Junior
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Post by dryshave on Apr 19, 2012 19:25:09 GMT -6
SPLIT CASTS. Much easier to clean up thx to the prep work. Remember these are negative casts not the final casts !!!! You can see from the last pics... how much room I have to work around the radiator. I am adding "bolt on tabs" after the first coat of fiberglass on the positive mold. I've already got eight bolt on points identified. Will figure out the radiator access after the positive cast is complete, as I'll be able to see what I'm working with by then. The next steps are: Additional fiberglass changes to the front tire splash area on the cowl (will have more pics soon) NOTE: I drilled holes through the two casts and am using zap straps to bind them together. Great for positioning as I will be glassing the bulk of each section apart. I will then zap the left and right panels together and glass the joints and 2nd coat the entire piece as one... sounds confusing, but hopefully the pics will illustrate. Just itching to get into the mechanical layout of the bike, but that's something I can do when the weather gets better. (Picked up an 85 elite 150 with just 11,000 km on for $250 - seat is perfect, and the panels are mint! Pulled the carbs and tank. Soaked both in parts cleaner for 6 hours and re-assembled. Fresh gas and it started right up! I plan to ride this one until I get the project finished)
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Junior
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Post by dryshave on Apr 18, 2012 17:28:19 GMT -6
Pulled the casts today and very happy with the ease of release.... this time, minimal clean up required. Will be ready to start the positive casts by the weekend. It sure felt good to finally get that off the bench and the frame. I shot most of it on video, but have a few pics to upload tomorrow. Now the real fun begins.....
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Junior
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Post by dryshave on Apr 15, 2012 10:56:40 GMT -6
Thanks for all your terrific words of support. The colour scheme will be a candy dark red/brown with cast brass (and paint) details - minimal chrome. Many of the detail pieces you don't see (dash gauges panel - signal light casing - detail strip running beside seat, as seen in earlier pics) in the final casting, are to be cast in brass, including the custom fuel tank (also modified since earlier pics - more on that later). I'd like to paint the engine casings in a high heat brass color as well, but haven't done much research. Madcollie - you can see a better detail the tail section on the first page. The tail end is more like the business end of a jet. I have an old domed style police light that fits into the middle, which I plan to wire up with LEDs for a brake light you can't miss. Justbuggin2 - You are seeing a couple pieces of the master mold (images of the tail section). I would have finished the front casting yesterday, but ran out of resin - have to wait until tomorrow I've been toying with the grillwork and will post a few sample ideas I've got going (photoshopped) I'm taking the 250 engine in for an MRI Actually I'm just having the cylinder honed and having the honda tech, check the tolerance between the crankshaft and piston rod (I think this one's a little slappy). The goal once the casts are complete are to layout the wiring harness. then finish up the frame welds and strip the frame for powdercoating. ..... still have to figure out how to build rad access through the front panel. Close to 300 hours of modelling and casting so far. I've been logging everything on video and keeping track of material costs as well. I'll post more images when I'm ready to start the positive casts. There will be plenty of bodywork to be completed on the final casts, but my goal was to get it perfectly matched on each side. Countless hours of measurements and custom templates made. Cheersh. If your not having fun, stay out of the garage
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Junior
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Post by dryshave on Apr 11, 2012 16:04:10 GMT -6
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Junior
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Post by dryshave on Mar 27, 2012 17:25:29 GMT -6
Forgot to mention the exhaust and airbox are also available. Both are in pretty good shape
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Junior
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Post by dryshave on Mar 27, 2012 16:02:37 GMT -6
I've recently stripped down an elite 250 engine with 89,000 kms on it. I could tell that the engine had been opened up in the past, but the cylinder hasn't been bored out, nor does it need it. The piston was in decent shape, though it looks like someone installed a fresh set of rings not long ago. The manual says the acceptable gap between the piston rod and the surrounding crank "thingy" is .002 in. I've measured mine at .006 on each side. There is no vertical play, but it does seem a little sloppy to me. Should I be looking for another crankshaft?
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Junior
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Post by dryshave on Mar 27, 2012 15:55:21 GMT -6
Pulled the castings off yesterday... Lesson to be learned about how much release to use. There is never such a thing as too much. One side I used 4 coats, the other side I used 6. The side I used 6 on came off a little cleaner, but the other side requires a lot more clean up. The beauty of using plasticine is that I can just smooth the residue back in to fill the scratches and gaps left from a few air pockets I missed. Pretty happy about the results so far. I also turned my brother loose on the 250 tear down, while I worked on removing the mold. Lots done so far. I will post pics of the split casings over the next couple of days along with photos of the progress to date. I plan to start casting the front over the next weekend, still some tweeking to do.
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Junior
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Post by dryshave on Mar 27, 2012 15:48:32 GMT -6
Have completely stripped down an '85 elite 250 for the electronics and engine. I am also keeping the rims and throttle and brake cables.
Everything else is available (sorry - sold the mats already). Dash is good and most of the plastic is in reasonable condition (color red). I live in Vancouver, Canada and am willing to ship via post office or greyhound to pretty much anywhere for shipping costs. If you need something let me know, forks are good and straight as is the frame. Gas tank is clean with no rust, the seat has a couple of tears, but I will send pictures if you need them. Not looking to make money on this, just pass on the parts to those who need them at a fair price.
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Junior
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Post by dryshave on Mar 23, 2012 19:35:27 GMT -6
Rear panel has been fiberglassed... finally! Ready to remove it from the frame and then it's on to finishing the front. Still doing some tinkering, but the front cowl from the CH250 I just picked up gave me an idea to finish the area around the front wheel, will be working on that later. In between the hardening cycles, I've got to haul the 250 engine out for the once/twice over. No spark, so I'll test all the usual suspects tonite. More pictures soon... I'm rethinking the gas tank position now that I've seen the battery and tank position on the 250... would be pretty easy to switch over... more on that when I finally get the tank off.
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Junior
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Post by dryshave on Mar 20, 2012 15:09:37 GMT -6
YAHOO! A couple of good scores this weekend. First I was able to source out a great fiberglass material supplier and able to purchase 4 gal of resin w/hardener, 2 gal of PVA and a roll of matt that is enough to complete both male and female castings for $120.00, about a 5th of the cost of retail around here. But the really cool deal on the weekend, was picking up an 85 elite 250 with regi for $350!! Have papers in hand and over the next month I will be tearing it down to the bones. I will post a list of the elite 250 pieces that I will have available.
WORK UPDATE: I've completed the second fiberglass casting on 1/2 of the rear panel. I will post pictures shortly. I expect to have the female castings of the rear panels finished by the end of the weekend, it's been pretty cold in the shop and trying to keep the shop temp warm enough to cure has been a real pain in the arse.
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Junior
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Post by dryshave on Mar 9, 2012 17:43:21 GMT -6
Have pretty much finished off the rough out on the front and tail pieces. A contour gauge replaces the CNC machine, that and many hours of checking and double checking each side for alignment. I'm pretty happy about the result so far and hope to be able to latex cast the highlight pieces (such as turn signal "eyes" and rear signal light pods) some time this weekend. Once they are cast I will cut the "cast" pieces out of the plasticine mold and build up the mounting tabs. I have tried this before, rather than using plaster in the mold. I put the plasticine in a glass bowl and place the bowl directly on the oil heater in the shop and 20 minutes later.... pour liquid plasticine. After it cools, it's still workable... in case there are any final adjustments to be made with the final fiberglass cast of the panel. Kind of hard to explain, more pictures in a week or so hopefully will help to explain. The yellow "eye" shows you where the turn signal lights are going. I plan to vacuum mold those pieces along with the tail lights.
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Junior
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Post by dryshave on Mar 1, 2012 19:15:09 GMT -6
Hoping to get my hands on a 250 if I can. I've got the original 150, but feel like jumping it up for this one. Can hold off on that decision until later on as any modifications won't affect the panel design.
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Junior
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Post by dryshave on Mar 1, 2012 17:31:59 GMT -6
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Junior
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Post by dryshave on Feb 28, 2012 16:54:22 GMT -6
Latest update: Have made my final decision on the dash and instrumentation placement. It's a pain to cut away the original foam shell, but much easier than making those changes when I get to the fiberglass stage. I've roughed in the tank location, you don't see all the tank as there is still work to be done on the bullet end where I've located the fuel gauge. I plan on welding in a locking fuel cap on the top dead center. The rear signal lights aren't the ones I'm using, but good enough to give you an idea of the overall look. Most of the modeling has been completed on the riders left side rear and the right side has been sized and is in it's final carving stages. I'm much happier with the "tom tom" dash arrangement. Speedo in the middle, with temp and oil pressure on either side. I'm going to have a big "easy" start button that is activated by a hidden keyswitch. Behind the front forks you can see how I laid up the foam for the front leg shield. I will cut away the foam and shape this properly once I have cast the inside piece and top in glass, that's why it looks messy. Still making it up as I go along. I should be able to get to final modeling over the next couple of weeks. Just about ready to drop it off the table and check the look with the motor and wheels in place... More soon! and in response to your inquiry bong... it will be for sale.... eventually. I never sell anything until I've ridden it for a while and have worked all the bugs out of it. I hope that I will have a good set of molds that can be used a couple of more times. I might just do another on for my grand daughter, now that the difficult part of designing the shell has been completed. I've been keeping a cost and labour log and so far I've got @ 120 hours into it and @ $150 in materials (scooter was free)
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Junior
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Post by dryshave on Feb 22, 2012 21:27:55 GMT -6
If the weather is sunny tomorrow I'll move it outside and get a better shot. Shooting in the low light and no flash is murder on the quality.
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