Back to the drawing board with the frame. The problem with stop/start progress is that things get overlooked. Setting up the exhaust mounting and the seat frame at different times meant that I designed a disaster. A muffler that required the seat off to mount, and a seat that required the exhaust off to install. Glad I spotted it early. Made a few mounting brackets, Modified existing engine mounts and designed a battery hanger. It's a lot of work getting a custom frame to work....
Visible progress has been slow, but lots of little jobs have been done that nobody will ever notice. Motivation low to do time consuming work, so fitted 2 headlights that I had to see some shapes. I Don't think either is right, square one sits too low and round single is too big. Plan at this stage is for twin small singles. Just food for thought. New wiring loom backbone is done, will be time to test run soon. Been working on getting the front end geometry right. Making some spacers and a caliper mount to suit the new caliper. Going for a 4 piston caliper rigid mounted to the fork. Re tapped some threads for the mounts, and got the alignment right now. Just need to bleed lines and should be right.
Rear end is done, fitted everything up to check clearance and all worked as planned. 160/60/17 Bridgestone Battlax rubber, nice tyre, fits well and very sticky. Brake lines and new master cylinder set to go on the back too. Enjoy the pics.
Wow, what a terribly overcomplicated loom. Trimmed all the non essentials out and fitted all the wiring components into little hidey-holes in the frame. Next to make some brackets up and weld them on to mount components and battery.
Redesigning a subframe on the kitchen table, a good way to annoy loved ones. New supports made up, and widened to fit the exhaust and muffler up higher. Getting there now. Old shortened subframe pictured, new one is the bees knees.
A good score. Working on KLX I came across a crew selling ultralight lithium batteries. Heaps smaller and so light I can easily pop it under the fuel tank. Price online 330USD, price in Indo 30 dollars with warranty and genuine registration card. :) Decided to redesign subframe and put muffler up high. Design is ready for welding. More to come soon.
Ok, exhaust is chopped down to size, and i have 3 options. I can follow the frame in 2 ways, one as pictured, follows the lower subframe. The second option is to widen the subframe at the back, and push the exhaust right up and follow the flat of the seat underside. 3rd option, to go for a slim round exhaust, tucked right up under the seat. I need another opinion, please comment.
Some points about how its pictured....
Threw some wheels on this arvo to test fit. Front will go wider, to 110 minimum, and rear likely wider to 140 or 150. Making a custom underseat exhaust is next, and trying to find some battery space.
Well, not really sure where all the pics of the frame chopping got to, but suffice to say there is nothing left of the original. (Except the head stock bearings) Frame still needs lots of mounts and brackets made, and a few tricks pulled to get things to fit but the idea is there....
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Megelli 250
This is my second project. Mild engine work, a new tank and seat, ill use the swingarm and underseat exhaust. Ill drop the front forks a little and rewire with minimal styling and none of the plastic fairings. Archives
September 2013
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