Cateye Midi Bike project

[Munkul]

dis is what tupac and biggi neva managed.

y dont u buy my 125cc pit bike engine tuned by the renault F1 team develops 90bhp at the spare wheel 4 lyf

aw wicked!

 

[puntoluva]

are you for real???

blud i always keep it real on da streets an on the forums

 

[willieboy]

blud i always keep it real on da streets an on the forums

lmfao!!!!!!!
aiiiiii

 

[Munkul]

I decided to keep it real, and buy dec's (puntoluva) other engine, which is 125cc, but more importantly in good condition and it cost about the same as it would to sort all the problems on the 110cc engine

So... trial fit of the engine revealed that my chassis extension wasnt good enough it fitted, but only just!, and it would have been impossible to remove once fitted...

So we moved onto the wheel, and how it was going to be driven.

ghey standard (useless) free-wheeling sprocket:

Tyre and sprocket removed:

Now at this point, we thought that the last part of the sprocket inner race was a press fit. So we tried pulling it, heating it, hammering and chiselling it, all to no avail! So i took a grinder to it... and discovered it was threaded...

The plan is to either: find two threaded nuts (maybe two inner races off scrapped sprockets), turn the new sprocket to fit the threaded dia. and fit that way; Or, turn the threads off the wheel, turn the sproket to fit, and weld it on.

Well that was last week, and since then all i did was spend a couple of hours on it this evening.

Chopped the old spars out completely, fabbed some new ones up and welded them in:

The engine now fits in and out perfectly with plenty room for mounts

- Chopped up an old pitbike mount, the idea is to save effort and integrate this into the frame instead.

Hopefully this next week i will concentrate on it in evenings, im getting quite enthused about it now

 

[Munkul]

Trimmed and smoothed engine mount with a flap wheel:

I fashioned up a bottom mount to hold the engine's weight, locating through four holes.

Err... woops, it wasn't wide enough for the frame So a little trimming down to fit the engine contours, and extensions welded on:

In the end that mount was no use at all because of a number of reasons, but im going to blame the fact that the mounting holes are offset from the main centre of the engine, which i hadnt noticed. So a new, one peice mount was made up.

More bits of the frame removed; the obselete footpegs and the centre spar were junked:

...so that the rear mount could sit like so:

Bolted the mounts to the engine, lined it up as best i could and tacked it:

Remove the engine. Oh no, wait, it wont come out because of the shape of the top mount

Grinder time!

Engine removal, then flap-wheeling the butchered mount (and re-welding of the outer mount that had to come off to get the grinder near the engine in the first place!):

Finishing "pose" for tonight:

The mounts are far from being ready to take a working engine. First we need to adapt the rear wheel, then extend the sprocket on the engine outwards(which will be no easy task due to the design). Only then can i find out how straight my mounts are, so that i can finish welding and bracing them.
So there may not be any more updates until T.E.D. gets those jobs done

 

[Munkul]

Jordan completed the wheel and sprocket on friday

Welded (just decent tacks, cos i didnt want to warp the wheel)

So i started to fashion the base for the front sprocket extension... so the plan of attack was: take two old sprockets (one with hardly any teeth left) drill out the threaded holes bigger, plug weld them together, then give them to Jordan to turn them down.
What actually happened was: the sprockets are made of HCS or some similarly hard material, so didnt like being drilled. At one point the drill was cherry red along half its length!
but it resulted in one case of this:

and one case of this:

bummer :bang:

So... on with the rest of the bike!
Bottom mount trimmed down

welding and and bracing of the mounts

Yeah the welding looks poor, but its quite awkward to weld in those positions!

Now to make a bracket to hold the rear brake

 

[T.E.D. Jordan]

Some good progress - looking forward to seeing it up an running

Jordan

 

[Munkul]

Last night: whacked a tank of fuel and one of dec's small exhausts on, connected up all the loom, and test started the engine, which proved to be absolutely fine

Tonight: finished off the rear brake caliper mount and fitted the back wheel

The rather nice S/S exhaust i had was too big to clear the frame, so an inch was taken out of it

Then fitted to the bike... looks like its suited to the frame, but nothing is ever that simple

I dug out the top fairing to fit

The exhaust had to be twisted in the mount to make it fit

It now actually looks like a proper bike :slayer:

So... of course the exhaust was never going to run like that. The plan is to bend it so that it runs along the top of the engine casing, and kicks out at the rear swing-arm.

 

[Munkul]

Didnt get as much done on it as i hoped

bent the exhaust in a couple of places, and it sits pretty nice

its not staying like that though, i want it upswept and out the back. But to do that i need more stainless pipe, so thats on hold atm.

Rigged up the throttle, that was the only other meaningful thing that got done on it today. Tried rigging up a thumb-operated clutch but there is too much pressure needed, and not enough space on the handlebar. So i will use a conventional setup of left handle clutch lever, right handle front brake lever; and rig up a foot-brake for the rear. No idea how accessible the rear brake will be yet though.
Got a spare output shaft and gear, which we have decided will be the best way forward for making a sprocket spacer, so that should get done soon

 

[Munkul]

Tonight got the exhaust finished.

+ some of this

= this

Looks pretty good on the bike

 

[C17MGO]

Coming along nicely now.

Keep up the good work.

 

[Munkul]

No updates.

I am STILL waiting on T.E.D. Jordan for this sprocket spacer to be made up when they get some time.

And he says today that i've only been waiting a month - HA.

 

[craigb244]

over 3 months since last update!!! lol want me to make the said spacer?

 

[T.E.D. Jordan]

Be my guest, the little time i have away from work at the minute I treasure!

Jordan

 

[Munkul]

well, it got done over the weekend

So now this is what it looks like, after i drilled and tapped it tonight for bolting to the sprocket bits.
(The top bit is the bit that has been made, and the bottom two bits are sprockets that have been shaved down, because making internal splined holes is too hard work)

Made of EN24T steel, so if anything is gonna break, its not gonna be that!

Still needs drilled and tapped in the sides for grub screws, and the bolt threads sawn flush, and a small chamfer on the new splines, but CBA tonight

So, with this done, theres not much still to do to get it running

 

[puntoluva]

Haha someone put a link up on PBC (pitbikeclub.co.uk) for this saying it was cool must be poplar.

And just for the record

POW POW iyyyyeeee

that it for real and repping

I like the emotions on this forum :yum::devil::slayer::worship::idea::yuck:


Rather cool

 

[puntoluva]

http://www.pitbikeclub.co.uk/showthread.php?t=30357


Cool ey

pow to the pow

 

[Munkul]

i see you be gettin me rep up to the max! Me is gonna join PBC and show them up with knowlege, aaiight?





(no thats not gonna happen


pow pow)

 

[puntoluva]

i see you be gettin me rep up to the max! Me is gonna join PBC and show them up with knowlege, aaiight?





(no thats not gonna happen


pow pow)

But www.pitbikeclub.co.uk is better than ..... www.fiatforum.com



PBC:worship:

 

[Munkul]

Well, i finished it enough to ride tonight. The first time its moved under its own steam for at least a year, never mind with a big engine.

fast doesnt even begin to describe it. it must be geared for 60mph+ and i was still wanting to wheelie in 3rd.

It was dark. I had no lights, the boys had went home. There was no brakes or clutch or footpegs, just felt like sitting on a rocket with an accelerator :slayer::slayer::slayer::devil:


Plenty work still to do on it to get it safe and reliable, mind. I would have got pics but i was overcome with glee