help! my bike is falling apart! :(

[alex.s]

what should i do?!?!

[TheDementedDrummer]

Duct tape.

[alex.s]

i'm not sure. ducttape leaves residue

[subxero]

I see you have a hammer, looks like you are good to go what's the problem?

[allanoue]

Prozac

[massacremasses]

semen

[NevadaWolf]

Bubble gum and bailing wire, solved!

[Motofool]

Originally Posted by alex.s

.............what should i do?!?!

You need to find an engine and a tank !!!

......... what is the plunger for?

[tfkrocks]

zip ties

[crazymadbastard]

you really messed it up, should look like this:

[alex.s]

Originally Posted by Motofool

You need to find an engine and a tank !!!

......... what is the plunger for?

engine is in the mail, and the gas tank is just outside the photo

this bike will be my new dedicated race bike (other 250 served dual purpose, but no more)

todo:

straighten the frame (pull jig being built tonight, we'll see if it gets done in one night though... straightening hopefully tomorrow. the neck is twisted 2.5d clockwise and the bottom of the neck in about 1cm. once it's back in true form i will resurface the backbone (currently chipped paint from the bend causing some minor surface rust) and weld in ninja-300-style plate webbing for extra support on the backbone. once its all done its getting painted deep red with a bunch of clear on top. i'll probably swap to allballs tapered bearings just to keep up with the johnsons (current bearings are nearly shot after the last crash it seems) also theres really minor damage to the front wheel i will need to repair also.

gsxr rear shock coming in soon, which will need to be resprung and serviced

the front end is stock right now, 0.75 springs will go on with some diy preload adjusters and new oil. nothing fancy.

i have a yoshi full SS exhaust that has a crack in it that needs to be welded up, after its repaired it'll go on with cleaned out carbs. the engine in the mail is stock with only a few hundred miles but when it gets here it will get a full service along with a smaller head gasket.

the gas tank and race glass need to be resurfaced and painted. with the red frame i will go with a white body, red underbelly, with a grizzly bear on each side, rebel star above it. basically a californian flag. yellow (amateur) "256" plates front and back painted in.

levers
throttle housing
clipons
rearsets
vesrah pads
might need a new front disk
chain/sprockets
tires

[Motofool]

Originally Posted by alex.s

...............the neck is twisted 2.5d clockwise and the bottom of the neck in about 1cm...................with the red frame i will go with a white body, red underbelly, with a grizzly bear on each side, rebel star above it. basically a californian flag..................

How did you measure the frame twist?
Did you measure the caster angle of the neck as well?

[alex.s]

i used string to measure it all up and compare to a true frame then did the math to get degrees, this is a great video on how to do everything:

Link to original page on YouTube.

for the twist you need to level the engine mounts, then have a square that can reach the top, or a true jig.

if the frame is in a true square you can use string from top to bottom over the neck or inside the neck and measure the distances between the walls and the string at the top and bottom.

[Nemesis]

Originally Posted by alex.s

[IMG]
what should i do?!?!

Stop molesting it!

[alex.s]

Originally Posted by Nemesis

Stop molesting it!

Link to original page on YouTube.

[Felipe the Ant]

Your rear wheel is backwards, try flipping it around and see if that helps

[Motofool]

Originally Posted by alex.s

............this is a great video on how to do everything..............

Indeed !!!

Thanks, Alex

[alex.s]

this little frame is tough. after bending the box jig from the jack on the frame and only moving the head about 1mm, and then bending two steel tubes trying to bend it by hand, i've decided to cut the welds on the back bone and have my friend (expert welder) reweld it all straight with webbing support. i may have to replace the back bone all together. we'll see. its a pain in the ass.

[Motofool]

Originally Posted by alex.s

this little frame is tough. after bending the box jig from the jack on the frame and only moving the head about 1mm, and then bending two steel tubes trying to bend it by hand, i've decided to cut the welds on the back bone and have my friend (expert welder) reweld it all straight with webbing support. i may have to replace the back bone all together. we'll see. its a pain in the ass.

Did you try some serious heat on the frame before applying force?
Pipes are very weak for that task, they bend easily.
If you anchor the steering head close to the ground, you could use the frame itself as a lever.

Just a couple of ideas, trying to avoid a cut and re-welding of those tubes of thin wall and maybe some difficult to weld alloy.

[Asspire]

R6's come pre assembled..

[alex.s]

You are right Hernan. I'll try with heat today. I blame the alcohol for yesterday

[cuong-nutz]

Originally Posted by alex.s

You are right Hernan. I'll try with heat today. I blame the alcohol for yesterday

I believe you did not have enough

[alex.s]

more alcohol, lots of heat, a sawsall, and plenty of swearing, and the tube is now straight with the swingarm. frame needs welding around 4 spots and im going to add gusseting

[JohnnyBravo]

Looks like your on the right track... Don't drink an drive

[alex.s]

before


after cuts and bends


need to remeasure and adjust i think before welding. the top T is going to get remade

[Motofool]

Originally Posted by alex.s

before


after cuts and bends


need to remeasure and adjust i think before welding. the top T is going to get remade

You had good 6~7 degree of twist there !!!

I wonder what kind of forces that frame felt in order to get that deformation.

Have you verified that both tracks for the head bearings are parallel respect to each other (if the head tube itself was bent)?

[alex.s]

the tube itself is true though the races are going to get replaced anyway. theres a small ding on the top (my fault) that i'll need to tap back into shape before installing the new race. still not sure whether to completely replace the back bone or to try to rebend and lay down W's and just rejoin it. decisions decisions

[alex.s]

we welded the frame last night.



some of the smaller inner tube is pretty thin walled and melts very easily. extra steel was added under the welds. tonight i'll be adding in a little bit of gusseting before i scrub it and paint it red with lots and lots of gloss

[massacremasses]

too bad you dont live closer. Id trade you some work for work getting that frame and everything powder coated.

[rasta]

Garage seems like a strange place for a plunger..

[alex.s]

you say plunger, i say dent puller.

[rasta]

Ooooh yea duh

[alex.s]

so all the welding is done. i added 1/8" plate webbing and a top brace around the aft of the backbone where it T's out to the side beams. i tried jumping on it and it seems good enough for government. i guess i'm colorblind or stupid, but the frame is now mostly yellow. i didn't notice until it was half way done and my brother mentioned it wasn't red. i was thinking about the welds and sealing them properly and didn't even think about color until i was through a can of yellow. so maybe i'll do the whole thing yellow...

[alex.s]

new todo:

- paint frame red
- install new head bearings
- fix ding in front wheel.
- gsxr rear shock - respring, service, install
- need rear swingarm adjusters and an axle
- front end springs and oil
- install the new engine
- repair yoshi exhaust
- redo controls
- need sprockets, have chain.
- needs new tires
- needs paint
- front brake need love

[Motofool]

Originally Posted by alex.s

............
- fix ding in front wheel.
..........

Amazing rim repair by Papo Restrepo

Would you mind posting pictures of the webbing and a top bracing?

[alex.s]

sure i'll take some photos tonight. phone was dead when i finished yesterday so i didn't take any. unfortunately you can't really see the webbing underneath the top bracket that i made but you'll be able to see the enclosed topside. i'm not the best welder and since its structural and not external i decided not to sand/grind the welds afterward. so they're a bit ugly but they do what they need to do

[Motofool]

Originally Posted by alex.s

..........i'm not the best welder and since its structural and not external i decided not to sand/grind the welds afterward. so they're a bit ugly but they do what they need to do

Hey, we are not judging here but admiring and learning from your work and ingenuity.

Welds don't need to be pretty to be strong, I was always against grinding welds.

[alex.s]

[simook]

looking good!

[alex.s]

i took off the tire from the front rim last night and was trying to heat it and bend it but i think i'm going to need better suited tools than what i was using. also i forgot to take out the valve stem and it started to burn from the heat. oops.