Project Raucous - NPS450t - Updated 11/17!!! ;)

ComposiMo · Posted: Tue May 13, 2008 3:32 pm Post subject:

Here we are again... today was a REALLY busy day at the shop, so i didn't get as much done as i would have liked, but i got a pretty good bit done Wink

Today i'm going to begin to box the entire rear section in, so that there is enough strength for this extremely torquey motor, as well as because this structure is also going to be the main base for the right-side rear axle mount... So this entire arm needs to be extremely strong.

Here is the trailing arm where we left off...

I began by making a template with some tracing paper of the rear area

Which allowed me to cut out two steel sections... one for the top, and one for the bottom. The top one also had to be notched for the motor mount

So, i started to tack weld it all together...

Before i could go too far, i also had to finish welding up the slots that i had cut in the arm so that i could bend the rectangle steel into the shape for the trailing arm.

Once that was done, i slowly finished welding the upper and lower plates... i had to weld small sections at a time, and let things cool off a bit between each one, so this process took a little while, but it came out beautifully, with hardly any noticable warping, which is the goal Smile

I'm still not totally done boxing, but i was tired of doing that today, so i began working on another project with the Ruckus...

The rear axle blocks... these are used so that you can slide the rear axle forward or backwards to adjust for chain tension. I decided that moving the hub would be easier than making the engine slide for and aft, so that means i have to make these little adjusters. They will be oval shaped blocks, with a bolt in one end. The axle will tighten down on the blocks, and then the bolt is used to "jam" the axle so that it cannot slide forward once the adjustment has been made. fairly simple deal, but very much required.

So, i pulled out my favorite rectangle tubing (seems like i'm using this a lot on this project.. haha!), and drew my lines, marked my holes, and drilled them out.

Then, using the trusty Dewalt grinder, i trimmed out the section in the middle between the holes to form one long oval hole... then, i trimmed a small piece of tubing into two halves, which will become the front and back of this slot.

Then i welded up the halves on the top of the bar..

Then it was time to install the flat sections, which i cut out of a flat piece of steel... unfortunately its a bit thicker than the tubing i'm using, but i can always hide that later.

Once welded, i ground the entire thing down to make it all flush and smooth... It won't wind up like this though, for decent strength, i'm going to run one very nice bead of weld all the way around the perimiter, because in some of the pics farther down, you'll see that there are slight hairline slits that aren't fully welded... the visible bead should look pretty cool though Smile

haha!

Then, i have to round off the front and back, so that they are pleasing to the eye when done Smile

And here is a picture of how they will sort of sit when installed... obviously they will be at the same height as the hub center, since they will be holding the axle... I still have to cap off the ends, and install the adjuster nut, but its a decent start for now..

Also, earlier i went next door and bought some temporary bolts, so that i could actually bolt the swingarm to the chassis rather than the slide-through sleeve thing i was using earlier. The stainless bolts i'm going to be using are on their way though.

So, theres where we stand at the end of the day... There will be more boxing in of the rear swingarm, and once the wheel s arrive, and i get the rear axle back from the machine shop on Monday, i'll be able to begin mounting the rear hub, and building the other side of the swingarm Smile

OH... and for those wondering about how much the motor weighs, it is a bit more than i remembered... according to my Nitrous scale, it weighs:

87.75lbs... well, i was close Razz

hahaha!
_________________
John.W
www.NPS450t.com - 450cc Turbo Ruckus Build Thread

mrfantasmik · Posted: Tue May 13, 2008 3:36 pm Post subject:

_________________
"mopeds are always broke but they're easy to fix, but we stay ridin clean rollin on all you trix"

sanjuro62 · Posted: Tue May 13, 2008 3:38 pm Post subject:

Well whoopty doo! I can't believe people are drooling over your work just because you have some fancy camera and a clean shop. I'm still waiting for you to show your skill. Laughing

_________________
My Flickr photostream http://www.flickr.com/photos/sanjuro62/

"Wasteful as for rev please be modest."
-TP

ComposiMo · Posted: Tue May 13, 2008 3:50 pm Post subject:

mrfantasmik: THanks for the inspiration Wink

SJ: Hahahaha! Banana Get Down

How dare you SJ! i'm going to go pout now Sad

... lol!

As a side note.... that fancy-schmancy camera took a BAD fall back when TC's Ruck was here getting stretched... it got knocked over, and fell from the aluminum table, down to the concrete floor, and broke the lens in two pieces... i push the lens back together, and it amazingly still works (sorta). It doesn't like to focus down close or through the whole range without a bit of assistance, but it is still shooting all of these pictures... BIG thumbs up to Nikon for building a durable camera.. Oh, it also shot all those pictures of TC's RUck being broken as well.

So, i'm expecting it to fail at some point completely, so i'm saving up right now for a new lens so that you guys won't be without pics for very long (hopefully thats all thats hurt)... i really don't want to have to buy ANOTHER uber-expensive camera (even though this thing costs less everyone thinks it does Razz

)
_________________
John.W
www.NPS450t.com - 450cc Turbo Ruckus Build Thread

RUCKSTER · Posted: Tue May 13, 2008 4:38 pm Post subject:

Are you trying to go "BACK TO THE FUTURE" ...

because if you do, pick me up a Sports Almanac!!!

Great work. Interesting build. I'm about to trade in my MIG for a TIG welder.
_________________
www.RUCKSTERS.com

Dr.EZP · Posted: Tue May 13, 2008 5:32 pm Post subject:

need to sit down and actually focus and concentrate as I read/look/watch this thread. Much being learned...

i wanna go fast · Posted: Tue May 13, 2008 7:22 pm Post subject:

I just like looking at all of the pictures Propeller Head

S2 · Posted: Tue May 13, 2008 7:55 pm Post subject:

ComposiMo----i see little details that make me realize i need to step up my fab game.

tig welding 1ft total lengths of box tubing----whoever heard of such a thing, gotta be a watercooled machine!!!!!

making your own adjusters------your gonna bake some noodles with those!!!!

i like that photo with the weld still glowing----must of had the camera waiting.

in my experience, with all the unfinished 2 wheel projects i've started, you gotta have direction-----and my friend you have direction!!

please dont ruin it for me and say your using drawings or prints to build from. soapstone, back of your hand, napkins, greaseboard, all OK with me.
_________________

ComposiMo · Posted: Tue May 13, 2008 8:19 pm Post subject:

Ruckster: Hahah! 88mph is a decent enough goal Cool

However, i have a feeling that this'll go a tad bit faster than that. oh, as for trading the MIG for TIG, i wouldn't... not until you get good at TIG. Its only as good as you are, and the learning curve to do it right is steep... practice is your friend.

EZP: If you read the thread while drunk, it'll all make more sense Smile

j/k

iwanagofast: Nice username.... you're in the right thread for it.. LoL! Thanks... I like taking the pictures..

skangele: Well, i wouldn't want to dissapoint anyone... hehe. No, i am not building this from prints or CAD. The only thing that i drew on CAD for this project is the rear hub, and thats because the machinist couldn't grasp what i was wanting him to build when i presented him with my napkin drawing Razz

Everything else comes from my head. I have many many many many hours of sitting down and thinking through every single aspect of this build, including basically building the entire thing in my head. I know what every part looks like that i have to build to make this thing work, and yes there is a plan to everything... its just not written down Head Banger

As for the details... Actually, this entire Ruckus is being welded with my air-cooled machine, not the watercooled unit. Yea, it gets pretty hot, but i'm used to it. I think my hand is part barbequed by now.. Laughing

There is no glowing welds in any of the pics... what you're probably seeing is the orange residue left over from slightly dirty metal/contamination of the weld. I always allow the weld to cool with the torch still flowing argon over the hot spot in the weld... so that means no pics of glowing steel Sad

and yes, i do have direction... its different direction than most would probably be comfortable with, but it works for me Wink

Thanks for all the great compliments (and yes, even the criticisms from some) Smile

I certainly do appreciate them, both good and bad... they do make building something like this even more fun to build Cool

_________________
John.W
www.NPS450t.com - 450cc Turbo Ruckus Build Thread

Marcus · Posted: Wed May 14, 2008 12:58 am Post subject:

really learning alot from your welding shots. Thanks for sharing / keeping us updated.

Fucking bad ass Cool

ThunderstRuck · Posted: Wed May 14, 2008 2:35 am Post subject:

Composimo: There was a time when I was in art school when I was commenting on a museum piece at the Met in NY. I said to the prof "I could've done that!" Yeah, he said...but you didn't. Your project reminds me of that time. However, I am wize enough now to realize I couldn't do that: That's why I didn't. Your build is fascinating and motivational. Every time I've welded something recently I think of your work and that visualization keeps me motivated to do better. Wether or not people agree with what you're doing is completely beyond the point. The quality of the work speaks for itself and the fact that you are not hiding anything shows your confidence and attention to detail. I'm going to be in FL the 22nd June, I'd love to drop in and see your shop! Maybe watch you work for a few minuites.
_________________
Check out my garage & please rate my Scoot!
http://totalruckus.com/phpBB2/garage.php?mode=view_vehicle&CID=454
See my Ruckus do 62.5 mph (100 km/h)
http://www.youtube.com/watch?v=eG31IZJ4OR4

ComposiMo · Posted: Wed May 14, 2008 6:40 am Post subject:

Thunder: WHats interesting, is many times i've had that same reaction to items i've seen in art galleries or for sale... "dang, i could have done that"... followed very shortly by "wow, they are getting that much $$ for that little chunk of steel?!?!?" LoL! Laughing

But then the reality hits, that yes i could, but no i didn't... so i'm definitely in tune with what you're saying there.

I'm very hapopy that i'm able to help motivate you, and through my project help you bring your fabrication to new levels... Its exciting to me for sure!

As for the 22nd, that would work out great... the weekend before i'm going to be in Pomona for the Fathers Day car show at the FairPlex... should be fun times... but i'll definitely welcome you into the shop to check out whats going on Smile

By that point, this thing should be a rolling chassis, and maybe even idling... haha!
_________________
John.W
www.NPS450t.com - 450cc Turbo Ruckus Build Thread

tallkyle · One of Us Joined: 10 Apr 2008 Posts: 676 Location: Chicago

OUT OF CONTROL!!!! Laughing

_________________
R=C=A
Ruckus Chicago Alliance

sanjuro62 · Posted: Wed May 14, 2008 8:05 am Post subject:

ComposiMo · Posted: Wed May 14, 2008 9:11 am Post subject:

Well, i got about 2 cuts into a fresh piece of steel, and got a phone call, and now i have to go to Orlando for the rest of the day for some family stuff... so, nothing will be getting done on this bugger today Sad

Tomorrow ought to be fun. I'll be picking up some more steel today while i'm in Orlando, so look forward to more progress tomorrow Wink

_________________
John.W
www.NPS450t.com - 450cc Turbo Ruckus Build Thread