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Project Summer project.

Discussion in 'Other Projects - Other Bikes (non 250's)' started by Murdo, Dec 30, 2016.

  1. Murdo

    Murdo The Good Doctor Staff Member Premium Member Ride and Events Crew Contributing Member

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    My Bike:
    Maico 250, Royal Enfield 250, CF 250 V5 and 650TK, XL250, CBR250, ZZR250 plus a few others.
    After a recent visit to the National Motorcycle Museum at Nabiac, NSW, I came home with the idea of building a replica of Brian Collins record setting bike that he built in 1973 and set three Australian Land Speed records with at Lake Lefroy in WA.
    Trip to museum 16 016.JPG Trip to museum 16 015.JPG
    Now I just happen to have a spare Yamaha YB100 engine and bits left over from my 1974 YB100 restore,
    Camera stuffup 183.JPG
    and the more I thought about it I thought 'why not make a copy'. I will never take it to the salt lakes, but will probably give it a run on some quiet country roads.
    I knew the engine had been through a flood, but when I got it about two years ago I drained the engine and filled with Diesel. It was, I since found, too late and the damage had been done. I brought it home and put on the bench.
    The mice had had a lovely time in the aircleaner.
    YB100 speed racer 004.JPG
    I lifted the engine out and off with the head.
    YB100 speed racer 002.JPG
    YB100 speed racer 001.JPG
    Tried the hot oil, but no good. Too far gone for anything but a big hammer.
    Took the side cases off and it didn't look much better.
    YB100 speed racer 005.JPG
    YB100 speed racer 006.JPG
     
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  2. Murdo

    Murdo The Good Doctor Staff Member Premium Member Ride and Events Crew Contributing Member

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    My Bike:
    Maico 250, Royal Enfield 250, CF 250 V5 and 650TK, XL250, CBR250, ZZR250 plus a few others.
    Had to remove the through bolts that hold the head on and split the cases from the crank.
    YB100 speed racer 010.JPG
    Was pretty tight, but eventually it let go with a bang.
    YB100 speed racer 011.JPG
    What I found inside did not make me smile.
    YB100 speed racer 012.JPG
    YB100 speed racer 013.JPG
    The crank and rod were frozen together, so I cut the rod with angle grinder to get the barrel/stuck piston off.
    YB100 speed racer 014.JPG
    I sat the barrel on a big wooden block and used a punch to knock the side out of the piston. This allowed it to contract enough to get the rest out.
    YB100 speed racer 015.JPG
    The hardest part to free up was the selector drum, and I ended up breaking the end off it before I got the selectors off.
    YB100 speed racer 018.JPG
    Have now bought new crank (complete with rod) NOS, 1mm oversize piston and had the barrel rebored to suit (just cleaned up the rust pits), NOS selector drum and other small bits and pieces.
     
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  3. risky

    risky risky

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    ever thought of adding a supercharger to it?
     
  4. Murdo

    Murdo The Good Doctor Staff Member Premium Member Ride and Events Crew Contributing Member

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    My Bike:
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    New bearings and seals fitted to cases (can you believe that Swedish SKF bearings are now made in China).
    speed racer 010.JPG
    And look how much grease was NOT in them.
    speed racer 013.JPG
    Didn't worry me as they were going into the gearbox where they would swim in oil, but could be a problem in a wheel bearing.
    Needed to make a new steering stem. Bought some 50mm bar and tapered roller bearings and made the 'caps' to hold the cones for the bearings.
    speed racer 015.JPG
    These I welded each end of a piece of 40nb pipe, and turned to final dimentions in the lathe. Fitted the YB stem with the new bearings and assembled.
    speed racer 016.JPG
     
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  5. risky

    risky risky

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    active little devil- the heat must agree with you.lol.
     
  6. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    Nice work!
    That YB barrel look's very similar to the Chappy LB80 barrel, same style screw on pipe flange
     
  7. Murdo

    Murdo The Good Doctor Staff Member Premium Member Ride and Events Crew Contributing Member

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    The spare YB didn't have any forks, but I had some from a Yamaha 100 trail bike. These are 1mm larger in diameter than the YB forks, so to make them fit I made a boring bit with a ground down lathe tool and fitted in the drill press.
    speed racer 001.JPG
    By clamping the yoke to the drill table and going slowly I was able to skim the 1mm needed out.
    speed racer 002.JPG
    speed racer 003.JPG
    I clamped a couple of washers in with the bolt to hold it slightly wider so they will clamp nice and tight to the new forks. All cleaned up and looking good.
    speed racer 004.JPG
    Fitted to headstem.
    speed racer 005.JPG
     
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  8. Murdo

    Murdo The Good Doctor Staff Member Premium Member Ride and Events Crew Contributing Member

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    My Bike:
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    The rear sprocket had done its turn.
    speed racer 3 001.JPG
    New one fitted to wheel.
    speed racer 3 002.JPG
    The rear axel had to be mounted to the frame with two 6mm plates. I cut some cardboard templates and transfered them to steel. Cut out with plasma and trimmed up. speed racer 3 003.JPG speed racer 3 004.JPG
    I moved my heavy steel jig (I used to build racing cars on this) into the shade and leveled up. I welded four bits of 25x25 to hold the wheels verticle and at the right distance apart. Using another 25x25 to support the headstem at the right angle (29 degrees, this gives 95mm of trail). Note the fancy string line.
    speed racer 3 005.JPG
    Then, after a trip to the steelyard I cut the main tubes from 20mmx2mm and the smaller from 16mmx1.6mm and tacked them into place at headstem and rear axel.
     
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  9. Murdo

    Murdo The Good Doctor Staff Member Premium Member Ride and Events Crew Contributing Member

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    I turned some bar stock on the lathe to make engine mounts, bolted to engine cases and tacked them together.
    speed racer 3 007.JPG .
    Lots of little bits to be made and welded on yet.
    I cut the rusted bottom off the fuel tank.
    speed racer 3 011.JPG
    And made a new bottom for it. I used .8mm mild steel which I hand formed the edge with hammer and dolly. The swage in the middle I did on a machine I built many years age to make bits to weld into the floor of my mothers Gemini car.
    speed racer 3 012.JPG

    Also made a fill in piece for the front and welded together.
    speed racer 3 013.JPG
     

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  10. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    Another fine piece of work in the making. That SKF bearing is atrocious should send that pic to SKF.
     
  11. Murdo

    Murdo The Good Doctor Staff Member Premium Member Ride and Events Crew Contributing Member

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    My Bike:
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    While waiting for the ordered NOS parts to arrive, I've been blasting and cleaning up engine bits. The carb wasn't pretty on the outside, but inside was even worse and when I bead blasted the bowl it turned to dust.
    speed racer 3 015.JPG
    speed racer 3 017.JPG
    Found a new Chinese made carb on evilbay for $27.00 posted so will go no further with the old one. Even the gear shaft didn't escape the worms.
    speed racer 3 014.JPG
    That has been the last months work, but getting too hot for much more until next year.
     
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  12. Murdo

    Murdo The Good Doctor Staff Member Premium Member Ride and Events Crew Contributing Member

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    A few new bits have arrived and I have most of the engine together. When fitting the new rings to the piston I discovered that they are two thin rings stuck together. Never seen that before, but they fit so in they went.
    speed racer 4 001.JPG
    Painted the cases after blasting them and fitted.
    speed racer 4 002.JPG speed racer 4 003.JPG
    Waiting on NOS magneto and carb to finish engine.
     
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  13. Frankster

    Frankster See the World before you leave it Staff Member Premium Member Ride and Events Crew

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    I'm going back to the salt in 2018. I can't get near the 250cc record, but it will be fun having a go. If your project is as much GO as SHOW then it might warrant giving it a run. I might check the DLRA records for that type of bike to see what you'd be chasing. I don't recall the Museum having those details with the bike. Did you see, or know what the records are @Murdo ?
     
  14. Frankster

    Frankster See the World before you leave it Staff Member Premium Member Ride and Events Crew

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    Can't wait to see the finished piece. Always in awe of Murdo's skills, knowledge and creativity.
     
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  15. Murdo

    Murdo The Good Doctor Staff Member Premium Member Ride and Events Crew Contributing Member

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    Brian Collins did a bit over 100Km/h back in 1973, but last I looked the record now stands at just over 160Km/h, way out of my capabilities.
     
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  16. kiffsta

    kiffsta Administrator Staff Member Dirty Wheel Club Contributing Member

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    Put linkin on it , he is light enough
     
  17. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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  18. Murdo

    Murdo The Good Doctor Staff Member Premium Member Ride and Events Crew Contributing Member

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    Thanks, but that is a later model and most bits are different.
    As listed above I have replaced with NOS; crank, piston, selector shaft, selector shaft cover, rotary valve and magneto.
    Replaced with pattern parts; carb, all bearings, seals, kick starter, aircleaner, coil, fork seals, fuel tap, circlips, etc. So parts are not hard to get, even things like guards, seats, tanks, etc.
     
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  19. ruckusman

    ruckusman Well-Known Member Premium Member Dirty Wheel Club

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    @Murdo - are you all over this technique already?

     
  20. Murdo

    Murdo The Good Doctor Staff Member Premium Member Ride and Events Crew Contributing Member

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    Haven't tried it yet, but have the basics.
    Planning to do a pipe with this method.
     

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