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PostPosted: Thu Nov 14, 2013 8:44 am 
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Joined: Thu Aug 18, 2005 10:13 am
Posts: 3760
Location: PERTH WESTERN AUSTRALIA
Thanks hoser.

Quick update,been playin' hooky from work...hope the boss don't find out,heard he's an A hole!Image
After some major mods on the cheaparse bender dies,it's all coming together.
Got my tubes joined done this arvo :shock: ,thanks Leon for tig'n.
Just need to finish off with some diagonal bracing,then thin alu chequre plate top.

When all the nerf bars are sorted into a truss like structure,then onto the air bag system? :shock:
Nah no AB's,but same impact protection result.
I'm thinkin' diff rubber density punched out discs,sandwiched inbetween the nerf ends and INside their relative chassis spigots.
Or maybe even 2 suitable sized washers,joined with silicon or rubber sheet,kinda like the Honda OEM rubberised double Engine/TRANS washer mounts.
I will have a thin R pin holding it all into the spigots,that will act like a fuse,break,then allow the rubber :shock: to do it's thing! :-)
The reduction in force absorbsion to the chassis and mounts would/will surely get MORE outa ya std nerf bar design/longevity?


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PostPosted: Sat Nov 16, 2013 9:03 am 
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Joined: Thu Aug 18, 2005 10:13 am
Posts: 3760
Location: PERTH WESTERN AUSTRALIA
Sat night here now Downunder,been workin' on the nerf brackets,painting etc
What a stincker of a day,half way thru the last month of spring,over 100F,but it's the killer humidity today that drives a man to drink,and pool,I ain't no fool? :shock:
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PostPosted: Sat Nov 16, 2013 9:07 am 
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Joined: Thu Aug 18, 2005 10:13 am
Posts: 3760
Location: PERTH WESTERN AUSTRALIA
After all the work on the Pilot's nerf mounts,I was totally shagged baby,so into the pool,drink in hand,then the thoughts were chill out,PLUS that blondie woolywoman Nukem posted :shock: ...bliss! :-)
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PostPosted: Sun Dec 22, 2013 10:41 am 
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Joined: Thu Aug 18, 2005 10:13 am
Posts: 3760
Location: PERTH WESTERN AUSTRALIA
Nerfs are 90% finished,chequre plate screwed on,making a stronger sandwich plate,plus blocking the front tyre roost crap on full turn.
They're not pretty,but designed for max side intrusion.
I punched out some 6mm rubber discs,that side up with steel washers,that fit inside the nerf chassis spigots,and are the same OD as the nerfs.
They will act as shock absorbers...hopefully. :-)
Even if they dissapate only 10% of the lateral forces,it's better than a poke in the eye with a blunt stick? :shock:

They are held on by thin R pins,which will be sacrificial,like a fuse.
They'll bend a bit,while the rubber and washer compress.
Time will tell,and will be easy to tune with diff rubber thickness,density etc.


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PostPosted: Sun Dec 22, 2013 10:46 am 
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Joined: Thu Aug 18, 2005 10:13 am
Posts: 3760
Location: PERTH WESTERN AUSTRALIA
more pics
The R pins are chassis tethered with braided SS fishing wire trace line and swivel.


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PostPosted: Thu Dec 26, 2013 5:29 am 
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Joined: Sat Mar 03, 2012 11:45 pm
Posts: 3610
Location: CHICO,CA
Loving the look of the alumium nerf bars


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PostPosted: Thu Dec 26, 2013 11:48 am 
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Joined: Fri Feb 29, 2008 1:51 am
Posts: 2703
Location: Upland, Ca
nerfs? I thought he was making a side car for the ice chest of beer!


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PostPosted: Thu Dec 26, 2013 12:17 pm 
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Joined: Wed Jan 14, 2009 2:10 am
Posts: 4678
Location: Carson City NV
I was thinking gas cans but I like your idea better Shoub!

Rand


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PostPosted: Fri Dec 27, 2013 11:47 am 
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Joined: Tue Feb 12, 2013 1:01 pm
Posts: 341
Location: North San Diego
I think this is a great job

Okay, so I've started with a compliment, now critique, sorry

My concern is the aft tubing section on the side nerfs that gets close to the rear tire

If there ever was an incident that collapsed/jammed the tubing, I'd hate to have that section poke or rub on the tire

I think of this because I had built a pre pruner bumper on a truck, and after finding a steep drop the bumper jammed into the front tire

P.S. Why do you have a picture of my sister in your pool with a beer?


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PostPosted: Wed Jan 01, 2014 9:27 am 
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Joined: Thu Aug 18, 2005 10:13 am
Posts: 3760
Location: PERTH WESTERN AUSTRALIA
The nerfs are to display all the trophies you clowns! :-).......................then bar beer.......................then more beer...........then sleep :-)

Consol,it's not finished yet,I'm gonna add a curved alu tube section pre-rear tyre...and oh I don't mind critique...so long as you agree with me!!! :-)
Just for the record I have had many a racer's wheel barge in that very spot...then either wheel over to the front and over the bumper,OR try and enter my cockpit via my head!!! :shock:
This is why I won't be leaving much GAP there.We have a couple of real cowboys in our club that think their racing for sheep stations (sorry BigGaz) :-)

Anyway some time off lately to get jiggy with the Pilot again.
Not much more to do...so decided if Twerkin' works for Moley Cyrus...then I'd try it.AC550Pilot needed some lovin' and polish bling.
SO,in my best Bazkini(Honda red of course),buffer pads strategically placed,I twerk'd and twerk'd till I collapsed, woke up an hour later,lying on paving, skin burnt from the 90F summer brick paving! :shock:
But boy,nice bling.Only got thru the back fenders tho.After I get outa hospital,I'll finish off the rest! :shock:

Then had to re-thread the RHS rear fender tube hole,stripped out.
Had some Bigsert bushes,just the right size that I ordered from USA previsouly to fix up some Polaris 800 cylinder-head holes for the mighty FL800Pilot.
These are like a reducing bush,unlike the Helicoils-wire.
I don't like their install threaded driver,so made up my own.
Theirs activate the 2 locking steel pin tabs too early,thus stopping full thread insertion.
I found using a set bolt to drive the insert, with 2 locking nuts the go.


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PostPosted: Wed Jan 01, 2014 9:43 am 
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Joined: Thu Aug 18, 2005 10:13 am
Posts: 3760
Location: PERTH WESTERN AUSTRALIA
I removed the orig # 13 roof side triangular plates,and made my own(MUCHO lighter too)....plus some more polish twerkin' :shock:

This year of '13 has been BAD luck for not only me,but a couple of my close mates.
So F' off with you #13!!! :shock:
Plus I'm #2 racing # anyway....# 2's are good? :-)

I eventually plan to make up a one piece roof and triangular # panel.
This one is just tab'd and pop riveted for now.


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PostPosted: Wed Jan 01, 2014 10:02 am 
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Joined: Thu Aug 18, 2005 10:13 am
Posts: 3760
Location: PERTH WESTERN AUSTRALIA
There is a countersinkin' tool as well.


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PostPosted: Wed Jan 01, 2014 10:13 am 
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Joined: Thu Aug 18, 2005 10:13 am
Posts: 3760
Location: PERTH WESTERN AUSTRALIA
After I got outa hospital with brick pavin' skin burns :shock: I decided to bling up the front Poly Carb rim covers,and adding some redness by only spraying the PC cover insides RED.
This is I till I get some new bead locks


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PostPosted: Sat Mar 29, 2014 5:05 am 
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Joined: Thu Aug 18, 2005 10:13 am
Posts: 3760
Location: PERTH WESTERN AUSTRALIA
Hoser is it possible to transfer this AC550Pilot thread into my world? :-) Thanks.

Onto the new alu fuel cell now,as you can see with the rear end setup,it's dangerous for racing being jammed between the rear chassis and bumper.
I'll be using the vacant spot above the trans,where the OEM muffler used to be.
I wanted to use the OEM radiator rubber mounts and bracket to help hold the cell,but it just restricted the overall size too much,dratts!
Mocked up the cell shape using an ol USA St Lucia Rum box,perfect size...see I see everything relates to buggies...sooner or later! :-)
The cell will extend over the driven as well,total capacity about 20Litres,exactly what I wanted max for the enduros.
It will have a sump right at the bottom,and include the PilotOEM fuel sensor light switch.
Have a weld on type alu neck and screw cap on order too.
Was gonna buy the flush filler style,but then realised it would hold all the crap we drive in around the cap lever etc.
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PostPosted: Sat Mar 29, 2014 5:16 am 
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Joined: Thu Aug 18, 2005 10:13 am
Posts: 3760
Location: PERTH WESTERN AUSTRALIA
The weight transfer forward should be beneficial too.
I will run an alu angle welded to the cell,so that it sits on top of the shock brace and rear chassis bars.This will hold most of the weight.
They will be rubber isolated between angle and chassis tubes.
Further down there are a few Pilot OEM brackets to mount to for lateral stability eg reverse light bracket,exhaust brackets.
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This is the cap I'll be using,ordered the anodised RED cap of course. :-)
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PostPosted: Sat Apr 05, 2014 8:22 am 
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Joined: Thu Aug 18, 2005 10:13 am
Posts: 3760
Location: PERTH WESTERN AUSTRALIA
More work done on the fuel tank today,Saturday 5-4-14.
Fab'd up lateral brackets,sumpthen tapped threads for,fuel outlout, and separete crap/water deposit spigot etc.
All taped together for the Tig'r.
Am real happy I got the 20Litres needed,to cope with enduros...and my ol mate...Al Zeimer! :-)

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PostPosted: Sat Apr 05, 2014 8:26 am 
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Joined: Thu Aug 18, 2005 10:13 am
Posts: 3760
Location: PERTH WESTERN AUSTRALIA
More pics.....................what else? :-)
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PostPosted: Sat Apr 05, 2014 8:42 am 
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Joined: Thu Aug 18, 2005 10:13 am
Posts: 3760
Location: PERTH WESTERN AUSTRALIA
I am now just waiting on the Aeroflow Alu cap(RED of COURSE!) :-) and weld-on neck I got my #2 son to buy on my behalf from Aus Ebay.
Pay'mt made last Sun,postage was MEAN"T to happen the following Monday,next day,seller stated arrival on my side west coast from East coast Aus on Wednesday.
I payed extra for $$$ EXPRESS :shock: ...Now I'm just EXPRESSING MYSELF to him!!!
Wed gone,then Thurs gone,then Fri gone.I emailed him Thurs and he says you'll get it by Thurs cause "I just rang Aus Post and they said...blah blah"!!!!Grrrr!!! AArrgghh!!!
Anyway,it's ALL being held up now till my new neck arrives. :-)


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PostPosted: Sat Apr 05, 2014 9:05 am 
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Joined: Sun Jan 10, 2010 9:14 pm
Posts: 1779
Location: Ma
Nice work bug a boo!
That will allow you to smoke em in the long races too.
Regards


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PostPosted: Sat Apr 05, 2014 9:28 am 
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Joined: Sun Feb 23, 2014 10:01 pm
Posts: 379
Location: Monette Ar
I like the tank idea. how much does it hold?


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PostPosted: Sat Apr 05, 2014 9:28 am 
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Joined: Thu Aug 18, 2005 10:13 am
Posts: 3760
Location: PERTH WESTERN AUSTRALIA
Thanks StevaRoo!Image...Gotta get all this down pat,and down the road before "I actually GO down the road"....Not sure if there's any Race tracks at the pearly gates Mate? :-)Image


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PostPosted: Sat Apr 05, 2014 11:09 pm 
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Joined: Thu Aug 18, 2005 10:13 am
Posts: 3760
Location: PERTH WESTERN AUSTRALIA
ChrisV wrote:
I like the tank idea. how much does it hold?


Thanks Chris,tank volume is 20 Litres,about 5.3 US Gals in your money.


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PostPosted: Sun Apr 06, 2014 7:07 am 
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Joined: Sat Apr 22, 2006 9:15 am
Posts: 793
Location: Central Coast, N.S.W, Australia
Looks great Baz. you putting in any sort of baffle or anti slosh

http://www.evomx.com/

I am looking for something for my upper fuel tank.

A


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PostPosted: Sun Apr 06, 2014 7:40 am 
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Joined: Thu Aug 18, 2005 10:13 am
Posts: 3760
Location: PERTH WESTERN AUSTRALIA
Yo Adrian,how are ya Mate?
Yeah the fuel slosh around while racing was a major design prob to address...rivalling my BeerBellySlosh! :shock:
I was gonna weld internal up/down baffles but decided NO.You just never know if they break,or hinder flow too much/wrong?
Then thought I'd make use of my vast crushed alu can collection? You know...half a dozen of those thrown in the tank would slow things down huh? :shock: :-)

I decided on buying a couple of small foam sheets,then slotting them midway but opposite to eachother so that they slot into eachother forming a CROSS +,know what I mean?
Then slip this + thru the top fuel inlet,maybe 2 of them?
Also remember,look at my pics,I have a small 50 x 50 x 180mm FINAL drain sump welded at the base of tank.
That FINAL sump is only fed by 3 x 10mm holes from main tank base,so as to minimise slosh to outlet.

Can't get over your link Adrian,they use a $30 sheet,then cut it into 1" cubes,then expect the rights to charge 3 time$ more?...WTF! :shock: :-)


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PostPosted: Sun Apr 06, 2014 7:49 am 
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Joined: Sat Apr 22, 2006 9:15 am
Posts: 793
Location: Central Coast, N.S.W, Australia
do you have a link for the sheets / large bits of the foam


A


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