When starting this build, I had very little mechanical knowledge. I did not know how an internal combustion engine worked, how to change the oil, how to disconnect a battery or anything else for that matter. I am learning as I go, making mistakes & growing from them. I'm very open to advice but sometimes experimentation & failing is the only path to knowledge. Thanks for following me on my journey.
First, I start with my helmet. It needs to reflect where I'm going with this build.
â€˘ Flywheel, p13
â€˘ Tach, p15
â€˘ Rear fender bracket, p16
â€˘ Modifying stock perches for 1" bars, p17
â€˘ Floater seat frame, p18
â€˘ Stock Cable Measurements, p19
â€˘ Modifying stock perches & clutch disassembly, p19
â€˘ All weather tires, p20
â€˘ Mojo mount install, p24
â€˘ Motor cleaning & colored hoses, p25
â€˘ Installing Mojo mount, p31
â€˘ Douglas 12x8, p32
â€˘ Broken Auto-choke, p37
â€˘ Playing with Angel eyes, p39
â€˘ Angel eye wiring, p41
â€˘ Angel eye install breakdown, p43
â€˘ Floorboard sectioning, p43
â€˘ Cell charger, cable routing & cleanup, p44
â€˘ Velocity Stack & Carb vent, p45
â€˘ Velocity stack, rear brake cable relocation, Horn, p46
â€˘ Horn bracket, p48
â€˘ Starting Custom coolant overflow tank, p50
â€˘ Custom Coolant Overflow Res, p51
â€˘ Coolant tank bracket, p57
â€˘ Exhaust install, p60
â€˘ RFID progress, p66
â€˘ Coil swap, p68
â€˘ Angel Eyes how-to, p68
â€˘ Red paint on exhaust, p69
â€˘ Red Coolant, p69
â€˘ Waterproof multi-connectors, p76
â€˘ How-to Change tire rubber, p77
â€˘ Angel Eyes LED link, p81
â€˘ Couch lift kit, p81
â€˘ Redirecting blinker to High Beam indicator light, p82
â€˘ GitD paint, UV LEDs, Alarm, p86
â€˘ Vari C-Clip Massacre, p82
â€˘ Rim Design history, p99
â€˘ Running wiring through the bars, p102
â€˘ Making custom length front brake line, p103
â€˘ Custom length brake cables via homemade crucible, p105
â€˘ Lubricating brake cables, p106
â€˘ More crucible action, p106
â€˘ Custom Rim & Hub spacer, p107
â€˘ Blinkers Integrated into handlebar grips
â€˘ Custom Gussets, rough cut
â€˘ Painting the full exhaust
â€˘ Gussets welded on
â€˘ Bleeding/installing disc brakes off the bike
Archive of Mods
- GP Exhaust from webike
- Turn signal relocation
- Horn relocation
- Custom Windshield
- MNNTHBX DORF
- MNNTHBX Turtlehead
- MNNTHBX Peg Legs
- RonkSolid Velocity Stack w/float vent tied into coupler
- Polini Variator w/5.1g Doppler rollers
- Posh CDI
- NCY Forks w/ MNNTHBX Drum adapter
- 10" Mojo GET Fatty Extension
- 12x8 Fatty w/Viper Stryke to be replaced with Schwabbe All Weather
- 1" Apes, 18"
- Tail light bracket removal
- Poon shock (Net 265mm Red/Silver)
- DIY License plate bracket
- JC Lightened Flywheel
- Gates Drive belt MopedMotion via eBay.
- 12V Outlet for phone charger
- Dremeled-out Stock Controls for 1" bars
- 1" stem off Amazon: Origin8 Fix-8 Ahead Stem for $30
- New fuel line . Helix Red
- Triple Angel Eyes, 120mm, 60mm & 40mm
- Cleaned & painted engine VHT Matte Black
- Custom Sake bottle Coolant Reservoir
Current Jetting: M82 & SL38 w/shimmed needle
First Mods: Horn & Front Signal relocation. Easy, no pics
That gave me some confidence...so moving forward with a windshield to help keep off this Cold Ass Rain!
First, went to TAP & bought a beautiful piece of red acrylic
With the paper still on, I mocked up ideas to make it uniquely mine...ended up with a horn-style top.
I sharpied out the lines using bowls, dollar coins & other round bits found around the house:
Then, I took my dremel & etched out the lines so I could see them with the paper off.
I was so sketched out with the thing melting in the oven over the racks, I found some trash wood on the street and made a little frame to go in the oven. I felt I needed some way to hold it when inserting/extracting from the oven, also.
For the most part, it worked like a charm. Next time, I'll use smoother wood or something to protect it from the grain of the wood._______________________Top: ____________________________________________Front:
After taking it from the oven, I had a few seconds to warp it, so I mocked up the brackets on another piece of wood and matched as best I could. First mounted testNow for the cutting!
I used a rotary cutting blade to cut most of the curves. I used a hole-saw to cut the inner curves (so much easier!)
Mounted it back on to see the results:_______________________Inside view:____________________________________________Head-on:
Looks sweet & VERY functional. I'm an all-weather, all-year rider, so this was very important in keeping rain from pooling in my crotch. Even with TWO rain pants on, a nice crotch puddle will soak in. Pee-spot = Super lame.
After all of this, I'm really feelin' the mod itch! So, I hook up with MNNTHBX & grab the DORF, Peglegs & Turtlehead. _____________________Pegs from the front: __________________________________________Pegs from the 45Âş:
You can also see my 2Bro's pipe on there. I added a noise suppressor, but DAMN this thing is LOUD!
I wish there were a way to close it up in the mornings (I'm firing her up at 5.3a -- not cool.) I end up rolling it out to the street & barely twisting for a few blocks.
The pipe is all scratched up b/c the douche I got it from strung it on with wire
I'll have to be painting that.Here's the Peg leg installed, close-up:
I hate the VIN is partially covered, but I took pics before I covered.
Pegs are from a local BMX bike shop.
Next up: The DORF!
Man, was I excited about this
I also swapped out the rear shock for a used Aero80 off eBay. I need a better replacement, but it does the job for now. Bouncin' like a caddy, y'all!
As much as I wanted to do all of the airbox removal mods & put in those pod filters, it's just not practical with how wet I get this bike. For more air flow, I drilled some holes in the stock airbox & put in some little filters:
They work pretty well after rejetting
In the works:
I need some good wet-weather tires for my Winter riding.
I'm looking at:
First Choice: Schwalbe WeatherMan
Second Choice: Heidenau all weather
I just bought some pieces from a part-out by Ruckherpanties:RED Password JDM stretch kit (in "excellent condition w/no scratches")
The shock extension was included.RED NCY FULLY ADJUSTABLE forks, w/ the piggy backs on them & BLACK NCY matching rims with brand new Michelin boppers
Anyone take a close look at that rim & tire? Clearly spray painted :/
I put one of my stock POS forks on there to see the difference in the forks.
Also included in the deal: Posh CDI & KN Variator (w/Dr. Pulley sliders, mix of 5.5 & 6g.)
I went to start stripping my ride down for the install & stripped a F'n bolt! I fixed this by super-gluing the hex into the bolt & taking it out easy. Worked like a charm!
SO, CDI not getting installed. Variator tool in progress, so had to pass on that, too.
Looking at the Rims & forks...holy hell. Different axle size!
and..wait...these forks don't have the same setup as my stocks...OH. Disc brake setup.
We're having a pattern here : (
More info to come in the way of SCREAMING FOR HELP!
My used Posh CDI, to be installed:My used KN Variator
(How do I even know this is a KN? Can anyone verify?)
Thanks to Pyrogen for this insertion pic: And my NEW Mojo Customs Lowered Handlebar Setup:
Now...to make a Variator tool [done], figure out how those sliders go in [done] & attempt install [done.]
I made the variator tool:
Thanks to all y'all for the assist! http://totalruckus.com/phpBB3/viewtopic.php?f=34&t=581&hilit=variator+tool
One bit of advice to tool makers: One of the bottom bolts is longer than the other for a reason: to compensate for thick metal bars used & the distance created by marrying them together
(IOW, use the longer bolt on the piece bolted in back to make them more even.) Mine is done wrong, here.
Here's my stock Variator, soon to be relaced:
Not quite sure why I expected this to be all dirty in here, heheh.
And here she is, all broken up like a dumped gf:
Lots of upgrades to my fairly stock Ruck. I tried to slam in a few things and get her out for the Hagg Lake ride this past weekend, but it just wasn't safe enough for a long ride.
Rode the GF's stockie & worked my ass off Sat & Sun to get all of this on.
â€˘ I added Mike155cc's Stripped Screw Repair Kit
to my rebuild. SO sick of those shitty control screws!!
â€˘ KN Variator installed. This was so easy with the homemade tool! Easy swap out. Except...I did not mark the nut. I wonder why I would need to do this? Â· What is meant by "marking the nut" before taking this thing off?
Â· I assume it's not a sexual reference, you dirty bastards ...
Â· Best I can figure, it's a low-tech way to compensate for not using a torque wrench? I used a torque wrench to spec
â€˘ Posh CDI installed. A little tricky since the used one I received had the wires cut really short
â€˘ Cut off back lights & bracket then finished Turtlehead install (it's been on my seat since I got it in, just not hooked up.)
Â· The relay part didn't fit so well, plus had different connectors, so I used heat-shrink to affix the connections:
...then zip-tied them to the original bracket.
Â· I want to still be able to flip my DORF up from the back without taking it off. I ordered a single 6-pin Deutsch Connector off eBay for $22 [cheaper options
] and installed it without much issue. They are fairly easy to disconnect & take back apart if the pin sequence gets messed up while assembling it. They use a special tool for crimping, but I did well with a regular cheap-ass wire crimper. I was just very thorough and tested everything. Also heat-shrinked all of those wires for a clean install. I had a solder ready, but it worked without it, so I didn't bother. See p2 post for more info on these.
The only issue I'm seeing is running the wire through the stock floorboard (which I'm keeping, in part.) I'm looking at cutting the back half off under the seat & fabbing a different cargo tray that's easier to remove for carb work (& looks nicer.) I need to figure out a solution that's easy to unhook & looks nice. More to come on this....
â€˘ I ordered an MNNTHBX Drum adapter to work with the forks & rims.
Â· I need an axle!! I almost forgot, lol. Ordered!
Â· I did not
need a new 12mm axle! the MNNTHBX Drum Adapter came with shims and spacer -- everything I needed to throw a set of disc forks on my stock tire/rim.
Another big Fuck Yeah!
Works like a charm.
â€˘ PW Extension installed. This was a bitch, but not too bad w/two ppl. My only complaint is the frame is now resting on the head
That can't be so good. I'll get pics up of that & see if it's normal.
â€˘ Those NCY Rims & Mich Bopper tires are gonna be up for sale if anyone wants 'em.
Clearly I knew nothing
about what I was doing and didn't realize Disc Rims were NOT going to fit with drum brakes.
I thought the adapter would solve that, but the hardware is clearly incompatible. Yeah, I know, y'all got a good laugh outta that ridiculous post
is not how you stick drum brakes on a disc rim. ____________________________________ ____________________________________
Upcoming potentials: Holy Hell I need a more comfortable seat! 15-20 mins is max ride time before my ass starts hurting. I'm gonna start looking at alternatives for seating. Most likely gonna fab something from another bike on since I haven't seen much other options other than reworking the stock seat. Tempted by the gel inserts & the vendor that pimps them out with new foam & stuff, but I think I want a different seat altogether. Anyone have experience or seen a fun seat?
I'm starting to lean towards a more cruiser style.
I have a DORFsac installed from MuthaRUCKUS
. I'm stoked ab having some STORAGE on my girl! It looks really nice, BTW. Great crafts(wo)manship and quality material. The rear straps don't line up with the DORF frame, but it's easy to make it work. Highly recommended. Pics coming.
I have three KN filters in to replace my airbox (finally.) I sure didn't want to do this, but I want a better shock. Plus, after the PW extension, it doesn't fit on very well.
Oh! I also have a poon shock OTW, too!
Current look as of July 2nd, 2013:
YES, I know it's dirty (just like me
) We can't all sparkle like Rola
I'll try to wash her soon, hehe
While down, I started playing with some paint & painted my Rad cover hammered silver. You can't really tell the color/texture, tho. This won't stay long.
Got in my Poon shock!
Left to Right: Stock, Aero80, Poon NET 265
Here's the NCY Rim & Miche Bopper installed on the rear:
I've really been dreading the separation anxiety from my airbox, so I rigged up spacers to kick the box out from the CVT. It worked a LOT better than I'd imagined! After a month, this mod is working perfectly.
Now to clean it up & make it look nice.Front: Rear:
I used two 2.5" long bolts that matched the stock ones and a 1" steel spacer & a 1/2" steel spacer for the two mounting holes. The hoses look
like they're rubbing the shock pretty hard in these pics, but it's just barely resting on there. I'll give routing and hose clean-up more thought soon.
Just look at that dirty girl. Eat your heart out, Rola!
I took my can apart & painted it to not look stupid. I really love how it came out! Traded beat up chrome & gold for black w/gloss highlights:
I made a license plate bracket that wraps around my rear tire. Very functional & I like the way it looks. Sprayed with black tool dip. I've gotta get me a plate frame.
Painted my BB matte black...got rushed & the wind picked up, making my job less than perfect. Def'ly on the redo list.
Current look:Project continued on following pages. I didn't realize how obnoxious a large first post would be. Sorry about that.Upcoming projects:
- Front Brake: 6ft
- Rear Brake: 9ft (Mocking up foot brake to avoid a mile of cable) new length TBD
- Throttle: 666mm
- All hardware specs on p19
- NAPA air filter: SME 7-02257 $7.99
- RFID (purchased)
- New Horn (purchased, installed) Needs wiring
- Fab Fatty fender (RuckinRonk as guide)
- Custom switches (purchased)
- Design Leg shields (Designed) -- waiting for finishing touches
- OF Front Fender Mod
- More paint!
|Lovin' my Haters: MOBSTER, s2525|
Keepin' these little guys here for links: