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

stickler64 · Posted: Thu May 22, 2008 8:58 am Post subject:

Starting to take shape. Looks good! Smile

ComposiMo · Posted: Thu May 22, 2008 9:25 am Post subject:

ruck_off: well, i was kinda hoping to keep the seat frame a bolt-on affair, so that it would be more "ruckus-like"... it may still be a bolt-on setup, but just very different locations... we'll see. The owner had a look at the pics, and he doesn't like the seat so high either.

stick: thanks! Smile

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

amsa116 · Junior Mint Joined: 03 Jul 2007 Posts: 130

what's going to cost to build one. Look's awesome dude.

Tuesday Club · Posted: Thu May 22, 2008 11:45 am Post subject:

Ooh...Very nice!

(OT:Did you get the parts in the mail?)
_________________

S2 · Posted: Thu May 22, 2008 12:25 pm Post subject:

wHEN'S THE 6AL4V ti COMIN OUT?
_________________

ComposiMo · Posted: Thu May 22, 2008 3:38 pm Post subject:

Well, today was yet another wash... well, not completely, but i just don't have any pics of anything.

I got the custom made aluminum rear hubs back to the machine shop, because i was not happy with the way i received them.. there were scratches and scrapes everywhere on them, and the bearing surfaces had slight gouges in them. So, he took them back to refinish them and true them up.... i had to drive about 45 minutes each way to get them there, but it'll be worth the drive.

Also, another friend helping me out with rear axle components got the 4130 chromoly axle shaft and bearings completed for me.. with this setup, the wheel hub rides on this chromoly axle, and the bearings are from the front wheel of a Harley Davidson... so they should be more than up to the task of being the rear wheel bearings for this project Smile

So, i picked that up. Now that i have the axle shaft, i can get going on the rest of the rear trailing arm, and getting that all completed.

Update on the wheels... they still have not arrived... not sure whats up with that, but i've been calling the manufacturer all day about them with still no word back...

Otherwise, the rest of my day was spent in the showroom, because i had to man the phones most of the day, since our sales guy Kevin was out of the shop with our mechanic all day helping a customer with his car on-location... lol!

amsa116: Thanks! But sorry, i cannot disclose the exact build cost. However if you read a few posts back, you'll get a general idea.

TC: YES, i did! Thank you very much Smile

hows the Ruck running? I haven't talked to you since dropping off the tstat housing.... is everything good?

skangele: ..........uh................ what?
_________________
John.W
www.NPS450t.com - 450cc Turbo Ruckus Build Thread

S2 · Posted: Thu May 22, 2008 4:28 pm Post subject:

6AL4V
Grade 2 Titanium

Man i'm a nerd!
_________________

ComposiMo · Posted: Fri May 23, 2008 3:17 pm Post subject:

5/23/08

Today is the day to locate, modify, and finally mount the radiator!

The radiator we got fits perfectly within the Ruckus frame, but it still is needing a bit of massaging to make right.

First things first, since i decided that the seat was too high, and i have to lower it more, the stock rear seat brackets won't be needed... also, that pesky cross-bar on the chassis that is in the way can go away as well Smile

So, i broke out the trusty dewalt, and went to work!

Next up, i had to remove the radiator cap from the radiator, because i will be relocating it. Now, i want to reuse it, so i have to cut it off VERY carefully...

About 3 minutes later with the Dewalt Grinder with a cutting wheel, and it was off!

Then, i had to smooth it out...

There! Now it fits in there exactly how i want it to... but we're not done yet, it still has to clear the big bad motor!

The angle was where i wanted it, so i went ahead and cut some cross-sections out of steel that i could mount the radiator to, and tacked them in place...

Then welded them

Next thing was to clearance the radiator to fit the motor... the motor sticks inward quite a ways, so i had to cut a decent amount off the right-side tank on the bottom.. you can sorta see that cut in this pic at the bottom-left corner of the radiator:

Then, remember all that work i did to smooth out the top of the tank where the radiator cap was? Well, that was all a waste of time (still needed the radiator filler though, but still)... turns out i needed to shift the entire radiator over about .250" so, i had to cut the entire top of the left-side tank off, and i'll have to weld on a new piece of aluminum on to cover the huge hole that is now there:

You're not supposed to see all those fins in there... haha!

Ok, so now that the radiator was clearanced for everything, it was time to now notch the frame so that the motor wouldn't hit it anymore. Here is what the problem is... the bolts on the side of the head are BARELY grazing the framerail...

So, i marked where it needed to be notched, and begain the process...

Cuts are made:

Clear!

Then, i cleaned it up a bit, and deburred the edges

Next up, was to start boxing it in with new steel...

And now, the frame very cleanly passes by the motor without hitting it! yAy!

So, the radiator has enough clearance, and has mounts, and the motor doesn't hit the frame.. fairly productinve day Smile

But WAIT!.... theres more... Wink

I got the rear axle shaft back from my friend yesterday, and this axle is what the custom aluminum rear hub assembly will ride on... It has a 3/4" 4130 Chromoly Shaft, and uses Harley Davidson front wheel bearings...

So, i decided to mock up the rear axle a bit, and start taking down my measurements, because the next thing i work on, will be mounting this here rear axle Wink

So, thats kinda where we're at for now... I also played with a couple of different seat locations, and i may wind up with this one:

Good ol' Honda Wink

Happy Memorial Day Weekend! More Rip-Roarin-Ruckin-Fun to come on Tuesday! Smile

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

RUCKSTER · Posted: Fri May 23, 2008 3:34 pm Post subject:

Are you sure your not PAUL Jr. from ORANGE COUNTY CHOPPERS?
_________________
www.RUCKSTERS.com

Masa · n00bie Joined: 30 Mar 2008 Posts: 3 Location: Hilo, Hawaii

ComposiMo: can't say how much i admire your fab work!, welding skills for days!, inspires me to get out there and try harder on my own work.

keep it up!

Tuesday Club · Posted: Fri May 23, 2008 4:30 pm Post subject:

Masa · n00bie Joined: 30 Mar 2008 Posts: 3 Location: Hilo, Hawaii

^^^ i was gonna say, but didn't know if he was being sarcastic?

ruck_off · Posted: Fri May 23, 2008 4:39 pm Post subject:

Radiator setup is tits. What are you gonna do for radiator hoses? I sure hope there are some steel braided hoses in line for it. Very Happy

_________________
2008 Black Ruckus

ComposiMo · Posted: Fri May 23, 2008 5:40 pm Post subject:

Ruckster: Was that supposed to be in a GOOD way, right? lol! Its kinda hard to tell, since Jr. is.... well... yea, he's on tv... lol!

Masa: Thanks man! I'm glad that i'm able to help inspire you Wink

TC: hahha! Yea, i wasn't sure if he was being nice or not... lol! just kidding... i'm sure he meant it in the best way Laughing

ruck_off: Thanks! Yes, there are braided lines in the works for the radiator hoses Wink

for instance... the coolant port that exits directly towards the seat... i'll be cutting that off, and welding a new fitting on there for the braided line.
_________________
John.W
www.NPS450t.com - 450cc Turbo Ruckus Build Thread

aone · Posted: Fri May 23, 2008 6:16 pm Post subject:

Damn u freakin work fast! what color are u guys gonna paint the frame or did i miss that???
_________________
--------------------------------------------------
music > www.myspace.com/aone
cars/scooter > www.myspace.com/maniladori