Author Topic: xs1100 Trike  (Read 4938 times)

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Dennis

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Re: xs1100 Trike
« Reply #45 on: October 09, 2018, 11:44:32 AM »
Picking up where I left off in April.  The project was put on hold for the summer months.  No weekends at home, lots of sunshine, and what time I did spend in the shop was routine maintenance.  A rainy long weekend is a sign that fab time is approaching.

I left off with having many parts finished and getting ready for the final frame build.  My plan is to use a straight line on the floor, and center everything to the line. 

I borrowed (in the spring ...) a laser from Paul.  Worked great.





Peace & Grease, Dennis

Dennis

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Re: xs1100 Trike
« Reply #46 on: November 26, 2018, 09:31:07 AM »
I needed to assemble the front forks for the mock up, and to see if all of the parts I've purchased on Ebay will actually go together.

I am pleased with the parts.  Everything went together fine.

I've decided to not use the registered Yamaha neck tube.  I purchased an aftermarket neck tube from a chopper supplier, which is designed for Harleys.  I purchased Harley bearings and races.  I will deal with the registration issue later.





I did a rough mock up to get the steering neck jig close to where it will be when I start fabricating.  I need to stare at it for a few more hours to decide if I am ready to make the commitment.

Peace & Grease, Dennis

Dennis

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Re: xs1100 Trike
« Reply #47 on: December 03, 2018, 09:40:30 AM »
Back to mock ups.  Always fun to kick start some garage time.



Measure twice, cut/weld once. 

As discussed previously, trail is important in how the trike will handle.  I think this will be perfect.



Screwed up assembling the universal joint.  I used too much pressure when it was obvious something was not right (some of the roller bearings in one cup had dropped out of place and blocked the bearing cup from sliding on).

The first sign something was wrong.



Confirmed.  Bent.



I could have heated this up and bent it back myself, but I figure I am going to want it line bored afterwards, so I will see if Jeff is working in this winter.

Peace & Grease, Dennis


Dennis

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Re: xs1100 Trike
« Reply #48 on: December 13, 2018, 10:30:20 AM »
Jeff opined that if the yoke were bent back carefully, it probably would not have to be line bored.  Plus he reminded me that I have a spare; the original Suzuki Samurai donor drive shaft had identical ends.  It would be easier to just machine the spare to fit the Yamaha. 

Bent yokes are very common with the 4x4 community.  A quick google and I found this idea.  With a few minutes of the torch (never got red hot though), it seems to have worked, but I have not yet tried to see if the new universal joint will go together.





Peace & Grease, Dennis

Dennis

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Re: xs1100 Trike
« Reply #49 on: December 17, 2018, 12:33:44 PM »
Got the drive shaft together ... at least enough for a measuring the final distance between the frame and the differential.  I actually have a problem with the GM universal joint; I can't get the bearing cups in far enough to expose the circlip grooves.  After screwing up the Suzuki end, I want to think it through before using a big F'ing hammer or a press.

Tapped out the yoke on the GM side.  I have new mounting hardware.



Drive shaft in place.  No clearance issues.



Set up my tubing bender for the 1.5" back bone tube.  I learned that 1.5" tubing is a big as I can bend manually.  It took all I had physically to bend the tube.  Fortunately, there is only on 1.5" and the rest are 1.25" which I have bent before.



Peace & Grease, Dennis

Dennis

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Re: xs1100 Trike
« Reply #50 on: January 09, 2019, 10:50:11 AM »
I did some work before Christmas. 

The back bone tube (1.5" tubing) went in easy.  Learned that 1.5" (1/8th" wall thickness) is just about the most I can bend manually.  It took all my strength to bend it.  I then went onto the front down tubes connection to the neck tube.



Up close you can see the gaps in my notches.  I did the bends first and tried to free hand/eye the notches. 



I am not satisfied with the notches, so I set up my notching jig and cut the notches first.  If I have time this weekend, I am going try to bend the pieces I have notched to see if they will fit better.



Peace & Grease, Dennis

Dennis

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Re: xs1100 Trike
« Reply #51 on: January 21, 2019, 10:28:20 AM »
Better.



Bent, bevelled and welded the lower rear tubes.   Made a wooden jig for part of the upper rear tubes.





Peace & Grease, Dennis

Dennis

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Re: xs1100 Trike
« Reply #52 on: January 31, 2019, 10:09:06 AM »
I finished and tacked in this rear cross piece.



I made a jig for the upper two rear tubes connecting it to the back bone.  It's basically just a flat plane to set the tubes on.



The two rear tubes need to be symmetrical, so I made this jig to carve them



Mock ups are necessary to make sure I'm heading in the right direction.  This mock up confirmed I am NOT going for the 70's style King 'n Queen chopper seat ...  well at least not right now.  It wouldn't be the first time I've changed my mind during construction of a bike.



Peace & Grease, Dennis

Dennis

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Re: xs1100 Trike
« Reply #53 on: February 04, 2019, 10:45:32 AM »
Rear tubes tack welded in and jig removed.





Used some wood in conjunction with my steel jig to line up the two front down tubes. 





The jig was sacrificial.  After disassembling what I could, the rest had to be cut out.  Looking good though.



Removed the engine and differential so I could weld everything up.



I prefer to weld on flat surfaces, so I rotated the frame as I welded.



Peace & Grease, Dennis

Dennis

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Re: xs1100 Trike
« Reply #54 on: February 27, 2019, 10:30:17 AM »
I've had a few developments since my last post.  Most positive ... one, not so much.  Here's the play by play.

I reinforced the neck with these tubes.



The mounts on the differential had only been tacked in, so I disassembled the whole thing and finished the welds.







While the axles were out, I reinforced the lug bolts.  Two of the small welds I had done before had let go.  I ground into the axle casting to improve my odds of full penetration welding.



I was pretty stoked that I was ready to stick the engine back in and actually have a roller when disaster struck.  I had hoisted my engine onto the rolling table I regularly use in my shop (see the pic of the differential above).  I was trying to put the engine on its side when suddenly it rolled, fell off the table and hit the concrete floor hard.  A rear mounting casting is smashed right off.



... and given the multiple bits, probably not repairable.



I've already ordered a replacement bottom engine case from Ebay. 

Things happen for a reason (my mental game of trying to create a silk purse from a sow's ear).  My engine had obvious signs of an oil leak.  However, because of its low kms, was just going to try to fix the leak, and give it the "rattle can rebuild."  Now the engine is destined for a strip down and rebuild.  No tears.

Peace & Pounding the Pavement, Dennis
« Last Edit: February 27, 2019, 10:33:08 AM by Dennis »

Hans

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Re: xs1100 Trike
« Reply #55 on: February 27, 2019, 07:52:22 PM »
Ouch.... Aren't the top half of the case and the bottom half line bored to each other? 
I live with fear and danger everyday, but sometimes I leave her at home and go motorcycling.

Dennis

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Re: xs1100 Trike
« Reply #56 on: February 28, 2019, 09:40:57 AM »
Ouch.... Aren't the top half of the case and the bottom half line bored to each other?

I don't know.  I hope not.  Now I'm worried because I had the opportunity to buy complete cases when searching on Ebay.

I've already spoken with Paul about his xs1100 engine.  He's willing to sell it to me if I wait until the snow is gone and he is back in town.  It's buried deep. 

Dennis

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Re: xs1100 Trike
« Reply #57 on: February 28, 2019, 05:33:32 PM »
Ouch.... Aren't the top half of the case and the bottom half line bored to each other?

I visited Russell today for the first time in awhile.  He opines it could be repaired.  As long as the holes end up where they should.

Hans

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Re: xs1100 Trike
« Reply #58 on: February 28, 2019, 06:30:36 PM »
If it's like my FJ1200, the bottom case carries the bottom bearing shells, there are no main bearing caps.
I live with fear and danger everyday, but sometimes I leave her at home and go motorcycling.

Dennis

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Re: xs1100 Trike
« Reply #59 on: March 11, 2019, 08:45:39 AM »
I'm not going to let the busted engine mount impede my momentum.  There is a ton of fabrication still to do, and the trike needs to be a roller to do it.  Decided to pick up where I left off, but this time lower the engine into the frame.



Peace & Grease, Dennis