The Diesel Project

[bogieboy]

i like breaking into the workshop and playing with the big boy tools....LOL i built a cart for my new welder....

[cheesy]

Originally Posted by JerryHawk250

Those flap disk are magic. They will turn the crappiest welds into works of art. Ask me how I know. I couldn't tell you the last time I stick welded. I got spoiled with the MIG welder. lol I've done my share of stick welding back in the day of fabricating metal buildings. Spend all day welding up steel columns and rafters. Man was that boring. lol

The original plan was to just tack the mount in place using my tiny stick inverter because I didn't need to move half the garage to get it to the bike. I also just kept going.
I wanted to try the Eastwood TIG/Stick welder but didn't have enough cable length to get it there. Probably would not have been able to get the TIG torch in there but I could have gotten serious with some 1/8" 7018 rod instead of the 1/16' 6013 I was using.

[cheesy]

So, made the welds look better. Not pretty, but better. While doing this, I realized that I didn't have a mount for the tail light and license plate holder or the horn.

The back of the frame is open. There is supposed to be a rack back there but I imagine it has gone to that great recycler in the sky. 15mm hydraulic tube to the rescue. Cut a piece of tube to fit between the ears of the frame, then cut a piece of 10mm tube about a 1/2" shorter that I dropped into the larger tube to support the M8 nuts I brazed in place. That's bolted to the frame now.

I did a layout for the tail light bracket on 16ga steel. That will get cut out today with the plasma cutter, holes drilled, then welded to the 15mm tube. The license plate bracket will get welded the tail light bracket.

And just got an email from AliExpress that the rear fender shipped.

[cheesy]

A few pics of the project.
Laying out the tail light bracket that didn't get cut out today.


The hydraulic tube and rear turn signals.


Fuse box mount. Not showing the welds.


Fuse box in place.


Front turn signals.

[Emerikol]

Originally Posted by cheesy

A few pics of the project.
Fuse box mount. Not showing the welds.

]

An entire days worth of posts and replies devoted to the welds on the fuse box, and you won't even share pictures? For shame!

[cheesy]

Originally Posted by Emerikol

An entire days worth of posts and replies devoted to the welds on the fuse box, and you won't even share pictures? For shame!

Kind of late but oh, alright.

[Emerikol]

Well, terrible they may be, but you're still light years ahead of most people and what they think constitutes a "professional" build. Really excited to see this one run and ride.

[cheesy]

Finished the tail light/license plate mount today.

This is the mount for the tail light.

Cut out with a plasma cutter, cleaned up with a bench grinder, and punched out the big hole with a 22mm hole saw.

First attempt TIG welding since 1997.

Heat was a tad high but I'm pretty pleased with it all the same. Going to take a bit to get used to the foot pedal again.

Save for paint, finished bracket.

[bogieboy]

Originally Posted by cheesy

Kind of late but oh, alright.

it may not be the prettiest weld, but it will hold... i have been playing around with my welder a BUNCH lately, getting a feel for it, its completely different to set up than our shop Hobart 220v gas mig... i am getting pretty good with it though, heres some snowblower skid shoes i just re-faced...

[Landsvw]

Hey Cheesy,
This is a Chinese bike forum. All you’re doing is making us feel at home with the welds capturing the spirit of all the bad welds on the Chinese bikes! You also should be using inflexible bad quality steel, so things can vibrate, crack and fall off! Good thinking on the non balance shaft engine too, so it can help that process. Make sure it’s about 100 pounds too heavy too!

In fact, don’t make the bike too good, or we will have to ban it from being mentioned!

Love the project, carry on!

[cheesy]

You forget that I have a well loved, hard ridden Russian steed that makes some Chinese bikes look good.

[Landsvw]

Just like cowbell, we want more diesel project!!!

[cheesy]

Last two weeks were spent on the road and I had suffered a bad case of Assus Draggus during the last two weekends.

That said, I wrapped up wiring the horn on the stinker this afternoon. I figured it would be the easiest as it's the only thing on that circuit. Sounds like an old VW horn.
Lights will be the most time consuming. I'm using weatherproof multi-pin plugs throughout the harness and testing each circuit individually using a 15V/1A DC power supply. All pins in the plugs are crimped and soldered.

So, more time spent upfront in assembly means less time spent troubleshooting on the backend.

Just realized I need to get a flasher relay for LEDs. Need some more two pin plugs, too.

[cheesy]

We did a social distanced birthday for my MILs 86th yesterday. Five hours of my day were used up for that, so nothing got done.

[Landsvw]

86 is rocking. My mom is 84 and so far, avoided the Covid.