Rear Bumpstops

So the next item on my to do list was the rear bump stops. Since the shock were old and don't have built in ones the Certifer wanted bump stops. After looking around I got some off Trademe.

Next I had to decide on what I was going to make the mounts from. The trusty 25x50 box section was selected. I cut some cardboard out to make the templates required before cutting the steel.

So after making a template / guide on the axle to mark the amount of travel I wanted before the stop was hit, I then started playing around with mount locations and angles

 

I think this will be perfect ......

Transfer of the template to the box section, ready for lost of hacksaw work....

Hack sawing away.... I found this to be the fastest and easiest way for mounts like this, then hand filing.

 

Mount one cut out

 

Ok test fit .... Shit.... due to the location of the newly fabbed Pan hard bar there wasn't enough space to fit the mount..... even after I checked it with the cardboard template. Well it fitted the gap OK but I did allow for the 25mm thickness so I would not be able to blot the pan-hard bar in..... 

 

So after fiddling and thinking... and a little swearing the decision was to mount at an angle off the corner of the Z frame. This also allowed easier access to do the vertical welds required. I hate welding vertically.

 

 First welding job was the bottom plate to mount the stops to.

Test fit, Looking good.

Both bottom plates all welded on.

 

Mounts with the top wedges cut to allow mounting to the chassis.

Tacked onto the frame to check alignment and position before full welds.

 

 

Both mounts fully welded in, Pretty darn happy with how it looks. 

 Next steps will be getting the last items on my Certifer checklist done. This requires getting some engineering work done that I cant do,  But shouldn't take to long.

The best .....

Catalunya 2009 Motogp 'Rossi teaches Lorenzo a lesson!' from Tim Fowden on Vimeo.

Drifting... bikes

Black Smoke Racing

Panhard bar mount extension

Well finally back into the garage to start the little jobs that the Certifier noted that needed correcting. First up was the pan hard bar. It was on to much of an angle and was pushing the rear diff assembly to the left when under compression.

So I had to either extend the mount on the diff or the one welded to the frame. I though and played with just extending the one mounted to the diff, but was worried about the strength and that the extra leverage would place on the mounting bolts. There was also that once it was raised it didn't leave a lot of room for the fuel pump and plumbing that are sitting below the fuel tank.

So I went the route of extending the frame mount. I was a much bigger job doing this way, but the best solution. Best of all I could do it without spending any money.

First job was to turn the RattyT around so that it was face the other way so I could get access to the rear end.

As you can see from this shot the angle the pan hard bar was on before I started.

I noce fine even to get out there and start cutting :)

Panhard bar removed to allow the cutting off of the mount. I left plenty of meat on the frame so I have a lot to weld to.

Mount cut off and then trimmed to fit the tune I was going to use to extend the mount with.

Mount be gone

Next can the fab work on the new mount. First I cut a tab out of a 50x20x3mm box tune to slot the trimmed mount into. This gave a lot of extra contact and welds. Above you can see it tacked on.

Next was to cut the top part of the mount to be the right height and fit around the exist mount still on the frame. All the cutting was done with a hacksaw and hand file ......

Test fit for height and fit to the frame. More filing required.

After a lot of test fits, cutting and filling I finally got good fit. Next was to re-add the side tab. This so that the was addition laterial reinforcement for the mount. 

All welded up tidied up.

The next evening I removed the fuel tank to make for easier access to the welding that I was going to need to do. It was going to be a pig of a job. All weld were either vertical or upside-down.

Existing mount cleaned up ready for welding

New extended mount clamped ready for some tack welds.

After numerous welds and grinding the mount is now welded on tp the frame. It is not pretty but sure is strong.

Next job is to get so bump-stops and make some brackets for them and weld to the frame.  That will require some $$ so might have to wait a couple of weeks. That then completes the backend to cert level.

Japan Hotrod

The Derelicts

The Derelicts a short film by eGarage from eGarage on Vimeo.

Motomethod

The Motomethod Story from Zenga Bros on Vimeo.

OffRoading

Progress

Yes ... 2012 is off to a good start. I will have the Ratty-T finished this year. First step toward that was to get the LVVT inspector to come and check out the work completed to date. So that happened today. So heres the list of what needs correcting.

• Pedal box (Brake pedal needs re-engineering) 
• Brake push rod (Need to be one machined rod) 
• Rear suspension needs bump stops 
• Rear panhard bar needs to be more parallel to diff. 
• Master brake / booster adapter plate 
• Front dragbar longer no adapter

So the list is quite long and requires a fair amount of work. But I am pleased that none of that is anything that I have altered changed. All the work I have done passed with flying colours.

So once again Im correcting the bad work carried out previously.

Pretty darn excited to be back at it.

MotoDrifting 2

Hero : amazing artwork

Hero from Miguel Endara on Vimeo.