old - Fazer Owners Club - old
General => General => Topic started by: NorthWestern on 21 November 2013, 07:27:36 pm
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Offered up the frontend to a bike I am building for my daughters 2nd xmas! Its a TZ750 Balance Bike made of wood (predominantly self-laminated ply). Forks are made from broom handles, an Ohlins one naturally....
Just got the handle bars to make (these will be alloy), seat (from foam) and the number plates which will either by more ply or I might laminate some Carbon Fibre ones, its been a while since I have done any CF and I think I will be making some fairing panels for the Fazer soon so this should blow off some cobwebs.
Paint went on quite well! Forks/Triple clamps will be silver.
(http://farm6.staticflickr.com/5493/10982424405_6bb2b0cc47.jpg)
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Maybee christo could get insured on that.
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thats cool. keep the photos coming.
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Exactly what Ducati needs to get the Desmoedici to "Turn" in, but rider might complain of suspension feeling a bit wooden. :lol
Looks cool, cannot wait to see the finished product :)
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Offered up the frontend to a bike I am building for my daughters 2nd xmas! Its a TZ750 Balance Bike made of wood (predominantly self-laminated ply). Forks are made from broom handles, an Ohlins one naturally....
Just got the handle bars to make (these will be alloy), seat (from foam) and the number plates which will either by more ply or I might laminate some Carbon Fibre ones, its been a while since I have done any CF and I think I will be making some fairing panels for the Fazer soon so this should blow off some cobwebs.
Paint went on quite well! Forks/Triple clamps will be silver.
Your daughter is a very lucky girl! Looks brilliant!
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Wish i had one of them :)
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Thanks for the comments :)
Obviously this is a replica of the Kenny Roberts flat tracker rather than the road racer.
Here are a few more pics of the "build"
I bought an 8x4 foot sheet of 4mm ply from the local timber merchant. This was to be the main stock for the bike and I would laminate it to the desired thickness for the parts I needed. I could have bought some 16 or 20mm ply but I wanted to form some curved pieces for the swingarm otherwise if I used straight pieces it would have jutted out too much and look a bit rough.
Here is the main frame core, I cut the rough shape 5 times to get the thickness I wanted, glued them all together and clamped it.
(http://4.bp.blogspot.com/-KNp6GqY5Tis/UVc38OKnrYI/AAAAAAAAAP4/ga4aqiTlrFo/s1600/2013-03-30+07.06.46.jpg)
This is the "core" in its final drying phase on the custom drying kiln - these are extremely expensive due to being such a specialist piece of kit. This will be drilled out to in places to reduce weight as I will put a final skin on each side.
(http://2.bp.blogspot.com/-4OOjdUjToIg/UVc5i1y4p1I/AAAAAAAAAQQ/A4ukVo3z3vQ/s1600/2013-03-30+07.13.03.jpg)
Once this was dry I drilled holes in it and cut channels etc to lighten it then put the outer skins on.
Here it is moved in to the larger drying bay. Clamps were thin on the ground so I had to improvise slightly...
(http://3.bp.blogspot.com/-VXPZzSWqK1s/UVc6qay58xI/AAAAAAAAAQk/5ud8N5a2h3o/s1600/2013-03-30+16.33.23.jpg)
Customer inspections are always pretty tense, you never know if they will change their minds or simply go off the whole idea. Thankfully it went well and after a heated argument over colours we were all back on the same page. (NOTE: Plywood offcuts that this is resting on catches glue drips and helps to keep 'er-indoors happy)
(http://1.bp.blogspot.com/-R4w2uJsQt38/UVc6r7mV34I/AAAAAAAAAQw/IEhgmuWbnIY/s1600/2013-03-30+16.33.27.jpg)
So here we are, after all that hard work the composite frame blank is out of the mold. (mould?) This is exactly the same process as what them Williams or McLaren boys do. Its now ready for shaping!
(http://1.bp.blogspot.com/-VZOkRru1qQw/UVf6VvCnz1I/AAAAAAAAARA/3pvV-SO2-Dg/s1600/20130331_094902%5B1%5D.jpg)
My original intention was to create asthetically pleasing "grain" lines as the frame was shaped and cut across the various layers of ply. As you can see by these pictures it does look rather nice. I was going to use an ebony stain to get the desired black frame while still retaining the visible grain when you got up close. Concourse stuff!! Alas the poor grade of ply meant that it had imperfections in the surfaces. These imperfections (either different wood vaneer or glue residues etc) meant the stain wasn't uniform across the piece so in the end I had to paint it as it looked rough.
(http://2.bp.blogspot.com/-yj0QpbLrfmc/UViQ0qQJchI/AAAAAAAAASA/G3saUlAeD3o/s1600/20130331_140114.jpg)
(http://1.bp.blogspot.com/-5lmk2Us0fQ8/UViQxDE4caI/AAAAAAAAARo/e9mngIYMFXw/s1600/20130331_140105.jpg)
Next up was the swinging arm! This had to be curved to keep things nice and slim. Here it is in the "forming jig". Now your probably wondering how I came across a genuine Red Bull F1 forming mold - well its not who you know its what you know... no wait...
(http://1.bp.blogspot.com/-dVvCDe1N1yg/UWPg8X5Jb0I/AAAAAAAAATg/7yG0iqFVcIg/s1600/20130407_155223.jpg)
Out of the mold, shape retained and the curve is spot on.
(http://1.bp.blogspot.com/-8NvGXwBdGxg/UWPg92RIcsI/AAAAAAAAAUA/2Wm6t7fnFk4/s1600/20130409_071755.jpg)
(http://2.bp.blogspot.com/-GjOPnXAa-5I/UWPg-NXTBNI/AAAAAAAAAUE/WuLsoa6JgBU/s1600/20130409_071803.jpg)
Next up was the forks. I was going to laminate a profile piece but it would have looked a bit naff and I wanted triple clamps and round forks. This is the aforementioned Ohlins broom from which I took the handle! Interestingly I had to try a few brooms and the handles were of very differing strength. Out of 8 the shop had this was by far the stiffest handle - even though they were all the same model! TTX!
(http://1.bp.blogspot.com/-wmUJWK_dOIs/UXf0pZpWhdI/AAAAAAAAAW0/TgQwp9oPVF4/s1600/20130421_135954.jpg)
Top Triple clamp I cut from a piece of ply I laminated.
(http://3.bp.blogspot.com/-_CkcSngmMo0/UXf1HXFs7xI/AAAAAAAAAW8/RaspnTdyFqI/s1600/20130421_162006.jpg)
This shows the frontend complete (structurally). Rather beefy - probably too beefy but you can't be too safe!
(http://1.bp.blogspot.com/-rJf0N60ax-w/UXf1n1zgsmI/AAAAAAAAAXI/kXTe3_5d-JQ/s1600/20130421_162044.jpg)
But how are you going to attach it to the frame? The frame spar is so thin?! &*%$ I had thought of this beforehand and this is the magical piece that solves all problems! Its a headstock with a flat fin on one end. The plan would be to cut a channel into the frame that this fin slides into and is both glued and clamped into place. Aircraft spec alloy of course.
(http://2.bp.blogspot.com/-WOkRn6Zv7MQ/UXf2MBOkMVI/AAAAAAAAAXc/6fUjeK45o9k/s1600/20130421_164709.jpg)
The recieving slot. I first drilled a hole the diameter of the headstock then cut the front off so I had a nice half round bit to seat it into.
(http://2.bp.blogspot.com/-Yy5qCm6YfiY/UXf2NC9SyNI/AAAAAAAAAXw/hZ9XkOJQElQ/s1600/20130421_165553.jpg)
Here it is, glued and clamped. It still needs sanding to feather it all in nicely but you can now see what I was banging on about. The previous pictures might be a little abstract until you see its final form :)
(http://4.bp.blogspot.com/-oyxb8sOGltM/UXf2NWZ8SEI/AAAAAAAAAYA/q2-gnpd6mXE/s1600/20130421_172035.jpg)
The forks assembled. The relief on the lower triple clamp is for clearance against the down tube of the frame. The "stem" is to be 6mm threaded bar, the bolts shown here are for ease of assembly at this stage. Note the forks dropped a couple of mm through the yokes to increase steering etc etc...
(http://2.bp.blogspot.com/-R2SgGeSaixE/UXjoyVJIcjI/AAAAAAAAAYg/pfkmJXHUegg/s1600/20130425_092114.jpg)
This is the assembled chassis. At this stage I had a strenghtening "rib" running along the top. I was unsure at this stage how to make the tank/seat and was thinking about making plywood boxes to sit on it. In the end I laminated them from ply and they fit snugly over the frame spar so the rib was removed as the additional thickness of the tank/frame greatly increased stiffness, plus the rib made it tricky to put stuff on as it had to fit around it etc
(http://4.bp.blogspot.com/-IWWt9463-jY/UXjox0A8pyI/AAAAAAAAAYQ/61Zbxgj565w/s1600/20130425_092032.jpg)
You can see the swingarm attachment. Yeah its solid and doesn't actually "swing". I added a 6mm bar through it just as a precaution really then its glued up and clamped. I sanded it all in leaving it thick as I will be putting the footrests off it later on.
(http://1.bp.blogspot.com/-CYMwEXqSYjc/UXjoxxhagbI/AAAAAAAAAYY/a8G2W3duOH4/s1600/20130425_092045.jpg)
Here are the shaped tank and seat units. These are a perfect fit around the frame as I laminated the 3 pieces from the same ply. At the mo they are simply press fit but once everything is done they will be glued in place forming a solid piece.
(http://lh3.ggpht.com/-tHVPQixGI4Q/UZh9huYoHJI/AAAAAAAAAZw/x7rUQgBj48Y/s1600/20130518_145448.jpg)
(http://lh3.ggpht.com/-sTcygBNP9Qk/UZh8-VdR51I/AAAAAAAAAZc/Uki6xUpLS98/s1600/20130518_145443.jpg)
(http://lh6.ggpht.com/-QZgAWKC5uCY/UZh9aFGdX0I/AAAAAAAAAZo/QjE-i7QvVo0/s1600/20130518_145434.jpg)
Next up was the engine! TZ 750 engines are quite rare and probably a bit heavy and lairy for a "nearly" 2 year old. So I am making a wooden one...
(http://lh3.ggpht.com/-fmuujD-RVTE/UZjz-Xf9QuI/AAAAAAAAAaE/QO5wVe7ItKE/s1600/20130519_164401.jpg)
So yeah, this is pretty much where I am up to... Not sure when I will get around to doing the rest, I need to lace up 1 wheel, make the risers and bars, footrests, paint the forks and number plates etc. The seat will be neoprene or something similar, perfectly shaped very much on par with a Corbin or Archer one ;)
I am thinking about adding some ancilliaries to it like spark plug leads, a carb etc but not 100% sure about it yet.
(http://lh5.ggpht.com/-i6WVhDt1PZ4/Um7X2ptQdLI/AAAAAAAAAbs/0XMBAxCa2nY/s1600/20131028_212530.jpg)
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That is totally awesome fella - love it! As said before, can't wait to see it finished and doubt anyone could offer you any advice.
Thought I was quite handy with wood & steel etc but I wouldn't get close to that quality!
A well deserved " Best Daddy" award. Gold star :lol
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Excellent. :thumbup
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There is definitely a job for you at Ducati :rollin
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Are they after someone good with a broom? ;)
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Nice one :)
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Awesome, keep up the good work
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Best project bike on the forum. :)
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Best project bike on the forum. :)
Almost as clean as Doddsie's bike!
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Almost as clean as Doddsie's bike!
Never happen....
But a much better colour! :lol
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Almost as clean as Doddsie's bike!
Never happen....
But a much better colour! :lol
Well he had to do it in yellow.... its for a girl!!!! :D
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Almost as clean as Doddsie's bike!
Never happen....
But a much better colour! :lol
Well he had to do it in yellow.... its for a girl!!!! :D
Doddsie: 1, Nick Crisp: 0!!
:lol
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Almost as clean as Doddsie's bike!
Never happen....
But a much better colour! :lol
Well he had to do it in yellow.... its for a girl!!!! :D
Must be a 600 then..... ;)
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Baboom Tish!!
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Almost as clean as Doddsie's bike!
Never happen....
But a much better colour! :lol
Well he had to do it in yellow.... its for a girl!!!! :D
Must be a 600 then..... ;)
That's 1 all... :lol
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Well its obviously not yours Christo or it would be fire wood!!!! :lol
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Lacing up the rear wheel reminded me just how tedious wheel building can be. I thought of how happy my daughter will be on this. Its still just as tedious...
So wheels ready. Forks will be painted tomorrow then its just handle bars!
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After a bit of headscratching and umming and ahhing we made some alloy drop outs to slide over the fork leg bottoms. There was just not enough strength/meat on the wood dropouts and I didn't fancy risking it...
So these were knocked up, alloy tube turned down so they were about 2mm thick then a box section was cut into two "L" shapes. These were then tig welded onto the tubes and sloted to accept the axle. They look pretty trick! These were pressed in with some araldite.
(http://farm6.staticflickr.com/5541/11273202965_fd8e29b007.jpg)
(http://farm3.staticflickr.com/2820/11273195325_8bfc9d28a3.jpg)
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Not much happening what with Familly etc over xmas but today I managed to shape a neoprene seat pad, get the forks sprayed and fit the wheels.
Foam cut and crudely given initial shape
(http://farm8.staticflickr.com/7441/11606799613_666ca6e19c_z.jpg)
Bike with seat sanded smooth and to shape with wheels/forks etc fitted!
(http://farm6.staticflickr.com/5489/11606892364_1641643f2c_z.jpg)
Starting to look like a bike!
The ToDo list is now quite short, fit the number plates and handlebars and thats it.
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Finally got a couple of hours to finish it off! Just in time for her birthday on Sunday.
Rusty nipples!! I rebuilt the rear after narrowing the hub down (removed the sprocket, cut the center and reattached the side cups) with new black nipples, might need to do the front - you know what women are like!!
(http://farm6.staticflickr.com/5490/12124073203_db93742a2f_z.jpg)
(http://farm6.staticflickr.com/5475/12124069693_144b1479bc_z.jpg)
Riders eye view. Renthal were kind enough to make these one off bars, proper bit of kit and come with built in bar ends.
(http://farm6.staticflickr.com/5516/12124063483_7537d32e07_z.jpg)
If I were to make another I would do it a bit differently - hindsight is a wonderful thing. ITs probably taken me about 8 hours in total, 30 mins stolen here and there. As I chose to laminate my own plywood a lot of time was spent doing that and waiting for glue to dry etc...
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Well done, looks ace :)
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Looks the tits, man! Awesome craftsmanship! :eek :)
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thats epic man! Im sure your little lady will be well chuffed with that :)
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Nice one, hope she likes it :)
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Cheers guys :) wouldn't mind one myself!
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I bet she wants a horse for her birthday. :lol
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Amazing work!
She's very lucky 8)
Chris