Pedro!'s rebuilding projects

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Pedrotq
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Location: Perth, Western Australia

Re: Pedro!'s rebuilding projects

#1816

Post by Pedrotq »

Set the hub up in the milling machine on the rotary table so i can drill 18 x 8mm holes evenly around her circumference.

Bought some 3mm steel sheeting and roughly cut out two circles with an angle grinder.

Drilled the same 18 x 8mm holes in the steel plate circles.

Bolted them to the hub so i can machine them down to size.
Attachments
Drilling 18 x 8mm holes.
Drilling 18 x 8mm holes.
101_1355.JPG (327.41 KiB) Viewed 370 times
Cut out two steel 3mm sheet circles.
Cut out two steel 3mm sheet circles.
101_1356.JPG (323.12 KiB) Viewed 370 times
Drilling the same 18 x 8mm holes.
Drilling the same 18 x 8mm holes.
101_1357.JPG (332.97 KiB) Viewed 370 times
Resulting in two rough flanges.
Resulting in two rough flanges.
101_1358.JPG (358 KiB) Viewed 370 times
Bolt the flanges to the hub for machining.
Bolt the flanges to the hub for machining.
101_1359.JPG (263.01 KiB) Viewed 370 times
Pedrotq ~ (Pedro The Questionable)

Perth, Western Australia.

1988 GL-1500 ~ HRD sidecar outfit.
1990 GL-1500SE ~ (project) ~ Stripped down to be a "Naked 90".
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Pedrotq
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Re: Pedro!'s rebuilding projects

#1817

Post by Pedrotq »

Now i have two nice concentric flanges.

Using all the measurements i took carefully and evenly TIG weld the flange into the blank rim.

Machine a chamfer on the edge of the hub to accommodate the weld bead on the flange.
Attachments
A pair of nice flanges.
A pair of nice flanges.
101_1360.JPG (383.39 KiB) Viewed 369 times
Welded in right side.
Welded in right side.
101_1361.JPG (360.2 KiB) Viewed 369 times
Welded in left side.
Welded in left side.
101_1362.JPG (342.69 KiB) Viewed 369 times
Chamfer the edge of the hub.
Chamfer the edge of the hub.
101_1363.JPG (324.41 KiB) Viewed 369 times
Pedrotq ~ (Pedro The Questionable)

Perth, Western Australia.

1988 GL-1500 ~ HRD sidecar outfit.
1990 GL-1500SE ~ (project) ~ Stripped down to be a "Naked 90".
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Pedrotq
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Re: Pedro!'s rebuilding projects

#1818

Post by Pedrotq »

Bead blast the hub and the rim.
Attachments
Bead blasted the right side.
Bead blasted the right side.
101_1364.JPG (310.56 KiB) Viewed 368 times
Bead blasted the left side.
Bead blasted the left side.
101_1365.JPG (313.96 KiB) Viewed 368 times
Bead blasted the rim.
Bead blasted the rim.
101_1366.JPG (323.95 KiB) Viewed 368 times
Paint the hub.
Paint the hub.
101_1368.JPG (258.38 KiB) Viewed 368 times
Paint the rim.
Paint the rim.
101_1370.JPG (215.69 KiB) Viewed 368 times
Pedrotq ~ (Pedro The Questionable)

Perth, Western Australia.

1988 GL-1500 ~ HRD sidecar outfit.
1990 GL-1500SE ~ (project) ~ Stripped down to be a "Naked 90".
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Pedrotq
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Re: Pedro!'s rebuilding projects

#1819

Post by Pedrotq »

Bolt the hub into the rim and paint the left side black along with the rim.

I was too impatient and didn't allow enough time for the first black coat to dry properly so it went all wrinkly with the second application :( No worries nobody sees that side anyway :)
Attachments
First coat of black on the rim and hub bolted together (using sacrificial bolts)
First coat of black on the rim and hub bolted together (using sacrificial bolts)
101_1372.JPG (243.55 KiB) Viewed 367 times
Ooops! paint went all wrinkly :-(
Ooops! paint went all wrinkly :-(
101_1375.JPG (396.11 KiB) Viewed 367 times
Replaced sacrificial bolts with button head stainless bolts and nyloc nuts.
Replaced sacrificial bolts with button head stainless bolts and nyloc nuts.
101_1376.JPG (321.85 KiB) Viewed 367 times
Right side.
Right side.
101_1377.JPG (320.14 KiB) Viewed 367 times
Left side.
Left side.
101_1378.JPG (275.23 KiB) Viewed 367 times
Pedrotq ~ (Pedro The Questionable)

Perth, Western Australia.

1988 GL-1500 ~ HRD sidecar outfit.
1990 GL-1500SE ~ (project) ~ Stripped down to be a "Naked 90".
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Pedrotq
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Re: Pedro!'s rebuilding projects

#1820

Post by Pedrotq »

Runs central and true :-D

Now the rim is wider i have to fit the final drive to the wheel before i can fit the wheel into the swingarm.

Fitted new tyre and assembled her.

Unfortunately that's where i started missing photos so i will have to take some today and publish them later.

I also fitted new bearings and seals to the hub for a reliable service life.
Attachments
Central and running true.
Central and running true.
101_1379.JPG (319.98 KiB) Viewed 366 times
New tyre fitted.
New tyre fitted.
101_1380.JPG (312.91 KiB) Viewed 366 times
Pedrotq ~ (Pedro The Questionable)

Perth, Western Australia.

1988 GL-1500 ~ HRD sidecar outfit.
1990 GL-1500SE ~ (project) ~ Stripped down to be a "Naked 90".
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Pedrotq
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Re: Pedro!'s rebuilding projects

#1821

Post by Pedrotq »

Now all that was the easy stuff, the nightmares are about to start :-?

The rear wheel is now off centre and to the left about an inch or so;

The left shockie will now not fit as it interferes with the wheel.

The stock mudguard will no longer do.

the fuse box / relay box will no longer fit.

the left saddlebag will no longer fit.


I found a thinner shockie with the same travel but a little shorter so i have to move the left shockie mount on the swingarm.

I had to lengthen the shockie/brake support bolt and cut up the existing shockie mount. This is my first attempt, i cut this all off and redid it all (pic to follow later).

I bought a wheel arch from a trailer shop and it will need some fitting to make it work.
Attachments
Left shockie mount hardware (first version).
Left shockie mount hardware (first version).
101_1382.JPG (481.55 KiB) Viewed 363 times
Cut the old mount off.
Cut the old mount off.
101_1383.JPG (333.76 KiB) Viewed 363 times
Weld the new one in place.
Weld the new one in place.
101_1384.JPG (331.56 KiB) Viewed 363 times
Fun with the trailer wheel arch.
Fun with the trailer wheel arch.
101_1386.JPG (345.98 KiB) Viewed 363 times
The other side.
The other side.
101_1387.JPG (302.67 KiB) Viewed 363 times
Pedrotq ~ (Pedro The Questionable)

Perth, Western Australia.

1988 GL-1500 ~ HRD sidecar outfit.
1990 GL-1500SE ~ (project) ~ Stripped down to be a "Naked 90".
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Pedrotq
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Location: Perth, Western Australia

Re: Pedro!'s rebuilding projects

#1822

Post by Pedrotq »

Now for all those (including myself) who wondered what is under the plates on the swingarm ..... Nothing!

But she rings like a bell without them.

All the relays have to be relocated somewhere else on the bike, i opted for just above the rear wheelarch.


Well that's it for now, i will snap some photos today of the shockie, relays and the work still happening on the saddlebag.

Happy and Safe Riding to Everyone, Peter :-D
Attachments
One of these sheets are made of rubber to absorb the sound.
One of these sheets are made of rubber to absorb the sound.
101_1388.JPG (340.91 KiB) Viewed 362 times
Wires.
Wires.
101_1389.JPG (429.49 KiB) Viewed 362 times
Wires.
Wires.
101_1390.JPG (357.28 KiB) Viewed 362 times
And more wires.
And more wires.
101_1391.JPG (328.04 KiB) Viewed 362 times
Pedrotq ~ (Pedro The Questionable)

Perth, Western Australia.

1988 GL-1500 ~ HRD sidecar outfit.
1990 GL-1500SE ~ (project) ~ Stripped down to be a "Naked 90".
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Whiskerfish
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Re: Pedro!'s rebuilding projects

#1823

Post by Whiskerfish »

Awesome to see you back working again!!!
"Agreement is not a requirement for Respect" CDR Michael Smith USN (Ret) 2017
"The book is wrong, this whole Conclusion is Fallacious" River Tam
2008 GL1800 IIIA "TH3DOG"
1975/6/7/8/9 Arthur Fulmer Dressed Road bike
1975 Naked Noisy and Nasty in town bike
and a whole garage full of possibilities!!

Psst. oh and by the way CHANGE YOUR BELTS!!!!
heli_madken
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Re: Pedro!'s rebuilding projects

#1824

Post by heli_madken »

Wow I have missed your wonderful fabrication and amazing design skills and imagination, great to see you back and hope all goes well with the tests
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pidjones
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Re: Pedro!'s rebuilding projects

#1825

Post by pidjones »

An ultimate darksider - welcome to the club! BTW, may I suggest a PET scan? Just to be sure. Although, with your brain activity it is liable to not be able to show any metabolic activity that exceeds your normal thought process.
"Love 'em all.... let God sort 'em out!"
Ex 2006 GL1800 - the Black Pearl SOLD! to make room for:
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1975 Red GL1000 project - ex Pistol Pete project
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1976 Yamaha RD400c
1978 GL1000 with '75 engine - the Hunley
Ex 1978 GL1000
Ex 1979 GL1000
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5speed
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Re: Pedro!'s rebuilding projects

#1826

Post by 5speed »

I want to come sit in your garage, drink coffee and watch you design and fabricate.
1982 1100 standard. (sold)
1986 Yamaha FJ1200
2000 Yamaha Roadstar
1976 GoldWing. running but not on the road
1978 Goldwing. future cafe project.
2019 Can-Am ryker (boss's new ride)

2002 Shadow American Classic(sold)
1983 Shadow 500. (sold)
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Pedrotq
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Re: Pedro!'s rebuilding projects

#1827

Post by Pedrotq »

Thanks for the Welcome Guys :-D :-D :-D

I have had CAT, PET and MRI scans, here is one slice of the latest MRI scan, the white streak down the middle is not supposed to be there.

:(
20211102_151837.jpg
20211102_151837.jpg (86.21 KiB) Viewed 340 times
I had to put the left shockie onto the right side, the air shock has been ditched into the scrap bin and another shockie in place on the left, i made a bushing to move the top out about 30mm, the bottom mount is now the right height and out about 0mm too and with a gap under for the brake line.
Attachments
The left shockie now on the right.
The left shockie now on the right.
101_1399.JPG (364.07 KiB) Viewed 340 times
Top left shockie bushing.
Top left shockie bushing.
101_1393.JPG (343.75 KiB) Viewed 340 times
Bottom left shockie mount.
Bottom left shockie mount.
101_1394.JPG (313.86 KiB) Viewed 340 times
Bottom left shockie mount with brake line running through.
Bottom left shockie mount with brake line running through.
101_1395.JPG (278.45 KiB) Viewed 340 times
Pedrotq ~ (Pedro The Questionable)

Perth, Western Australia.

1988 GL-1500 ~ HRD sidecar outfit.
1990 GL-1500SE ~ (project) ~ Stripped down to be a "Naked 90".
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Pedrotq
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Location: Perth, Western Australia

Re: Pedro!'s rebuilding projects

#1828

Post by Pedrotq »

I managed to keep the fuse box where it was, but the relays had to go elsewhere.

I put new relays in that have a mounting tab on them, also they are just a tad smaller and have the same pin configuration as the old ones. which i got from "Eastern Beaver" he is in Japan and has lots of nice electrical goodies for motorcycles.

As you can see the rear wheel is now off to the left, this is of no concern as i am riding a sidecar outfit and will probably enhance the handling anyway?
Attachments
Hacked up fuse box.
Hacked up fuse box.
101_1396.JPG (297.19 KiB) Viewed 339 times
New home for the relays.
New home for the relays.
101_1397.JPG (345.42 KiB) Viewed 339 times
101_1398.JPG
101_1398.JPG (319.15 KiB) Viewed 339 times
Rear wheel off to the left.
Rear wheel off to the left.
101_1400.JPG (269.41 KiB) Viewed 339 times
Pedrotq ~ (Pedro The Questionable)

Perth, Western Australia.

1988 GL-1500 ~ HRD sidecar outfit.
1990 GL-1500SE ~ (project) ~ Stripped down to be a "Naked 90".
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Pedrotq
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Location: Perth, Western Australia

Re: Pedro!'s rebuilding projects

#1829

Post by Pedrotq »

The right saddlebag only needed the mudguard flange cut off to fit into its original position.

The left saddlebag was not so accommodating, i had to cut a big chunk of storage capacity out to clear the tyre and mudguard, then make a blanking plate out of some ABS sheeting which i am gluing in place.

I also have to move the air pump and the only place it will go comfortably is inside the left saddlebag, it is difficult to access the left saddlebag with the sidecar boat in position and i only keep the tool kit, puncture repair kit, towels, first aid kit and toilet rolls in there anyway.
Attachments
The right saddlebag.
The right saddlebag.
101_1401.JPG (233.13 KiB) Viewed 338 times
The chunk i cut off the left saddlebag.
The chunk i cut off the left saddlebag.
101_1402.JPG (312.29 KiB) Viewed 338 times
the reduced size left saddlebag.
the reduced size left saddlebag.
101_1403.JPG (287.38 KiB) Viewed 338 times
The blanking plate i made to fill the hole in the saddlebag.
The blanking plate i made to fill the hole in the saddlebag.
101_1404.JPG (375.56 KiB) Viewed 338 times
Gluing the blanking plate into position a little at a time.
Gluing the blanking plate into position a little at a time.
101_1407.JPG (256.5 KiB) Viewed 338 times
Pedrotq ~ (Pedro The Questionable)

Perth, Western Australia.

1988 GL-1500 ~ HRD sidecar outfit.
1990 GL-1500SE ~ (project) ~ Stripped down to be a "Naked 90".
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Pedrotq
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Location: Perth, Western Australia

Re: Pedro!'s rebuilding projects

#1830

Post by Pedrotq »

It is not necessary but i like to be uniquely different so i have obtained a tail light assembly from a 1999 GL-1500, the one with the clear indicator lenses, they use Amber globes in them.

I only use the right indicator on the bike as the left must be on the sidecar so I will use the left clear lens for a reverse light.

I cut the amber lens off my old tail light assembly and will glue it in place soon.

To get the lens off i soaked the complete tail light assembly in my parts washer which is filled with kerosene for a couple of weeks, the glue/sealant just melted away so the lens popped off easily.

As you can see the work on my Naked 90 has come to a complete stop, i have been collecting components off e-bay for its resurrection which i am looking forward to completing. This will replace my Valkyrie that i lost to my brother Robert who has polished her up magnificently.

That's it for now,
Happy n Safe Ridin to All, Pedro! :-D :-D :-D
Attachments
Tail light lenses, they are upside down on the bench.
Tail light lenses, they are upside down on the bench.
101_1405.JPG (305.22 KiB) Viewed 337 times
The Naked 90  (a real mans pushbike) :-)
The Naked 90 (a real mans pushbike) :-)
101_1406.JPG (312.41 KiB) Viewed 337 times
Pedrotq ~ (Pedro The Questionable)

Perth, Western Australia.

1988 GL-1500 ~ HRD sidecar outfit.
1990 GL-1500SE ~ (project) ~ Stripped down to be a "Naked 90".
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