A new project arrives.... Volvo a-go-go

I finally have a new project. A proper project. A long term project. A very long term project. It's a 1973 Volvo P1800ES.

Stay tuned!

Much Much Build

The build diary in pictures:

The once neglected 1979 CB250T

Evaluation of stance: After striping the bike down I experimented with dropping the rear of the bike which gave a natural rotation to the motor and rake to the forks - but not enough! I then cut into the frame to further rake the forks and better centre the mass of the motor between the wheels.

Tank Modifications: the original flip-up tank cover was missing, I detail which I didn't much like anyway. The bayonet opening was cut out and moved to the new infill panel.

Details of some of the fabrication and modification:

Detail of some of the smaller components made: while the gear change and rear brake linkages look simple they took a long time to make, the brake in particular had to be set so that it didn't crash into the swingarm. The turnbuckle on the bottom right is the brace for the carburettors.

All in a days work - actually 55 days work.

Much Much Go...

Much Much Win!

I'm so excited to announce that I won both first prize and people's choice award at the inaugural Deus Boundless Enthusiasm Bike Buildoff yesterday.

More images to follow soon, I've only just driven back from Sydney....

Much much thanks to Shayne, Craig, Rob, Tim, Sam, MMSr, Simon, Pete and especially Esme for all your help, advice and patience.

And, much much thanks to Deus and Snap-on and all my friends who were there on the day!

(images by Deus)

or check out the coverage of the day as posted on Pipeburn

A false calm...

It's the end of week one and just 47 days remain until the deadline for the Deus Build Off. A plan has been laid out and the first week's progress has been good, though I still don't know if my bike runs... lucky I haven't entered yet...

The race is on....

With 54 days remaining until the deadline for the Deus Bike Build Off I've decided it's as good a time as any to start!

Model: Shayne.

Shayne is sporting this years latest fashion - the donated bike - much thanks!

Slowly moving forwards to look backwards... a bit...

This week I've changed the mirrors on the SR. While these are much smaller than the ones I put on originally, they stick out further and I now get more than a view of the back of my hands. It will take some of the aspect of Russian Roulette out of lane changes.

Decisions, decisions, decisions....

I've mocked up the bike and wheeled it out into the sun to take a look at the side cover in position, but more importantly to look at the orange dynoc on the tank.... I like it! But it also looks good without a stripe... does anybody want to comment?

It's only going to get shinier!

Seven months and two TAFE courses later, I've finally started to make aluminum versions of the factory plastic side covers.

The first night class that I enroled in was on welding steel (oxy, arc and MIG), and the second was on panel fabrication (panel beating). I got to use an english wheel and a vast array of hammers and dollies - then I taught myself to arc weld aluminium.... a proud moment indeed!

Since this image was taken, one of the covers has been polished - I'll post a picture as soon as I remember to take a camera to the workshop.

Major Stage Completed.... back on the road!

This picture was taken a week ago when I was about to take the bike out for a test ride. I consider this to be the first major phase complete, and probably how I'll ride the bike for the next couple of months. The next thing I want to do is make my own set of body side covers to replace the red ones and to be more in keeping with the rest of the bike.

Some time down the track I'll remove the side covers completely but this won't happen until I'm ready to remove the airbox and fit a new exhaust... and I'm yet to find some yellow/orange vinyl to do the final stripe on the tank.

Is home made better than store bought?

Over the last couple of weekends I've been whittling away at a piece of 4mm aluminium to make my own bracket which holds the small diameter after-market gauges in place. This positions the gauge faces flush with the yoke and at least 50mm lower than a standard bracket. I'm also integrating the warning lights onto the wings on the side of each dial.

Making your own stuff is incredibly satisfying even if this is just a small start!

Back on the Build... it doesn't get any better than this!

Well, I'm finally set-up, settled in, and back on the build!

The Honda is in for a service and minor upgrade. The world wide web of eBay has been kind and plentiful so I've bought new cables, clutch plates, short winker storks and a front fender.

The Yamaha is entering its next phase of transformation. The bike now has it's rear-set foot pegs and the pillion pegs have been removed. The next job will be replacing the original dials with two smaller Daytona units.


With all the cool stuff that's happening in the workshop I'm not short of inspiration... I'm thinking seriously about making some aluminium side covers.

One step forwards, two steps back... the bike becomes a 'mule'

With the likelihood of a move to Melbourne I didn't want to transport a disassembled motorbike. But with no hope of finishing in time, I thought it wise to reset the bike and get it running again. So its back on with the original tank, seat, gauges and headlight but also on with new decompression cable and a Daytona decompression kit from Vanem.

I don't mind putting lots of the original parts back onto the bike because I'll be able to test the adjustment of the cables and routing of the wiring in a much more straight forward manner. The original headlight is great for hiding all the wiring - I'm starting to think I should keep it!

The Second Major Stage

Hopefully with the original, rather than final parts in place, the bike will be less delicate to transport... I'd hate for something to happen to that shinny aluminium fuel tank.

Amazingly the motor turned over on the second kick - the tank had been off for 3 months! It was good to go for a ride and to test the new reduced turning circle (caused by the steering limiter which stops the clip-on bars hitting the tank). It was also interesting to experience the first stage of the new riding posture... reaching down onto the handlebars certainly does add strain on both the wrists and the neck. But these will be sacrifices worth making!

When I pulled up at the first set of lights another motorbike came up along side - the rider immediately started asking questions and complimenting me on my bike - and this without the cool tank and seat! It wasn't until I pulled away that I noticed that I'd forgotten to put on the rear view mirrors.

Well, the 'to do' list:

• install the shorter throttle cables and a new black hand grip on the throttle
  
• install the shorter clutch cable
• mount the smaller stainless front mud guard
• bolt on the now silver stone guard
• Cap-off the top yoke with a aluminium handlebar post cap
• reintroduce the indicator light kit - this is going to fit more neatly if I get a stainless steel bracket cut
• replace the gauges with smaller diameter Dayton units (both a speedometer and tachometer, probably mounted to the same bracket as the indicator lamps)
• install the engine breather filter
• remove the airbox and install the K&N air filter
• move the battery, fuses, etc. and introduce the required battery plate
• mount the carburetor support bracket
• remove the engine vapor return hose
• mount the horn (this will probably need a custom bracket)
• introduce the rearsets (removing the existing rider and pillion foot pegs)
  
• install the ducktail seat
• swap the petrol tanks (including swapping over the fuel tap)
• mount the new stainless steel exhaust and re-jet the carburetor
• resolve the graphic treatment on the tank... and the many other things that I haven't even identified yet!
  

First Major 'Stop Work Meeting'

I'm back on the build! And this time I mean business!... well, I thought I was back on the build. I've encountered my first set of problems which are either based on a slight incompatibility of the parts I purchased or I need more parts!

After slowly jacking up the bike, and in turn loosening and lowering the forks, I managed to slide in place the new headlight brackets and clip-on bars (top left and right images respectively). This is when I discovered the first of three problems (bottom left image). Firstly, the vintage headlight overlaps the main switch assembly (ignition) so that if I want to use this light I have to move the switch and probably replace the top yoke, which is my second problem. My third problem (bottom right image) is that the decompression lever hits the broad tank... I think I need a new clutch lever with the decompression lever on top. In this final image I have reverted to using the original headlight which is shallower but of a much larger diameter.

While in my possession the bike has only done about a weeks worth of riding, and the motor hasn't been turned over for 2 months now so I'm getting eager to ride the bike again. I'm also keen to check that I haven't inadvertently done something to the engine immobiliser so that the bike no longer starts. I know that the longer I wait to start the bike the harder it will be to diagnose starting problems as the number of variables climb.

Minor Works Report

I don't have a lot to show for my tinkering over the last few weeks - I keep telling myself that I can make time for the build 'next week'... next week is yet to come!


(Top left) This once black stone guard is now shinny and silver. I don't want to be accused of not doing things properly (if not actually over doing things)... this part bolts into place underneath the bike and is unlikely to be seen but is likely to get damaged, but I painted it anyway.
(Top right) The new 'vintage' headlight and brackets are ready to go onto the bike... once the forks are dropped out!
(Bottom left) Most of what has to come off the front of the bike has been removed and some of the new electronics have been fitted.
(Bottom right) The tacho cable has been removed and the hole in the top of the engine has been plugged... I'm not running a tachometer on the finished bike though I am toying with the idea of mounting a little dial on the side of the headlight... but that's something to think about later.

... not having time for the build is OK 'cause I'm getting some other cool things done...

The build - snapshots

These are some shapshots taken over the last few weeks - they give context to the build:

(Top left) the new winker and the big factory fitted unit. All new parts are machined aluminium, polished stainless or chrome.
(Top right) the wiring harness and connectors within the headlight - the new headlight doesn't have room for much of this... its my first big hurdle!
(Bottom left) the reorganised garage dedicated to all things two wheeled.
(Bottom right) boxes and boxes of parts.

The build commences...

It's serious business...



The starting point: stock 2005 model Yamaha SR400



The first major stage:

• Short stainless mudgaurd at rear (Daytona)
  
• Small indicators and tail light (Posh and Daytona)
  
• Aluminium fuel tank (Daytona)
  
• Ducktail seat (Nitroheads)
  

and the headlight has been removed...