Rusty's K100 Scrambler (lets try that again)

[natalena]

Looking fabulous. Are the rims a slight golden color .. colour .. now? The images look great.

Have a mate that when tit's go up, he quips "anyone fancy a tea?" and walks away to throttle down and formulate the new attack.

[RustyK]

Its "Green Gold" - has a bit if of a green hue to it. 

[RustyK]

This has sealed the deal. I think they look fantastic.



Now what color is the tank going to be? 

[LFC09]

are the wheels painted or powder coated Rusty?

[RustyK]

I believe its in prismatic powders.

So, full build mode. The motor is done.


I even duplicated the gasket to keep the OE (I have no idea why, seemed like a good idea at the time)

[The Mighty Gryphon]

That engine is looking kinda sweet!

[FTR]

Looks lovely!!

Im hoping my seats will arrive next week, then I can start on the frame :)

[RustyK]

The year is 2049 and I finally made some progress.

The crusty alternator.....


Looks kinda new... I really hope I didn't break it taking it apart and putting it back together. I was working fine before I f'ed with it.



I also assembled the throttle bodies and airbox. (I should not have crimped the clamps......)


Because then I started assembling....


I'm loving the look so far. Got to test fit.....


Fuel tank has not been painted yet. I'm not sure I'm sold on the seat rail being that color......

But the more pressing issue is - the airbox is in the way of the seat rail - which I was not expecting. Now I need to solve this problem.....


So mistakes made - do not paint before completely assembled and everything fits. And also dont tighten anything thats a 1 use only item. 

[RustyK]

I also got around to test fitting the forks, and triples.



But I had not drilled the holes for the handlebar mounts. So off I went to a shared workshop which had a new toy they were setting up


Its a mill, but why not? Lets get SUPER accurate with these holes :)

[Kaos]

Love it

[Thehandysam]

Looking very nice! Although I must admit it’s made me slightly scared of starting the strip down on mine haha!!

[RustyK]

Productive bank holiday weekend! 

To recap, I've got a set of 2014 GSXR 750 front forks, a custom triple set and brake rotors from Hedgehog garage and now I wanted to properly space the front wheel on the GSXR axle, which luckily is the same diameter as the BMW (25mm).

Sadly, when I put the callipers on I found out they were ±6mm out. I tested the spacing by adding some washers and it worked.....


I thought I had better sort this first, before then trying to figure out the axle spacers. Off I went to the local community workshop and found some 3mm steel sheet, which I then just had to make round. My first dive into "interrupted" cuts - which suck, but after a fair bit of time, I got it round. Interesting series of operations, and I got to learn some new things with the jaws.


We then thought we'd try the new mill, and went about waaaay overcomplicating finding the perfect centers of the holes..... which all went tits up when the plate bent under the force of the press slightly as we did not support it underneath very well.


I did the remaining holes manually with a hand drill, and then filed them perfect and I challange anyone to find a set of spacers filling this purpose that has more crafting time than these - ± 7 hours 


But job 1 done.

[RustyK]

I was very happy that these seem to do the trick, and perfectly align the rotors within the calipers.

Now I had to create the axle spacers. This was pretty tricky to measure - so I fully expected to be a bit out. But it was 160mm between the stanchion bottoms, the wheel's bearings were 84mm, which left 38mm per side. Working backwards I worked out how far I wanted the axle to sit, and I had the padded side as 23mm. It all made sense in my head.

Starting with some nice 40mm ali I faced it, turned it and then chamfered it, ensuring the outside diameter matched the newer style rubber seals (±34mm) that came with the wheel bearings


and I think they came out great.


I went home for the test fit, fully expecting some adjustment/changes were to be made, but they were perfect! 


This is without the rubber seals - I added them back in and it all fits like a glove. It will be a bit of a mission fitting the front wheel from now on with spacers on each side by thats okay.


All thats left to complete this is mount the side stand and the bike is then completely rolling/independant of being on the stand the whole time!

[Kaos]

I really do love following your build mate

[RustyK]

Toying with a few ideas to solve for the airbox and the seat rail, I hit a bit of a speedbump with the design. I really like the way the lines work with this seat rail (I dont like the hump, and I've not got the welding skills to reshape the frame yet), but its making the engine compartment complicated.



So I tried cutting the airbox....



which works, but then I had to figure out how to seal it. I tried a 3D modelling program thinking I could 3D print an insert or something



but ultimately it was taking too much of my time and I dont think it was going to work out - so I bought a custom made intake




Now I've got another problem - the Airflow meter now sticks out a lot further to the right. So I'm going to relocate that under the seat. Its going to take a bit of routing to do.

And just when the budget wasnt blown enough, I tried cleaning my injectors - and the tool I bought I didnt realise was touching the injector when trying to backflush it. So it broke the little end bits off.


Yay

Tried some AI color editing..... I think I've narrowed it down to the following 2 options:




Although somehow it became a 75 in the last photo - beats when it was turned into a boxer like this one. 

[Kaos]

The airbox could have been sealed with fiberglass, Sanded and painted.
I do believe there are some options for this airbox mod you currently have, to install it in a 90 degree angle, maybe even with the oem air-intake tubething.
Another option is to delete the airbox 

Colour wise,
I personally like the British Racing Green with the gold accents and the brown seat. If the seat were black, then the matte black tank wouldve done the job.

[RustyK]

I've put a lot more of it together rig0ht now. UK viewers will need a VPN to see the photos now - "think of the children". 





Radiator piping (getting the AS3 pipes through the engine cover was fun), radiator etc. I also installed a new SPAL fan with some custom brackets



But - last night I put engine oil in it. I expected to find a leak somewhere, but at least only when the motor ran. This morning I opened the garage to find:


 

Its leaking from the oil/water pump weep hole.


Now, I've not run the bike - so I'm struggling to think how its leaking so fast here without the motor running. Looking at photos from the engine sump and oil setup, it would need to flow through the top hole into the oil pump housing. I removed the oil pressure sensor and its bone dry in there. Could it be as simple as a leak on the bottom sump cover by the weep hole? I'm really hoping I dont have to take the water/oil pump assembly off.

[FTR]

You are some way ahead of me with your project so it's really interesting watching your progress (and now I have a VPN I can see the photos). I have binned the airbox too and found the same custom thing (but still need to paint it). It does make the air metering thingumy poke out to far so be interesting to see how you get over this. Im wondering if the orientation (on its side) of the air metering thing will affect its operation.

Also interesting to see that you have cut off the frame web which originally contained the seat lock, I was trying to find out what sale was attached to it but of all the photos I took before taking the bike apart, none covered that. If you have binned it I guess it can't have been anything important.

[RustyK]

You are some way ahead of me with your project so it's really interesting watching your progress (and now I have a VPN I can see the photos). I have binned the airbox too and found the same custom thing (but still need to paint it). It does make the air metering thingumy poke out to far so be interesting to see how you get over this. Im wondering if the orientation (on its side) of the air metering thing will affect its operation.

Also interesting to see that you have cut off the frame web which originally contained the seat lock, I was trying to find out what sale was attached to it but of all the photos I took before taking the bike apart, none covered that. If you have binned it I guess it can't have been anything important.

Not sure what frame web you’re referring to, but yeah everything the seat lock attached is not required.

I may actually go back to the stock air box and plenum. It’s proving a lot to do to work around that seat rail. If I can somehow shorten it it would be ideal. I want reliability as I will ride this a lot, and I, thinking the OE setup isn’t bad

[Kaos]

Have you used liquid gasket on assembly?
And just to be sure, does the colour of the fluid match any of the juices you've put into it?
Therse also a drainage bolt on the bottom that requires a spacer/gasket ring thingemy.

[RustyK]

I've pulled it apart, and it's definitely the seal. There was even some oil in the water side of the housing. I think I spectacularly messed up the seal install.

[Kaos]

Upside is, you found out (hopefully) before having your engine running. Finding out after would mean your oil would look like a salad dressing.
Cleaning that out is not the best afternoon spender out there