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Pedro's Customizing Projects

Posted: Sun Dec 31, 2023 10:36 pm
by Pedrotq
G'day to Everyone and a HAPPY NEW YEAR !!!

Well, it has been a while since I have posted anything, sickness has hit me hard over the past three years, still recovering from the side effects of a dose of Shingles which I got right in the Freckle, this has curbed my riding.

Just to start the new year off with a laugh I thought I might post a pic of My 1978 typewriter powered Goldwing. she has departed my possesion long ago now.

Re: Pedro's Customizing Projects

Posted: Sun Dec 31, 2023 10:42 pm
by Pedrotq
I have been working on my Naked 90 for a few years now, have started working on her again lately.

Here are a few pics of the raw material that I started with.

Re: Pedro's Customizing Projects

Posted: Sun Dec 31, 2023 10:46 pm
by Pedrotq
Here is what she looked like a couple of years ago, most of the panels are just cardboard cut outs to get the shape of what to make for the finished product.

Re: Pedro's Customizing Projects

Posted: Sun Dec 31, 2023 10:47 pm
by Pedrotq
This is what she looks like today (1-1-24)

Re: Pedro's Customizing Projects

Posted: Sun Dec 31, 2023 10:56 pm
by Whiskerfish
Great to see you posting! Been a number of us wondering how you were doing! So glad to see you are still with us

Re: Pedro's Customizing Projects

Posted: Sun Dec 31, 2023 11:16 pm
by Pedrotq
Thanks Wiskerfish :-)

One Mod I did was to go Darkside. As we all probably know the rim edge is different from motorcycle to car rims, the profile is not the same and the tyre could come off during a puncture, also it is not legal here in the West Oz.

So I got the rear wheel off the Naked 90 as it is meatier than the 88 rim, made up some biscuits from 6mm Aluminium flat bar to fill between the spokes, cut the outer rim off then I had a professional welder to weld them in as my Aluminium welding is not up to scratch yet.

I acquired some 16 x 6 inch rims off a Mitsubishi ute, then cut out the centers,

Re: Pedro's Customizing Projects

Posted: Sun Dec 31, 2023 11:20 pm
by Pedrotq
Continued.......

I then machined a flat surface to fit onto a flange and the outer circumference to a very snug fit inside the car rim.

Re: Pedro's Customizing Projects

Posted: Sun Dec 31, 2023 11:29 pm
by Pedrotq
Continued.....

I then set the hub up in the milling machine and drilled 8mm holes evenly around the edge.

Then I got some 3mm steel plate and roughly cut out the flange (I make two at a time so if I stuff one up I have another to continue with). Drill them in place as the hub is still set up in the mill.

Bolt all together, set up in the lathe to cut the inner and outer diameters.

Re: Pedro's Customizing Projects

Posted: Sun Dec 31, 2023 11:35 pm
by Pedrotq
Continued.....

I welded one of the flanges into the car rim in exactly the same dimensions as I measured earlier, painted the rim black and the hub silver, bolted it all together with M8 Stainless bolts.

Re: Pedro's Customizing Projects

Posted: Sun Dec 31, 2023 11:36 pm
by Pedrotq
Oops! .....

Re: Pedro's Customizing Projects

Posted: Sun Dec 31, 2023 11:43 pm
by Pedrotq
Continued.....

Fitted the rim into the swingarm and checked for trueness and clearance ...... All good!

Fit a new tyre and away I go.

Now the real fun starts getting the mudguard and saddlebags to fit.

Pedro! :-)

Re: Pedro's Customizing Projects

Posted: Mon Jan 01, 2024 12:11 am
by Pedrotq
I was curious to see what construction method is used within the GL-1500 rear muffler. I had recently replaced a set for a friend, his old ones were rusted out badly so out came the angle grinder.

Peter :-)

Re: Pedro's Customizing Projects

Posted: Mon Jan 01, 2024 12:35 am
by Pedrotq
Not too long ago I did a big repair on a Vulcan 1500, the agreed payment was for his trailer which he does not use anymore.

Unfortunately, I just got stuck into the job of designing and making a customized towbar and didn't take any photos, I am not happy with the ones that just bolt onto the saddlebag framework as I feel that it is not designed to carry the forces involved.

My thoughts were to have the downward forces attached to a substantial part of the frame, lateral forces by the sidecar chassis, and the pulling and stopping forces directed to the mainstand attachment point as I don't need a mainstand with a sidecar outfit.

The towbar would interfere with the left muffler, so I had to remove that, I cut off the central muffler outlet and welded a flat plate across the hole. now I have all the exhaust directed to the right muffler and it is probably not designed for that probably increasing the back pressure, I then cut off the 40mm right outlet from the central muffler and welded a 50mm (2") outlet pipe there, made up my own mid piece and fitted an e-bay muffler to her. I had to cut flip over and weld the right muffler mount to support it all.

She has a nice two-tone rumble similar to a V8.

Happy as Larry now :-) Peter.

Re: Pedro's Customizing Projects

Posted: Mon Jan 01, 2024 12:54 am
by Pedrotq
Another project I have been working on for years is to replace the auxiliary fuel tank under she sidecar body.

After much detailed measuring I cut out the top section of the desired shape out of 3mm Aluminium sheet also the baffles for within, then i took that to a professional Aluminium welder who also certifies the fuel tank, he made up the bottom section with a 50mm internal height as I do not have a panbrake to do the bends.

The fuel filler spout interfered with the sidecar chassis, so I had to do a little modification and welding so she would fit.

Re: Pedro's Customizing Projects

Posted: Mon Jan 01, 2024 1:07 am
by Pedrotq
I now had to make up the fuel pump out of an old GL-1500 one.

The fuel tank has a 3" dimple (dent) about 20mm deep right under the porthole that I previously cut out for the pump to draw out of.

I totally dismantled the stock fuel pump, modified the mounting, added a breather outlet and clamped the pump in.

The stock pump housing has a pressure relief valve built in so i knocked up one that would use this valve. Mother Honda didn't put one in if it didn't need one.