Large Spine Frame XS650 / Egli / Rau / Cafe Racer

[rehar]

Had the day off today, tomorrow the family vacation starts - and it won't be near the garage.
Today I mounted the Coil and got about 75% of the subframe "seat" mounting done.
I'm rubber isolating the seat similar to a production bike might.

Coil circled in red.

 

[azman857]

You have done some serious planning and building in this project! This has to be in the Top 10 (or less) extensive builds. Most impressive!

 

[rehar]

Well, there are a lot of cool, beautiful and inspirational machines on this forum! Just happy to be a part of it all!

 

[rehar]

Before I can move to the wiring harness, I will mount the brake light, turn signals, headlight, etc.
The sub-frame needs a brake light bracket.

Roughly locating the license plate and brake light...

 

[rehar]

The brake light is one of these cheap LED units off ebay. Cheap, but a nice piece. The steel bracket is a bit heavy. So, I fabricated a new in aluminum piece, 62% lighter, a whooping 96grams, or 0.21lbs weight reduction.

 

[rehar]

Plan of attack - something like this.


think I will hang the turn signals off the bracket as well. Then, two screws and I can remove all the rear lighting.

 

[rehar]

Got some time in the garage this weekend. My Neighbor peaked in, asked if I had a New Years' resolution yet... He said he had one for me: "Finish this bike."
Perfect, challenge accepted!

Working to the CAD model, got the basic bracket done. Made a mistake along the way and had to partially cut, bend and re-weld the main tube. Of course, had I made it exactly to the CAD model - I would not have had to do this... ahem. I haven't added the gussets - they may not be needed, but can add later easily enough.

I had some really nice Rizoma Graffio turn signals I was going to use... They are supposed to be M8 X 1.25 thread... Which should be around 7.8mm~8.0mm diameter, weird, but these are 7.3mm diam - I can't get a bolt to stay on - and as a result, they can't be mounted! So I had some back up turn signals, a bit larger than what I wanted... they can be changed later. These bullet shape units kind of fit the look though.

Anyone have any ideas how I can get the Rizoma's to work - or have had the same issue?

 

[TwoManyXS1Bs]

... They are supposed to be M8 X 1.25 thread... Which should be around 7.8mm~8.0mm diameter, weird, but these are 7.3mm diam - I can't get a bolt to stay on - and as a result, they can't be mounted!

Anyone have any ideas how I can get the Rizoma's to work - or have had the same issue?

That IS a wierd diameter. Closest would be a #18 wood screw.

https://www.boltdepot.com/fastener-information/Wood-Screws/Wood-Screw-Diameter.aspx

Had a similar problem with an undersized male molded plastic threaded water drain fitting. Had to make a matching undersized female thread to screw onto it.

I'd have to have a close look at yours.
In lieu of that, show them to a machine shop...

 

[rehar]

headlight thoughts... Fork mount, triple clamp mount, steering head mount? Pros and cons for each...
Of course the Rizoma turn signals are out (for now)...
I like the slim/thin look, got the idea from an adventure bike thread... Pretty simple, unique, lightweight...

Hmmm...

 

[NastyBeads]

I like the fork mount of the first picture. I would maybe make a single, thicker mount on each side. With the top and bottom mounts of the triple tree, it may be too "busy" with 4 clamps on each fork side.

 

[rehar]

Yeah, I've ordered a pair of fairly conventional fork leg brackets. Unfortunately - they look heavy and of steel, fortunately with Rubber mount and 52mm ID!
The R6 fork leg has a very gradual Taper from the top triple 50mm Diam to the bottom triples with 52mm diam. So the rubber will be good for Vibe and help absorb the taper. I'll give these a try.

I like the slim/thin headlight look and I found an aftermarket - nearly identical version to what I was thinking of fabricating.... So - that's been ordered.

 

[rehar]

The headlight above arrived - it's a "flashpoint LED headlight. Nice piece.
The fork mount headlight brackets arrived - but they are 56mm, not 52... So, no real progress this weekend. Just hope I can return those brackets and get the replacements without hassle and by next weekend...

 

[rehar]

Spoke to the supplier of the fork mount headlight brackets - they forgot to send me additional rubber to shim it with. Received it, and it's too thick... So - another week will pass for this...

In the meantime - Steering damper from an R6 will mount nicely to the top triple clamp, but I need a bracket attached to the frame...
A little more detail added to the CAD:

And the new bracket might look something like this (blue):

This will be welded onto the top of the spine.
After I fabricated the round section and welded it to the from - I may not need the flat support under the bracket legs... TBD
Sorry no pics, but it is welded to the spine now (less the flat part). I can always weld that on later.

 

[rehar]

And working on the electronics... Not sure I will stick with this "open" design... But, here is the snapshot... Top/side/ISO:


To start this work, I focused on the battery bracket.


THe Blue assembly was Fabbed this weekend. Again - no pics... Too busy between family and project...

Weights so far:
Lbs Item
2.67 Antigravity Battery 12 Cell
0.31 Brkt
0.63 Rectifier (approx)
3.61 Total weight

Just the battery that came in the donor bike was:
9.43lbs, 12N14-3A.

 

[Jim]

That bikes gonna be straight outta' the Jetsons...

 

[rehar]

Simple is never simple... The fork leg mounting brackets I purchased and was later told to use the spacer they sent me, was later embellished upon as just shove half of the 3mm thick spacer into the 2mm gap, biasing / offsetting the clamp... OFF concentric.... Not too thrilled with this... should I spend the ~$20 on the 2mm thick rubber sheet from McMaster? Hmmm... Going to think on this one for a bit....

In the mean time, the battery tray/electronics mounting bracket... From the CAD above - and not completed, but getting there...


Should have 0.5"+ clearance at full bump - between the swing arm and the bottom of the battery... Will work on this a little bit over the weekend.

 

[azman857]

Do you work for NASA or M(James Bond reference)? Aerospace industry somehow? This is some serious good/great stuff here!!

 

[rehar]

Close! Currently in Aerospace. Thanks.

 

[Jim]

Close! Currently in Aerospace. Thanks.

I spent my adult life as an aircraft mechanic. Now you've piqued my interest... care to elaborate?

 

[rehar]

Mechanical Engineer. Nothing special... Certainly, nothing as fun as what comes out of the garage.
Aircraft Mechanic eh? You've got my sincerest respect!