Thursday, April 20, 2017

Project Tonka - TW200 Custom Seat Build

The seat build for the Tonka build has come to an end with the leather work completed this week.

The construction was fairly simple with a fibreglass base with steel locators glassed into the base.  The base consisted of 6 layers of woven mat with a polyester resin which should hold up to any big boned riders.

I then picked up a block of high density foam which I attached to the base with some contact adhesive and continued to shape it with a hack saw blade until the rough shape was completed.  After that it was a flap disc on the angle grinder to smooth out all the bumps.

Sourcing some leather was fun as there were so many options but the client wanted somewhat of a tanned antique look.  I found something suitable out west and up getting a full hide which I'll be able to get a couple more seats out of.  

It follows the lines of the tank and frame and the vintage leather will age nicely over time.

Now to get it on the road!

Tuesday, March 14, 2017

Project Tonka - Gaskets and Wire

Cases split ready for new gaskets and a new front sprocket

The Tonka Project is getting close to finishing up.  I needed to replace the front sprocket and with these TW's you need to remove the left side engine case to do so.

So because of this I took the opportunity to split the cases and check out the internals and replace the gaskets at the same time.  I also replaced the all the bolts with the shiny stainless type.

After wrestling with getting the engine back in (found that using a mobile engine stand was the best way) I proceeded to layout the wiring.  I'm using an Antigravity under the seat and moving all the electricals under the seat.

The existing harness already had some work done to it with a couple of splices here and there, and I'd noted that the neutral and rear brake switch weren't working.

Powered by Antigravity

I ended up running a new neutral wire from the switch and pulling the rear brake switch apart to find a broken wire which I replaced.

Still waiting on a the indicators and the electrics will be done.

Rear Brake Switch with a non-existent connection

Wednesday, February 15, 2017

Buildboard V2.0 Beta is Now Live

Get your Sh*t Together in 2017

Let this year be the time you dust off those tools, and finish off those projects that have become a hostel for your local spider gang.
Buildboard was launched 3 years ago to allow handcrafted bike enthusiasts to source parts and keep track of their motorcycle builds easily.  It has grown to a community of hundreds of users worldwide including Australia, the US, UK and Poland
This new release celebrates the 3rd birthday of Buildboard and showcases new features including an updated skin, and the ability to tag, comment and share your photos of your project.
Buildboard now caters for a number of other build types reflecting the maker's revolution and the new wave of personalised hand crafted goods.

If you have any suggestions on how we can improve it we'd love to hear.  Many of the new features and enhancements have come from feedback we've received. 
If you need a bit of inspiration for your project, you can see what other builders users are doing

Or sign up for your free account.

Have a great year


Sunday, February 5, 2017

Project Tonka - Blast and Paint

All the body work is complete and I spent an afternoon pulling everything apart ready for the sandblaster.  Because the client had decided on stainless spokes I ended up cutting the rusted old ones to make removing the hubs easier.  It also meant that I could get a really clean finish by pulling the hubs completely apart.

The shock also needed some TLC so I decompressed it and removed the spring and send that off for powder.  Decided on a yellow spring to match the new gold chain we'll be running.

Everything came out really nice so I'll be looking forward to getting it all back together.  I'm just waiting on a few more parts to arrive for the forks before I can start.

Thursday, December 29, 2016

Painting the Buell headers

The Buell front forks were leaking so as a result I had to rebuild them.  While I was waiting on a few parts to arrive, I thought I take the opportunity to give the headers a bit of a clean up.  With some left over heat resistant paint I coated them a few times before curing them on the bike.

My camera ran out of battery while I was spray painting them so I had to find a substitute video to show the similar process.

Let's see how long the paint lasts for.

Monday, December 19, 2016

Build Diary Video Part III - TW200 Rear Fender Mount

I finally had some free time to edit some footage of making the rear fender mount.  Quality isn't that great as I'm using an old point and shoot.  I also forgot to film some of it including making the threaded bungs.

TW200 Build Diary Part 3

Monday, December 12, 2016

The Experiment - Yamaha SRX250 Cafe Racer

We found this bike on ebay as a stock 1987 Yamaha SRX250.  I was pretty excited to win the bike at a fairly low price even though there wasn’t much information at the time about this particular model.  Which is no surprise as Yamaha had only manufactured this for a couple of years.

We had picked up the bike from an area in Brisbane known for it’s close proximity to a large university and it’s toga parties.  I spoke with the then owner for a while, mainly small talk about the weather, the government and the fact that this might have yamaha’s 80’s experiment gone wrong, he then mentioned that he was in fact a scientist at the nearby university.  Irony aside is was only fitting that we named this “The Experiment”.

Once we removed all of the plastic a neat looking frame begun to reveal itself.  We kept the stock tank and hand shaped the rear seat cowl, with an integrated LED taillight.  We sourced some leather from an old mercedes bendz that we used to cover the seat pan.

Bars are controlled through some mini toggle switches to clean up the recycled clip ons We also added a nice stainless shorty exhaust to give it a throaty note and finished it off by airbrushing a mad scientist on the tank.

It all came under budget by reusing and sourcing some second hand bits and doing everything ourselves, besides the upholstery.

I was fortunate to have this bike on display at a new Maker Space opening and managed to finally take some shots.

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