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Project I'm a terrible welder. I'll get better tho. (Fuel injected ZXR project)

Discussion in 'Your 250cc Projects' started by DamnitLaverty, Nov 19, 2020.

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  1. DamnitLaverty

    DamnitLaverty Doing things the hard way since '78! Premium Member

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    Exactly. Being that it was key power, its now key power for the computer, instead of the coils. The computer will control the coils and injectors now. Trigger wiring stays, there is no ECU plug since the CDI wasn't a full ECU, only spark control. I've removed/repurposed all the wires from that, and running a separate ECU plug with way more wires.

    If this works, then I'll document it a little better for people to follow in my steps.

    Oh damnit. I knew what I meant, but said it totally wrong. :) Yes, the crank trigger comes from the pickup on the crank. It just has two wires that go into the CDI which is how I ended up saying it that way lol. I just replaced the crank trigger with a 36 tooth wheel that I drafted up and had laser cut so I damn well know where and how it is. I decided not to remove all the factory wiring because I wanted to keep stock lights and gauges. Instead I removed the wiring for spark control only, and am trying to reuse the factory stuff- because the fuse block fits, it has all the right connectors to my bar controls, etc.
     
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    DamnitLaverty, Dec 1, 2020
    #21
  2. DamnitLaverty

    DamnitLaverty Doing things the hard way since '78! Premium Member

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    A wild update appears!

    Exhaust is done. Spark-side wiring is done. Struggles abound with the manifold though! Also, I should probably buy a battery at some point to test this wiring out...

     
    DamnitLaverty, Feb 10, 2021
    #22
  3. thebeefsalad

    thebeefsalad Well-Known Member Premium Member

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    MC22 wheels might fit with a little love, I might know a guy in the states with a set :D
     
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    thebeefsalad, Feb 13, 2021
    #23
  4. DamnitLaverty

    DamnitLaverty Doing things the hard way since '78! Premium Member

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    My Bike:
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    I have the ZXR400 wheel- it’s the axle, cush drive, rotor, etc that are ballooning cost/complexity over what I wanna do.

    thanks for the offer tho! :)
     
    DamnitLaverty, Feb 13, 2021
    #24
  5. ShaneP

    ShaneP Well-Known Member Premium Member

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    What about a ninja 250/300/400 to get a 17-inch wheel?
     
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    ShaneP, Feb 13, 2021
    #25
  6. DamnitLaverty

    DamnitLaverty Doing things the hard way since '78! Premium Member

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    I did ZXR400 because it was supposedly the easy button solution... it wasn’t. I haven’t looked further though. Ninja 300 is a great idea with accessible parts for me. I’ll put it on the scope creep list to investigate!
     
    DamnitLaverty, Feb 13, 2021
    #26
  7. DannoXYZ

    DannoXYZ Well-Known Member

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    Honda CB125TT, Kawi EX250E, EX250F, EX250J street, EX250J race, Honda CBR250RR-MC19, CBR250RR-MC22, NSR250R-MC21 VF500F, CBR600RR, VFR750F
    I've got set of Velg vRossi wheels in 17x3,0/4,5" on my EX250J race-bike. Someone was importing them from Indonesia a while back. Came with crap bearings that died in couple 100 miles, so interest died out. I picked up set for peanuts and replaced bearings and it works great! Fits MotoAmerica JR Cup takeoffs perfectly.

    Maybe you can track some down. The brake-disc and cush-drive match. Gotta be some lurking in back of garages somewhere.
     
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    DannoXYZ, Feb 14, 2021
    #27
  8. DamnitLaverty

    DamnitLaverty Doing things the hard way since '78! Premium Member

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    Oh good lookin’ out! Do EX & ZXR interchange as well? If those swap to ex and ex swaps to zxr we might have a winner!
     
    DamnitLaverty, Feb 14, 2021
    #28
  9. DannoXYZ

    DannoXYZ Well-Known Member

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    Probably not as easily as between EX, GPX and ZZR. I've used EX250J ('08-12) rear-end to upgrade earlier '88-07 GPX/EX250G-J to 17" wheels (swingarm, shock, linkage, wheel, brakes).

    I just sent guy in Canada set of EX250G/H handelbars & risers for his ZZR. They have about 50mm higher position than ZZR for more comfort.

    I'll need to look over parts-diagram and have you make some measurements. Ninja 300 EX300 wheels may be direct swap. Tyres in 110/140 combo may be more appropriate than 120/160.
     
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    DannoXYZ, Feb 14, 2021
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  10. DannoXYZ

    DannoXYZ Well-Known Member

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    I took some quick measurements of my CBR250R-MC19 wheels and it'll take quite some work to fit. Due to differences in offset and disc diameters, it'll need custom spacers and brake-mounts to fit.
     
    DannoXYZ, Feb 14, 2021
    #30
  11. DamnitLaverty

    DamnitLaverty Doing things the hard way since '78! Premium Member

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    Don’t go to that much effort for me- I’ll get down to my Kawi dealer and take some measurements on US bikes. Thanks tho! Seems like a lot of work- my goal is a no-custom-machining solution for parts interchange.
     
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    DamnitLaverty, Feb 14, 2021
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  12. DannoXYZ

    DannoXYZ Well-Known Member

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    Would be interesting what you measure. I noticed that Ninja 400 didn't go to wider wheel, has 17x4,0" just like 300. So perhaps spacers & brake-mounts will work as well. Although there's 2 versions of 400. One with swingarm that bolts to frame and one that bolts to engine.

    Interestingly enough, CBR250R/RR and CBR400RR all use same frame... and bodywork...
     
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    DannoXYZ, Feb 14, 2021
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  13. DamnitLaverty

    DamnitLaverty Doing things the hard way since '78! Premium Member

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    Swingarm is off the bike for cleaning, and new needle bearings. Wheel is in the shop for a metal valve core. My R6R shock seems to have gotten lost somewhere in the last 2500 miles.

    In the meantime... lets make an intake manifold. We'll figure it out as we go along.

     
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    DamnitLaverty, Feb 22, 2021
    #33
  14. DannoXYZ

    DannoXYZ Well-Known Member

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    Really cool design on intake manifold!! Personally I like brazing for thin steel tubing, looks more sleek.

    i've got some extra shocks I can send you:

    - MC22
    - EX500
    - EX250J
    - EX250G
     
    Last edited: Feb 22, 2021
    DannoXYZ, Feb 22, 2021
    #34
  15. DamnitLaverty

    DamnitLaverty Doing things the hard way since '78! Premium Member

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    I'll let ya know if it doesn't show up, thanks man! USPS has gone dark on me, but I imagine it'll show up at some point. :)

    As far as brazing goes, you might be on to something- but I have a mig welder, and I need the practice anyhow for the 1964 Falcon I'm building next to the ZXR. Besides, this'll all hide under the tank and nobody will see but me. :)
     
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    DamnitLaverty, Feb 22, 2021
    #35
  16. DannoXYZ

    DannoXYZ Well-Known Member

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    Ah, hide it under bodywork! You're doing awesome one-off project. Might want to show it off someday. :)

    Brazing is actually good intro to TIG welding (you'll end up there some day). Two-handed operation and you can go slower with more control of puddle. For high-strength thin steel, it's only way to join them due to lower heat. Oh... so extremely pretty!!! I'm gonna build chromoly trellis-frame like this someday...

    83E89EC1-3AEC-49A8-BF02-72D3BCF9BA91.jpeg
    E3F43826-EE31-49D1-AB57-C50FF928946F.png
     
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    DannoXYZ, Feb 23, 2021 at 11:33 AM
    #36
  17. DamnitLaverty

    DamnitLaverty Doing things the hard way since '78! Premium Member

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    Haha you’re totally right, and I’m already lamenting the fact that I can’t TIG. Everyone says stick and brazing are the way to start- I jumped the training order and went to the tools at hand.
     
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    DamnitLaverty, Feb 23, 2021 at 1:10 PM
    #37
  18. DannoXYZ

    DannoXYZ Well-Known Member

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    BTW, what kind of MIG unit you have? Some of welds look a little cold. Perhaps you can slow down feed slightly?

    Also what kind of gas mix?
     
    DannoXYZ, Feb 23, 2021 at 5:47 PM
    #38
  19. DamnitLaverty

    DamnitLaverty Doing things the hard way since '78! Premium Member

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    My Bike:
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    Lincoln SP100T. Old box I stole from my brother. Running 75/25 on .025 wire.

    looks like I had the speed up at 6/10- what’s the give away to too much wire, weld size? image.jpg
     
    DamnitLaverty, Feb 24, 2021 at 1:17 PM
    #39
  20. ShaneP

    ShaneP Well-Known Member Premium Member

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    Too fast and it taps. Too slow and it burns the wire back to the tip with a lot of flaring. The weld stands up and doesn't penetrate the material (too cold, too low of Amps).
     
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    ShaneP, Feb 24, 2021 at 9:06 PM
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