Tuesday, October 25, 2016

Project Tonka - Rear Fender Mount

Things have been progressing pretty well.  With the fibreglassing of the fender complete I finished up with the rear fender mount over the last weekend.  I wanted to make this a single sided affair as on the right side of the bike I wanted the exhaust to be the hero and I felt having a support bracket to the rear fender would have spoilt that.

I made this out of 12mm round bar with 18mm slugs to connect them. This took a little time to get it right with a proper roller but I managed to bend the bar well enough using just a simple jig and a blowtorch.

I then created some bungs to mount the fender.  I had tapped 3 of them but snapped the tap inside one of them and took me the rest of the day to remove it.

I then reinforced the two supports with some steel sheet to stop lateral movement while riding.

Hoping to get the seat glassed this week so I can finally disassemble everything.

Tuesday, October 18, 2016

Build Diary Video Part II - TW200 Skid Plate

Finished off the custom skid / bash plate for the TW today.

Originally I wanted to give aluminium brazing a go for the first time but the stock that I'd bought ended up being too thick.  Because of this slight oversight, bending it would have given me a hernia.  So I spent a while thinking about the alternatives and I came to the conclusion to make one up with some left over steel sheet.

I first mocked it up with some cardboard and then used it as a template although not 100% accurate it did give me a good base to start.

Once I'd cut and bent it to the correct shape I tacked everything into place, once I was happy with the fit I welded it all up.  I then added some holes to reduce weight using a stepped drill bit.

The edges still need a clean up but will do all that before sending off to sandblasting.

Thursday, October 13, 2016

Build Diary Video Part I - How I made the TW200 Custom Fender

I had the original intention of documenting this build on video but as it turns out doing this requires charged batteries and new memory cards.  Two things that I didn't have at the time I started working on the bike.

I did however manage to setup the gopro for the fibreglass process.  Cut down a days job into under a minute.  Excuse the quality of video I'm still working on my editing skills.

I'll try and document most of the process from now on.

Tuesday, October 11, 2016

Project Tonka - Rear Fender Construction

Have made some good progress on the TW200 over the last couple of weeks.  Originally I was going to use a steel black fender and cut and shape to suit.  However I wasn't happy with the outer radius as most of these off the shelf fenders that would fit the 7" wheel were flat.

Scrap Ply to use for the plug

I decided to shape my own creating a plug out of plywood to replicate the radius of the wheel.  Once that was done I filled the spaces with expanding foam.  I probably should have used the two part expanding foam as the builders foam left too many air pockets after being shaped.

Nailed into place

Expanding foam to fill the voids

Should have used 2 part expanding foam as there were so many air pockets

Then I glassed a female mould with 2 layers of woven cloth and a layer of chop strand.  Because the foam wasn't perfect I had to spend a bit of time sanding and filling the holes left by the foam.

Next I created the final male mould, this time I used a Vinylester Resin for increased flexibility and strength compared to the Polyester.

Vinylester Resin with woven mat
Final result after sanding.  Ready for primer and paint

It came up really well after a trim and a light sand and fits perfectly to the rear tyre and is also super lightweight.  Now to fabricate the mounting hardware.

Friday, September 2, 2016

Honda CBN400 By Ed Turner Motorcycles

I was oblivious to Ed Turner Motorcycles until today when I stumbled across this Honda CBN400. The French workshop has been creating some one off customs for quite some time now, heavily influenced by 70's and 80's culture and the American Hot Rod scene.

 What I like about these builds is the attention to detail and the equal balance between machine and design. A perfect is example is the 1979 Honda CBN400

Pics by © Pierre Le Targat & Loïc Le Moullec

Friday, August 26, 2016

Project Tonka - Yamaha TW200

After a few months sourcing a new project I managed to pick up this 1990 TW200 in relatively good condition... by that I mean it ran.

TW200's a fairly slim pickings now a days since they stopped importing them into Australia a while back, along with being a popular base for custom builds.  The history of this bike as with most AG bikes was that it had sat on a farm until recently.

Unused and hanging with the tractors and other machinery for a number of years.  It was then picked up by "another guy" who had the intention of customising it but never got the chance.

The classic Tonka Truck with it's FAT wheels
The Dubs are recognised by their enormous fat rear tyre, and after hearing of it's history I couldn't help but to associate it with my childhood of playing Tonka Trucks in the sandpit.  For those that don't know anything about Tonka Trucks they were the toys to have in the sandpit.  Die Cast metal trucks that were able to move pales of sand from one side of the playground to the other.

Those were the days, digging around in the sandpit looking for your matchbox car that you'd buried last week, only to discover a nugget that your neighbor's cat had kindly left for you hours earlier. Anyway it seemed like a logical decision to name this build Tonka.
There are a couple of issues that I'll need to sort out.  The clutch drags quite a lot, also sounds like the valves need some adjusting but there are no significant knocks. The electric starter may need replacing at some stage but it's no biggie at the moment since it also runs a kicker.

The electrics have also been hacked into with a few things not running.  I'd love to use one of motogadgets m-units for this build but I don't think the budget will stretch this far.

Other than the obvious cosmetic damage it'll be a neat little build and my first commissioned build. Looking forward to getting stuck into it and learning and trying a few new things with this one.

The spaghetti harness that's already been hacked.  Neutral doesn't actually work

"Breather hole" in the crankcase cover

Wednesday, August 10, 2016

Screen Printing the LSG Logo Tee

I still get stoked when I get an order for one of our Tees come through.  It's so cool to be able to hand print these tees for someone that's gone out of their way to purchase one.

Thanks a bunch for the support everyone.


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