Spy mojo and charged me a very fair rate. I also managed to biff the throttle pretty good on the ride up there, and consequently I need to replace one of the cables before a proper TPS reset can be done.
The new fairing is here, and the new one is much closer to the look I was after. I haven't had a chance to get cracking on the mods to the fairing mount, what with getting Rhonda ready for the S2 Rally.
Finally - another badwebber was looking to get off of his spare 95 S2 motor. He put a lot of go-fast into the thing, and it sounded like just the thing for the "SR-1200" project. We worked out a deal and it should be en-route soon. The engine in her now came from the teardown of the Frog - a stock 2000 S3T engine with close to 50,000 miles on her. I was planning on rebuilding that one when the bike comes down for paint and plate, but I do believe that it will be faster and easier to just swap that hot rod engine in and deal with redoing the top end on that 2000 engine later.
(Message edited by Lynrd on June 25, 2014) |
Phelan
| | Posted on Thursday, June 26, 2014 - 09:17 am: |
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Nice John! Are you still planning on using the EFI parts on the build? |
Lynrd
| | Posted on Thursday, June 26, 2014 - 10:00 am: |
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Yep. That part hasn't changed. The new engine does not include the ignition or carb, and already has XB heads so it has a place for the cyl head temp sensor.
Doesn't a Fuel Injected 1250 with SE 536 cams and XB heads sound like fun?
(Message edited by Lynrd on June 26, 2014) |
Phelan
| | Posted on Thursday, June 26, 2014 - 10:17 am: |
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YES. It does . My goal is DDFI as well. I'll likely use X1 DDFI as a stopgap so I can play with it and ECM spy for a while, but my goal is a new motor build with a modified '08+ XB12 crank and DDFI3. |
Steveray
| | Posted on Thursday, June 26, 2014 - 01:48 pm: |
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I saw an article on the Biltwell blog archive about a sportster build where the owner utilized an external fuel pump on an injected sportster because he wanted a custom fuel tank. I think he used a ford mustang pump and mounted it exposed because he liked exposed components. Unfortunately the few photos did not show the pump. |
Phelan
| | Posted on Thursday, June 26, 2014 - 02:19 pm: |
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I wouldn't use anything with a FORD label because I want to ride it, not push it! XD |
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