The Diesel Project - Page 8

**JerryHawk250** · 12-22-2020, 08:42 AM

My mom turn 95 yesterday. She get around better than I do. lol

**cheesy** · 12-23-2020, 11:22 AM

Headlight and taillight wiring is done.

Still have brake, signals, and probably a neutral safety switch to do.

No pic of the headlight cuz it's blinding.

**JerryHawk250** · 12-23-2020, 11:24 AM

Looks good!

If someone rear ends you with that bright tail light they are totally blind. lol

**cheesy** · 12-24-2020, 01:55 PM

I now have working brake lights. Halfway through the turn signals. That's causing some head banging because I had to rewire the innards of the headlight bucket. Damn 24ga wires.

**cheesy** · 12-24-2020, 04:44 PM

We now have working lights all around. Couple of videos without my lilting Midwest twang but with Christmas music.

All Working by Mike Bullis, on Flickr

Front Works by Mike Bullis, on Flickr

Sorry about the jiggling but my arms only stretch so far.

Merry Christmas folks.

**cheesy** · 12-27-2020, 05:37 PM

Cleaned up and loomed the wiring this afternoon. Almost looks professional. Almost. About all that's left that I can do without the tubes is figuring out where to mount the starter switch, mount the speedo, and rebuild the front caliper.

**cheesy** · 01-09-2021, 05:12 PM

When I showed the Diesel Project to the grandsons last week, I found the left front turn signal not working. Looked into it this morning and found one of the pins in the plug out of place. All better and I made sure the pin clicked in place this time. For grins, I checked the total amp draw of the lights. With the tail lights, headlight on high beam, brake on, and the right turn signals flashing, the draw was a paltry 0.82 amps. I will take that any day.

It also turns out that I now have a couple of helpers. Both the boys didn't know grandpa could do magic with electricity or glue two pieces of metal together with fire. Or actually work on motorcycles. They just thought I rode them.

I'm figuring their help will only push the project back a few more months.

**cheesy** · 02-21-2021, 01:40 PM

So, something happened with the Diesel Project today. I got the tubing bender mounted to the bench and bent metal.

First attempt with 15 x 2 hydraulic tube.

Took a bit o' grunt but it came out pretty decent.

Okay, so I bent a tube. In my employers eyes, I saw it and did one, therefore I can now build Saturn 5 rockets(dating myself and I ain't BSing about GNA).

Time to try some 1" x 1/16" steel tubing for the frame.

I set everything up, double check my measurements because, even though this is Outhouse Engineering and Fabrication where our motto is "Measure Once And Hope For The Best", that tubing is not some of Menards' finest Chinese 1010 hot rolled. It cost real money. Back on task...I grab the handle and pull.

The 1" tube just laughs at me. I change my position and get behind to push the handle. EERRGGHHH! Nothing. Try again. MJ comes on the radio just after Madonna. Gahh! I don't want to hear this. EERRRGGHHH! Nothing. Catch my breath and search for something to use for a 'torque enhancer' because 'cheater bars' are mucho illegal on the railroad.

I cobble together enough 'TE' material to get a 6.5' extension and commence to push and pull and grunt and groan and pant. Yay? It's bending. It takes a good 5 minutes of starting and stopping, but I get my bend. I check it against the frame. Perfect.

Now comes the hard part. Making the second one exactly the same as the first one. Not always easy. Get set up and start bending. Good lord, this is hard work and I'm already pooped. Darkness gathers at the edge of my vision and my breath comes in ragged gasps. Blood is pounding in ears. ELO comes over the Zenith. At least I think it's ELO, too noisy in my head to be sure. Better than the other crap the local AM classic station subjected me to(Also known to play, gasp, Disco). Got this one bent, too, but it took almost 10 minutes and I had to sit down for a breather.

Lo, and behold, the second tube is a perfect match to the first. Fist bumps and toasts all around.

If I ever consider modifying another MC frame and it requires the use of 1" tube, I'm springing for a hydraulic tube bender.

Emerikol · 02-21-2021, 07:42 PM

Quote:

Originally Posted by cheesy

"Measure Once And Hope For The Best"

Totally ripping this off!!

david3921 · 02-21-2021, 08:48 PM

I've seen that bender on Amazon for around $150. In your opinion, would it be able to bend conduit without pinching it? And if so, what's the smallest die you could go to for 3/4"?

**cheesy** · 02-21-2021, 09:55 PM

Quote:

Originally Posted by david3921

I've seen that bender on Amazon for around $150. In your opinion, would it be able to bend conduit without pinching it? And if so, what's the smallest die you could go to for 3/4"?

To your first question, yes. It has a rolling die for the outside of the radius so it doesn't pinch. Not sure if you are asking about the size of the radius on your second.

$115 on fleabay. Handles 3/8"-10mm to 1"-25mm.

david3921 · 02-22-2021, 12:01 AM

Quote:

Originally Posted by cheesy

To your first question, yes. It has a rolling die for the outside of the radius so it doesn't pinch. Not sure if you are asking about the size of the radius on your second.

$115 on fleabay. Handles 3/8"-10mm to 1"-25mm.

I completely forgot that there are different sized dies. Thanks.

**cheesy** · 03-01-2021, 08:35 AM

Looks like it's time for Plan A v2.0, followed by Plan B. Possibly followed by Plan C. No matter how I look at it, I can't cram ten pounds of crap into a five pound bag without stretching the entire frame 4". I didn't take the starter motor into account when I went over the Lambordini dimensional chart. Right now, the engine is halfway into the front tire. That ain't gonna work.

Plan A v2.0 is a maybe. I MAY be able to rotate the starter 180* if it is like many small engine starters that don't have a nose. I'd gain a couple of inches with the solenoid going up instead of down. Then I'd need to do more hacking on the transmission case, probably losing the transmission oil pump in the process. Plan A, v1.0 and v2.0 just may end up in the 'Experience Pile'.

Plan B would consist of rotating the engine 180* and fitting a Comet 30 Torque Converter. Cheap and fairly easy to do, though I'd need to get creative from the jack shaft to the rear wheel because of the Suzukis' chain size.

Plan C would consist of slicing open a vein for an HD tranny and clutch. More compact than the Suzuki transmission but 4, 5, and 6 speeds lack an overdrive. Did I mention that they are expensive?

It always seems that it is a good idea, but...

franque · 03-01-2021, 11:32 AM

As long as the gear ratios are spot on, overdrive isn't necessary if you get the primary ratio right as well.

Emerikol · 03-01-2021, 09:14 PM

Quote:

Originally Posted by cheesy

No matter how I look at it, I can't cram ten pounds of crap into a five pound bag without stretching the entire frame 4". I didn't take the starter motor into account when I went over the Lambordini dimensional chart. Right now, the engine is halfway into the front tire.

Measure once and hope for the best!

12-22-2020, 08:42 AM	#106
JerryHawk250 Moderator Join Date: Oct 2016 Location: Houma, La. Posts: 11,707	My mom turn 95 yesterday. She get around better than I do. lol __________________ 2024 Linhai 300 ATV 4x4 2023 Lifan Lycan 250 Chopper 2023 Venom Evader 2022 Lifan KPX250 2020 Kawasaki Vulcan S (Sold) 2004 Honda ST 1300 2016 Black Hawk 250 (sold) Keihin PE30 carb,125 main,38 slow.Pod filter,ported & decked head 10:1 CR,Direct Ignition Coil,15/40Sprockets,NGK DPR8EIX-9,De-Cat,Dual Oil Cooler,Digital Cluster 2016 Cazador180 XL 2014 Coolster150 JerryHawk250.com My YouTube Channel
	2

12-23-2020, 11:22 AM	#107
cheesy Moderator Join Date: Jul 2010 Location: Elburn, IL Posts: 5,962	Headlight and taillight wiring is done. Still have brake, signals, and probably a neutral safety switch to do. No pic of the headlight cuz it's blinding. __________________ Cheesy ______________________________________ 07 Hi Bird Enduro-Flown the Coop 07 Ural Gear Up 79 Honda CX500 77 VeloSolex 4600 V3 73 VeloSolex 3800 I'm making this up as I go.-Indiana Jones Telling me something 'is for my own good', is a fast way to a fat lip.-Me I don't even care about my own problems, why should I care about yours?-Quote on one of my favorite t-shirts
	2

12-23-2020, 11:24 AM	#108
JerryHawk250 Moderator Join Date: Oct 2016 Location: Houma, La. Posts: 11,707	Looks good! If someone rear ends you with that bright tail light they are totally blind. lol __________________ 2024 Linhai 300 ATV 4x4 2023 Lifan Lycan 250 Chopper 2023 Venom Evader 2022 Lifan KPX250 2020 Kawasaki Vulcan S (Sold) 2004 Honda ST 1300 2016 Black Hawk 250 (sold) Keihin PE30 carb,125 main,38 slow.Pod filter,ported & decked head 10:1 CR,Direct Ignition Coil,15/40Sprockets,NGK DPR8EIX-9,De-Cat,Dual Oil Cooler,Digital Cluster 2016 Cazador180 XL 2014 Coolster150 JerryHawk250.com My YouTube Channel
	2

12-24-2020, 01:55 PM	#109
cheesy Moderator Join Date: Jul 2010 Location: Elburn, IL Posts: 5,962	I now have working brake lights. Halfway through the turn signals. That's causing some head banging because I had to rewire the innards of the headlight bucket. Damn 24ga wires. __________________ Cheesy ______________________________________ 07 Hi Bird Enduro-Flown the Coop 07 Ural Gear Up 79 Honda CX500 77 VeloSolex 4600 V3 73 VeloSolex 3800 I'm making this up as I go.-Indiana Jones Telling me something 'is for my own good', is a fast way to a fat lip.-Me I don't even care about my own problems, why should I care about yours?-Quote on one of my favorite t-shirts
	0

12-24-2020, 04:44 PM	#110
cheesy Moderator Join Date: Jul 2010 Location: Elburn, IL Posts: 5,962	We now have working lights all around. Couple of videos without my lilting Midwest twang but with Christmas music. All Working by Mike Bullis, on Flickr Front Works by Mike Bullis, on Flickr Sorry about the jiggling but my arms only stretch so far. Merry Christmas folks. __________________ Cheesy ______________________________________ 07 Hi Bird Enduro-Flown the Coop 07 Ural Gear Up 79 Honda CX500 77 VeloSolex 4600 V3 73 VeloSolex 3800 I'm making this up as I go.-Indiana Jones Telling me something 'is for my own good', is a fast way to a fat lip.-Me I don't even care about my own problems, why should I care about yours?-Quote on one of my favorite t-shirts
	2

12-27-2020, 05:37 PM	#111
cheesy Moderator Join Date: Jul 2010 Location: Elburn, IL Posts: 5,962	Cleaned up and loomed the wiring this afternoon. Almost looks professional. Almost. About all that's left that I can do without the tubes is figuring out where to mount the starter switch, mount the speedo, and rebuild the front caliper. __________________ Cheesy ______________________________________ 07 Hi Bird Enduro-Flown the Coop 07 Ural Gear Up 79 Honda CX500 77 VeloSolex 4600 V3 73 VeloSolex 3800 I'm making this up as I go.-Indiana Jones Telling me something 'is for my own good', is a fast way to a fat lip.-Me I don't even care about my own problems, why should I care about yours?-Quote on one of my favorite t-shirts
	1

01-09-2021, 05:12 PM	#112
cheesy Moderator Join Date: Jul 2010 Location: Elburn, IL Posts: 5,962	When I showed the Diesel Project to the grandsons last week, I found the left front turn signal not working. Looked into it this morning and found one of the pins in the plug out of place. All better and I made sure the pin clicked in place this time. For grins, I checked the total amp draw of the lights. With the tail lights, headlight on high beam, brake on, and the right turn signals flashing, the draw was a paltry 0.82 amps. I will take that any day. It also turns out that I now have a couple of helpers. Both the boys didn't know grandpa could do magic with electricity or glue two pieces of metal together with fire. Or actually work on motorcycles. They just thought I rode them. I'm figuring their help will only push the project back a few more months. __________________ Cheesy ______________________________________ 07 Hi Bird Enduro-Flown the Coop 07 Ural Gear Up 79 Honda CX500 77 VeloSolex 4600 V3 73 VeloSolex 3800 I'm making this up as I go.-Indiana Jones Telling me something 'is for my own good', is a fast way to a fat lip.-Me I don't even care about my own problems, why should I care about yours?-Quote on one of my favorite t-shirts
	2

02-21-2021, 01:40 PM	#113
cheesy Moderator Join Date: Jul 2010 Location: Elburn, IL Posts: 5,962	So, something happened with the Diesel Project today. I got the tubing bender mounted to the bench and bent metal. First attempt with 15 x 2 hydraulic tube. Took a bit o' grunt but it came out pretty decent. Okay, so I bent a tube. In my employers eyes, I saw it and did one, therefore I can now build Saturn 5 rockets(dating myself and I ain't BSing about GNA). Time to try some 1" x 1/16" steel tubing for the frame. I set everything up, double check my measurements because, even though this is Outhouse Engineering and Fabrication where our motto is "Measure Once And Hope For The Best", that tubing is not some of Menards' finest Chinese 1010 hot rolled. It cost real money. Back on task...I grab the handle and pull. The 1" tube just laughs at me. I change my position and get behind to push the handle. EERRGGHHH! Nothing. Try again. MJ comes on the radio just after Madonna. Gahh! I don't want to hear this. EERRRGGHHH! Nothing. Catch my breath and search for something to use for a 'torque enhancer' because 'cheater bars' are mucho illegal on the railroad. I cobble together enough 'TE' material to get a 6.5' extension and commence to push and pull and grunt and groan and pant. Yay? It's bending. It takes a good 5 minutes of starting and stopping, but I get my bend. I check it against the frame. Perfect. Now comes the hard part. Making the second one exactly the same as the first one. Not always easy. Get set up and start bending. Good lord, this is hard work and I'm already pooped. Darkness gathers at the edge of my vision and my breath comes in ragged gasps. Blood is pounding in ears. ELO comes over the Zenith. At least I think it's ELO, too noisy in my head to be sure. Better than the other crap the local AM classic station subjected me to(Also known to play, gasp, Disco). Got this one bent, too, but it took almost 10 minutes and I had to sit down for a breather. Lo, and behold, the second tube is a perfect match to the first. Fist bumps and toasts all around. If I ever consider modifying another MC frame and it requires the use of 1" tube, I'm springing for a hydraulic tube bender. __________________ Cheesy ______________________________________ 07 Hi Bird Enduro-Flown the Coop 07 Ural Gear Up 79 Honda CX500 77 VeloSolex 4600 V3 73 VeloSolex 3800 I'm making this up as I go.-Indiana Jones Telling me something 'is for my own good', is a fast way to a fat lip.-Me I don't even care about my own problems, why should I care about yours?-Quote on one of my favorite t-shirts
	2

02-21-2021, 08:48 PM	#115
david3921 Join Date: Feb 2009 Location: Michigan Posts: 1,040	I've seen that bender on Amazon for around $150. In your opinion, would it be able to bend conduit without pinching it? And if so, what's the smallest die you could go to for 3/4"? __________________ 2012 Kawasaki Versys 1984 Honda Magna V65 2016 Rhino 250 2016 Tao Tao 125D
	0

03-01-2021, 08:35 AM	#118
cheesy Moderator Join Date: Jul 2010 Location: Elburn, IL Posts: 5,962	Looks like it's time for Plan A v2.0, followed by Plan B. Possibly followed by Plan C. No matter how I look at it, I can't cram ten pounds of crap into a five pound bag without stretching the entire frame 4". I didn't take the starter motor into account when I went over the Lambordini dimensional chart. Right now, the engine is halfway into the front tire. That ain't gonna work. Plan A v2.0 is a maybe. I MAY be able to rotate the starter 180* if it is like many small engine starters that don't have a nose. I'd gain a couple of inches with the solenoid going up instead of down. Then I'd need to do more hacking on the transmission case, probably losing the transmission oil pump in the process. Plan A, v1.0 and v2.0 just may end up in the 'Experience Pile'. Plan B would consist of rotating the engine 180* and fitting a Comet 30 Torque Converter. Cheap and fairly easy to do, though I'd need to get creative from the jack shaft to the rear wheel because of the Suzukis' chain size. Plan C would consist of slicing open a vein for an HD tranny and clutch. More compact than the Suzuki transmission but 4, 5, and 6 speeds lack an overdrive. Did I mention that they are expensive? It always seems that it is a good idea, but... __________________ Cheesy ______________________________________ 07 Hi Bird Enduro-Flown the Coop 07 Ural Gear Up 79 Honda CX500 77 VeloSolex 4600 V3 73 VeloSolex 3800 I'm making this up as I go.-Indiana Jones Telling me something 'is for my own good', is a fast way to a fat lip.-Me I don't even care about my own problems, why should I care about yours?-Quote on one of my favorite t-shirts
	3

03-01-2021, 11:32 AM	#119
franque Join Date: Nov 2017 Location: Marseille, France -> Conakry, Guinea Posts: 1,481	As long as the gear ratios are spot on, overdrive isn't necessary if you get the primary ratio right as well.
	1