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

Renzsu · Posted: Mon May 19, 2008 1:59 pm Post subject:

I like stainless nuts and bolts, yeah, pricey though... but in some cases not as good as regular steel because of their brittleness? Anyways, those look really nice.. probably around $10 a piece?
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ComposiMo · Posted: Mon May 19, 2008 2:36 pm Post subject:

If the stress on these bolts was mostly in tension, i'd worry more about the properties of the stainless affecting how strong they would be in comparison to some nice 10.9 bolts or something.... but since they are in shear, i am much less worried about the strength of them, since the shear failure point is going to be WAY higher than the tension failure point... and being a 5/8" bolt, the swingarm will likely fail before the bolt will.

The nut and bolt package for each side is $14.50~... i bought 6 total sets, so that i would not only have them for a future project, but also as spares "just in case"...
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www.NPS450t.com - 450cc Turbo Ruckus Build Thread

Tuesday Club · Posted: Mon May 19, 2008 3:31 pm Post subject:

If I may be so bold to say...Nice nuts! Mr. Green

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S2 · Posted: Mon May 19, 2008 5:10 pm Post subject:

SBArmy · Posted: Tue May 20, 2008 9:42 am Post subject:

I think I cream myself a lil everytime I check on this thread. I cant wait to see a video of this thing hauling ass down the road.
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ComposiMo · Posted: Tue May 20, 2008 2:28 pm Post subject:

5/20/08

Another day down, and another day closer to having a running/driving Ruckus!

So, after the last mockup, we decided that it would be best to integrate the stock Ruckus rear frame into this bike, so that we can retain as much "ruckus" as possible... So, i sent the frame down the street to have all of the OEM powdercoating stripped off of it in anticipation of doing a lot of welding and smoothing work to the frame Smile

I stopped in on the way to the shop this morning, and picked it up... when i got to the shop, i began to mock it up and figure out where i wanted it to sit.

I'm thinking that i may also grind down some of the OEM welds, and re-do them... they all look absolutely nasty:

Well, now that i spent a good bit of time figuring out where i wanted it, i had to make new mounts ofr the frame, since there was no way in the world that it would fit in the stock location... so, i began making the main brackets that will extend the frame section to the back of the Ruckus:

I Cut two pieces of 1/4" steel, and tack welded them together.

The idea here, is of course that hwen i drill my holes, i can have nice precise holes in both plates.

So, i started with a pilot hole:

and moved onto bigger holes:

So, now i have my plates... so, i test fit them, because i'm going to have to put a bend in them to angle the rear frame slightly upwards, so i need to know how much i have to do that by:

I chose and angle, went over to the press, and installed the bend Smile

So now, with the bend in place, heres about where the frame section will sit:

That'll give me enough for a bit of suspension travel, as well as room for the tire to grow a bit as it spins

Next order of business... i got tired of looking at all of the stock bracketry and tabs, so i decided to smooth the frame out a bit...

There one minute...

Gone the next... haha!

Ok, now that i had all of that done, and could stand looking at the frame, it was time to start building the side-plates that will let me to have a lot of strength for the rear frame section... it will also be a large visual spot on the side of the chassis, so this will have to look good as well (not that everything else doesn't have to... lol!)

So, i made a cardboard template, and cut out a triangle out of the steel...

Then, i had to take a bunch of measurements, because i have to make a hole in the side to not only allow me to tighten the swingarm bolt, but it'll allow me to remove the bolt if needed. I thought a LOT about reversing the bolt in the swingarm, and using a nut on the outside so that i didn't have to make this hole, but i decided that the hole would actually look good... if i decide that i hate it later, i can always fill it back in, and grind it smooth, so i'm not too terribly worried about it.

So, a couple of minutes with a hole saw later, and....

Next up, i had to spot weld the plate on for better rigidity... so, i chose the locations for the rosette welds...

Centerpunched them...

and drilled them!

Next up,. it was time to weld them on...

Next up, i pulled out my forming hammer, and i had to form the sheet around some tubes and make it look nice, and give a good solid fit for welding...

Then it was time to weld the rest of it all up!

Then, i pulled out the dewalt, and ground down my spot welds so everything was nice and smooth!

Wow... lots of work...

Once all of that was done, i decided to assemble it all, and do yet another mockup to see how it was all coming together... The finished product is really nice, and it gives me yet another place to mount stuff, since i now have 4 extra bolt hole locations that i left available on purpose Wink

Oh, and for this mockup, i decided to put the whole thing on the floor, so that i could see what it was like at real-height, and not up on a table Smile

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www.NPS450t.com - 450cc Turbo Ruckus Build Thread

bigluelok · Posted: Tue May 20, 2008 2:39 pm Post subject:

wow that ruck is coming together quick and it looks spectacular

PomeRuck · Posted: Tue May 20, 2008 2:40 pm Post subject:

GORGEOUS FAB WORK~!!~!!!!! I HAVE WOOOD!!!!!
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rattmobbins · Posted: Tue May 20, 2008 3:21 pm Post subject:

God damn I want one of these SO bad! If only I had $10,000 laying around to drop on a scooter...
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LiteW8 · Posted: Tue May 20, 2008 3:33 pm Post subject:

Thats fucking sweet! You should sell rear frames done like that.

Dr.EZP · Posted: Tue May 20, 2008 4:20 pm Post subject:

NICE! But, if I may be so bold, why so low? I guess that's what the client wants? Cause, seriously, that thing is like a billimeter from the ground. One rock and BLAM!

ComposiMo · Posted: Tue May 20, 2008 5:09 pm Post subject:

Thanks guys! Smile

ratt: $10k?...

Lite: Cleaned up, or stretched? Or do you mean with the swingarm and everything? I've been thinking of different variations of frame mods... what would you be interested in? Smile

EZP: No problem! Yes, that is what the customer asked for... he likes the low, mean, and "top fuel dragster" look... so who am i to say no? Wink

Its not THAT low.... i mean, exactly how many huge rocks have you come across on the road? This thing isn't going to be ridden offroad or anything. Heck, my car is almost that low... hahaha! It'll be fine. You can dodge rocks Razz

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www.NPS450t.com - 450cc Turbo Ruckus Build Thread

Dr.EZP · Posted: Tue May 20, 2008 5:14 pm Post subject:

yeah, you're right, it'd have to be a big ass rock.

Your car is that low too? No wonder they call it the Dirty South, cause all you mofo's ride so low!

Dr.EZP · Posted: Tue May 20, 2008 5:17 pm Post subject:

And you know, I'm staring at it, and I can't help but wonder if it's not gonna wanna list to the right due to the wieght of the engine. I think I remember you having a plan for balancing the weight out...?

EDIT: the wieght of the swingarm would balance it? When do you get to start working with the swingarm?

ComposiMo · Posted: Tue May 20, 2008 5:31 pm Post subject:

No, not the weight of the swingarm.... the arm itself is actually very light. The balance will come from the placement of other items, and the creative use of other items... i.e. the NOS bottle isn't there only to provide Nitrous to the motor... you'll see Wink

Don't worry, this entire project has been very very well thought out. Nearly everything has been problem-solved, and a solution has been generated... well, at least on the big items, and the balance was one of the first things that we considered and developed a solution for.

And yea... my car isn't THAT low, but its close... lol! Yes, we all ride low down here though Smile

Not much around here in FL to get hung up on, other than speed bumps... which i do get over just fine with it... this Ruck might be a different story. But then again, this is not intended to be a daily driver, and therefore no one really cares if it can or cannot get over a speedbump cleanly... its a non-issue.
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www.NPS450t.com - 450cc Turbo Ruckus Build Thread