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 Post subject: Re: Project 2800 pilot
PostPosted: Sun Sep 30, 2012 10:14 am 
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Joined: Tue Dec 23, 2003 10:31 pm
Posts: 5539
Location: New Jersey
No, I currently have 1 on it. I do think in the pictures it is missing though :-)


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 Post subject: Re: Project 2800 pilot
PostPosted: Sun Mar 10, 2013 10:18 am 
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Joined: Tue Dec 23, 2003 10:31 pm
Posts: 5539
Location: New Jersey
UPDATE;
This pilot has been a staple for my friend's riding since completion.It has performed flawlessly. But now I have a slight issue after the last ride. My buddy hit a stump after a failed turn and bent up the front tube pretty good(upper) and wouldn't you know it the SPEEDCHASER front bumper had been removed for painting. I'll post pictures but this needs to be fixed in the coming weeks. I''l have to drop off at the fab shop for repairs. It did not crack the floor tub at all which is good.


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 Post subject: Re: Project 2800 pilot
PostPosted: Sun Mar 10, 2013 1:53 pm 
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Joined: Sat Jun 30, 2007 7:45 am
Posts: 1020
Location: hole above ground
Mudbogger wrote:
UPDATE;
This pilot has been a staple for my friend's riding since completion.It has performed flawlessly. But now I have a slight issue after the last ride. My buddy hit a stump after a failed turn and bent up the front tube pretty good(upper) and wouldn't you know it the SPEEDCHASER front bumper had been removed for painting. I'll post pictures but this needs to be fixed in the coming weeks. I''l have to drop off at the fab shop for repairs. It did not crack the floor tub at all which is good.


that sucks I wish the bumper was on there I would like to see that get bent not the frame

Speed


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 Post subject: Re: Project 2800 pilot
PostPosted: Sun Mar 10, 2013 2:07 pm 
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Joined: Tue Dec 23, 2003 10:31 pm
Posts: 5539
Location: New Jersey
Oh no, that bumper is too nice to have it damaged!! Do you have any left Speed by chance?


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 Post subject: Re: Project 2800 pilot
PostPosted: Sun May 26, 2013 9:22 am 
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Joined: Tue Dec 23, 2003 10:31 pm
Posts: 5539
Location: New Jersey
Finally had time to get this pilot in the garage for repairs.Here is a picture of the front bent tube with the plastics off:

Attachment:
2800 front tube repair 021.jpg
2800 front tube repair 021.jpg [ 39.88 KiB | Viewed 779 times ]


First thing first, we took the side caps off the front tube using a air hammer, they come right off. On this pilot the previous owner had some form of bumper or something welded onto the frame so in this picture you can see where I torched these brackets off:

Attachment:
2800 front tube repair 018.jpg
2800 front tube repair 018.jpg [ 48.6 KiB | Viewed 779 times ]


Attachment:
2800 front tube repair 020.jpg
2800 front tube repair 020.jpg [ 34.23 KiB | Viewed 779 times ]


I have a tool which was fabbed by Bill Okeffe some years back, It slides into the tube and you hammer it through, usually works well but in this case the tube was too far bent.

Attachment:
2800 front tube repair 022.jpg
2800 front tube repair 022.jpg [ 49.62 KiB | Viewed 779 times ]


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 Post subject: Re: Project 2800 pilot
PostPosted: Sun May 26, 2013 9:29 am 
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Joined: Tue Dec 23, 2003 10:31 pm
Posts: 5539
Location: New Jersey
We heated the tube and using a bar tryed to bend the tube back into place. I left the SPEEDCHASER front bumper on purposely to get the front mounts in correct alignment. After heating the entire tube and trying to get it back in place, we really did nothing. In this picture you can see the tool inserted in the tube on the side and we are heating the bent area. The tool is hammered through with the idea of the tube bending back. It did not work well at all.
Attachment:
2800 front tube repair 023.jpg
2800 front tube repair 023.jpg [ 42.27 KiB | Viewed 779 times ]


Attachment:
2800 front tube repair 024.jpg
2800 front tube repair 024.jpg [ 43.4 KiB | Viewed 779 times ]


After closer evaluation it was determined the tube was actually bent where all the downtubes and sub frame meet on the end of the front tube.This caused us to determine the method of bending was not going to work in the fashion we were doing.


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 Post subject: Re: Project 2800 pilot
PostPosted: Sun May 26, 2013 9:41 am 
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Joined: Tue Dec 23, 2003 10:31 pm
Posts: 5539
Location: New Jersey
So we moved forward and determined we were going to have to cut the front tube to make 2 separate sections, this would make the repairs much easier as you can now go in each side and bend them independently.If you look at this picture closely you can see actually how far the front bumper mount is away from the Speedchaser bumper. Here is a picture of the tube cut:

Attachment:
2800 front tube repair 025.jpg
2800 front tube repair 025.jpg [ 64.95 KiB | Viewed 778 times ]


After heating each side and using a big bar we got the Speedchaser bumper to bolt right in to the tube:

Attachment:
2800 front tube repair 027.jpg
2800 front tube repair 027.jpg [ 54.18 KiB | Viewed 778 times ]


After bolting the bumper up I bent this side over to meet the other. In this pic you can see just how far I need to bent the tube OUT to meet up the front mounts for the bumper. When I cut the tube it was under some kind of pressure too I might add.

Attachment:
2800 front tube repair 028.jpg
2800 front tube repair 028.jpg [ 71.75 KiB | Viewed 778 times ]


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 Post subject: Re: Project 2800 pilot
PostPosted: Sun May 26, 2013 9:48 am 
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Joined: Tue Dec 23, 2003 10:31 pm
Posts: 5539
Location: New Jersey
Tubes heated and bent to match finally. I use a vice grip to match the tubes exactly flush and welded them together.
Attachment:
2800 front tube repair 029.jpg
2800 front tube repair 029.jpg [ 66.99 KiB | Viewed 778 times ]

Attachment:
2800 front tube repair 031.jpg
2800 front tube repair 031.jpg [ 70.61 KiB | Viewed 778 times ]

Attachment:
2800 front tube repair 030.jpg
2800 front tube repair 030.jpg [ 64.79 KiB | Viewed 778 times ]


After welding them back together, I welded an additional piece of tubing over the weld to make sure it was strong.

Attachment:
2800 front tube repair 032.jpg
2800 front tube repair 032.jpg [ 70.7 KiB | Viewed 778 times ]

Attachment:
2800 front tube repair 033.jpg
2800 front tube repair 033.jpg [ 45.26 KiB | Viewed 778 times ]


I might add I am learning to weld and the finish welding was performed by my fab guy.
Any comments fellas?


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 Post subject: Re: Project 2800 pilot
PostPosted: Sun May 26, 2013 1:26 pm 
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Joined: Mon Dec 15, 2003 2:40 pm
Posts: 22131
Location: Chicago
Chop cut rebuild ride another day...

Whats left?


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 Post subject: Re: Project 2800 pilot
PostPosted: Sun May 26, 2013 3:17 pm 
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Joined: Tue Dec 23, 2003 10:31 pm
Posts: 5539
Location: New Jersey
Today what was left was grinding, sanding and painting the frame and Speedchaser bumper.
I went to local Hardware store and purchased Krylon spray paint red apple gloss color, matched pretty dam well. Some completed pictures for you. The plastics went right on-each and every bolt hole lined up so I am going to say the frame is close to being straight.


Attachments:
2800 front tube repair completed 001.jpg
2800 front tube repair completed 001.jpg [ 65.79 KiB | Viewed 764 times ]
2800 front tube repair completed 002.jpg
2800 front tube repair completed 002.jpg [ 49.06 KiB | Viewed 764 times ]
2800 front tube repair completed 003.jpg
2800 front tube repair completed 003.jpg [ 66.56 KiB | Viewed 764 times ]
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 Post subject: Re: Project 2800 pilot
PostPosted: Sun May 26, 2013 8:06 pm 
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Joined: Thu Apr 22, 2010 11:38 pm
Posts: 1745
Location: New Mexico
Nice work sir


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 Post subject: Re: Project 2800 pilot
PostPosted: Sun May 26, 2013 8:09 pm 
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Joined: Tue Dec 23, 2003 10:31 pm
Posts: 5539
Location: New Jersey
Thank you. I like input from fellas like yourself that have skills far beyond my knowledge in fabrication. I really appreciate it.


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 Post subject: Re: Project 2800 pilot
PostPosted: Mon May 27, 2013 7:57 am 
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Joined: Mon Sep 04, 2006 2:20 pm
Posts: 700
Location: Joliet, Illinois
Looks great!...Nice job!


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 Post subject: Re: Project 2800 pilot
PostPosted: Sat Jul 06, 2013 5:34 pm 
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Joined: Tue Dec 23, 2003 10:31 pm
Posts: 5539
Location: New Jersey
Installed a ATVR econo hood today on the Pilot. That old POS hood I bought off that jerk on ebay was cheap, garbage and needed to be tossed. Changed the oil in the balancer, installed fresh belt, and did a quick plug chop, it is spot on perfect.


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 Post subject: Re: Project 2800 pilot
PostPosted: Sun Jan 12, 2014 10:50 am 
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Joined: Tue Dec 23, 2003 10:31 pm
Posts: 5539
Location: New Jersey
UPDATED here is some pictures of the pilot taken this weekend.


Attachments:
MISC PICTURES 001.jpg
MISC PICTURES 001.jpg [ 39.7 KiB | Viewed 650 times ]
MISC PICTURES 002.jpg
MISC PICTURES 002.jpg [ 36.65 KiB | Viewed 650 times ]
MISC PICTURES 003.jpg
MISC PICTURES 003.jpg [ 47.34 KiB | Viewed 650 times ]
MISC PICTURES 004.jpg
MISC PICTURES 004.jpg [ 45.75 KiB | Viewed 650 times ]
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 Post subject: Re: Project 2800 pilot
PostPosted: Sun Jan 12, 2014 10:55 am 
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Joined: Mon Dec 15, 2003 2:40 pm
Posts: 22131
Location: Chicago
Is it the pictures or is the toe off ?


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 Post subject: Re: Project 2800 pilot
PostPosted: Sun Jan 12, 2014 11:01 am 
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Joined: Tue Dec 23, 2003 10:31 pm
Posts: 5539
Location: New Jersey
The toe is off yes, that's why I had it in the shop. Needed to replace the tie rods with Hoserized ones. Compression is still great, this Engine and Pilot has been a great ride for sometime.


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 Post subject: Re: Project 2800 pilot
PostPosted: Sun Jan 12, 2014 11:59 am 
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Joined: Mon Dec 15, 2003 2:40 pm
Posts: 22131
Location: Chicago
Mudbogger wrote:
The toe is off yes, that's why I had it in the shop. Needed to replace the tie rods with Hoserized ones. Compression is still great, this Engine and Pilot has been a great ride for sometime.


Is the sensor on the spark plug wire very heavy, looking in the pic it looks bulky and I worry about any added weight tugging on the plug wire while riding, if you remember Honda from the factory supports the wire about right where you added the sensor, the after market heads didnt have provisions for that support but I have never had a problem running then with out that support but I never added any weight other than a sensor for the tach right on the spark plug boot where its supported by the plug.

Might not be a problem thought I would mention so your not dealing with it on a ride trip and trail.


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 Post subject: Re: Project 2800 pilot
PostPosted: Sun Jan 12, 2014 6:56 pm 
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Joined: Tue Dec 23, 2003 10:31 pm
Posts: 5539
Location: New Jersey
no hoser in fact it is quite Light and weights practically nothing.
thanks for thinking about that though I always appreciate your input.


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 Post subject: Re: Project 2800 pilot
PostPosted: Thu Jan 30, 2014 7:18 pm 
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Joined: Tue Dec 23, 2003 10:31 pm
Posts: 5539
Location: New Jersey
This Pilot is going to get a HUGE upgrade in the coming weeks, more to come!!!!! :-)


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 Post subject: Re: Project 2800 pilot
PostPosted: Thu Jan 30, 2014 8:59 pm 
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Joined: Thu Apr 22, 2010 11:38 pm
Posts: 1745
Location: New Mexico
Mudbogger wrote:
This Pilot is going to get a HUGE upgrade in the coming weeks, more to come!!!!! :-)


Do I sense long travel?? :-) :-) :-)


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 Post subject: Re: Project 2800 pilot
PostPosted: Thu May 29, 2014 9:38 pm 
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Joined: Tue Dec 23, 2003 10:31 pm
Posts: 5539
Location: New Jersey
Little teaser for the folks that watch the threads:
Before Dave-Co and After Dave-Co upper roll cage.
More to come!! :-)


Attachments:
2800 before.JPG
2800 before.JPG [ 95.15 KiB | Viewed 567 times ]
2800 After.JPG
2800 After.JPG [ 88.57 KiB | Viewed 567 times ]
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 Post subject: Re: Project 2800 pilot
PostPosted: Tue Jul 01, 2014 7:50 pm 
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Joined: Tue Dec 23, 2003 10:31 pm
Posts: 5539
Location: New Jersey
Had to replace the steering shaft and column on the Pilot, Dave found both bent and the bushing area worn too much for the new power steering unit, BIG BIG thanks to Nick Pena for delivering both items for free to Dave's house in lightning fast time, Dave was under the gun and needed them asap, cannot thank him enough. Project is coming along, Dave is doing it in between other projects and doing a fine job indeed! :-)


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 Post subject: Re: Project 2800 pilot
PostPosted: Tue Jul 01, 2014 8:02 pm 
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Joined: Mon Dec 15, 2003 2:40 pm
Posts: 22131
Location: Chicago
Mudbogger wrote:
Had to replace the steering shaft and column on the Pilot, Dave found both bent and the bushing area worn too much for the new power steering unit, BIG BIG thanks to Nick Pena for delivering both items for free to Dave's house in lightning fast time, Dave was under the gun and needed them asap, cannot thank him enough. Project is coming along, Dave is doing it in between other projects and doing a fine job indeed! :-)


Looking good, save them old steering parts they are renewable ...


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 Post subject: Re: Project 2800 pilot
PostPosted: Thu Jul 03, 2014 8:41 am 
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Joined: Tue Dec 23, 2003 10:31 pm
Posts: 5539
Location: New Jersey
Yup already did :-)


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