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Needs Training Wheels
Needs Training Wheels

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Location: Hutchinson, KS.
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 Post subject: ***THE CATALYST*** EFI Air Ride etc... 10-1-12 thru 4-6-13
PostPosted: Tue Oct 30, 2012 11:51 am 
I am building a new ruckus from the ground up, including bending and welding the rear frame and anything else. I'm on a limited budget and can usually only work on the weekends so it will go slow, but steady. I have never built a ruckus before so everything is trial and error. I'm building ground up in an attempt to keep everything minimal as possible. I will big bore the motor once I get to that point. But here is where I'm at thus far.

We were also thinking about building these frames to sell. I don't know how many people would be interested, however if this is something people are interested in send me a pm and I'll let you know what we can do.

Bought one of these used for $350 (2006)
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Tear Down
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New front frame :banger:
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Tube Bender from JD Squared :D
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Bending of rear frame tube 8)
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Looks like my degree calculations were off a bit :headbashing:
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That's Better
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Strap Metal for the triangle mounts
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Cutting of triangle mounts
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Lookin' good
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Mocking up seat frame
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Mojo mounts not fitting exactly, oh well I can fix that.
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Some Welding
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And this is where I am at... until this weekend.
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What I plan on it looking like. That seat frame isn't mine, but you get the idea
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Build Thread


Last edited by Studflucker on Wed Feb 06, 2013 7:57 am, edited 4 times in total.

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Needs Training Wheels
Needs Training Wheels
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Posts: 30
Location: Vancouver, BC
Gender: Dude

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 Post subject: Re: Ground up build of "The Mistress" 10-1-12 thru 3-1-13
PostPosted: Tue Oct 30, 2012 12:36 pm 
sick man good luck with the build!

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TR's High Five Guy


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Location: Kentucky
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 Post subject: Re: Ground up build of "The Mistress" 10-1-12 thru 3-1-13
PostPosted: Tue Oct 30, 2012 7:38 pm 
interesting.......

:popcorn:

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Needs Training Wheels
Needs Training Wheels

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Posts: 17
Gender: Dude

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 Post subject: Re: Ground up build of "The Mistress" 10-1-12 thru 3-1-13
PostPosted: Tue Oct 30, 2012 9:01 pm 
:popcorn: :popcorn: :popcorn:


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One of Us
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Years on TRYears on TRYears on TRYears on TR

Posts: 945
Location: Colorado
Gender: Dude

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 Post subject: Re: Ground up build of "The Mistress" 10-1-12 thru 3-1-13
PostPosted: Wed Oct 31, 2012 1:32 am 
Curiosity :popcorn:

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Habitual Offender
Habitual Offender

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Posts: 357
Location: SL,UT
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 Post subject: Re: Ground up build of "The Mistress" 10-1-12 thru 3-1-13
PostPosted: Wed Oct 31, 2012 4:42 am 
I love seeing people do metal fabrication, just awesome watching something come to life.

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Needs Training Wheels
Needs Training Wheels

Years on TR

Posts: 13
Location: Hutchinson, KS.
Gender: Dude

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 Post subject: Re: Ground up build of "The Catalyst" 10-1-12 thru 3-3-13
PostPosted: Tue Nov 06, 2012 8:26 am 
Update: 11-03-12

Got some more stuff done, got my triangles mounted the frame and lined up with the front frame. Also, got my seat frame welded on and mocked up the seat. (This was a PITA :headbashing: )

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This is what the frame looks like mounted with a motor. This is my buddies frame so the seat is a little different, but you get the idea of the overall look. The front forks will be lower.

This was during the alignment of the motor mounting tabs. That was not fun and took the largest portion of the day to complete.

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Unfortunately I will be gone this coming weekend, so I will try to get some things done Wednesday (tom.) and update before I leave Saturday.

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Junior Mint
Junior Mint

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Location: Big Spring, TX
Gender: Dude

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 Post subject: Re: Ground up build of "The Catalyst" 10-1-12 thru 3-3-13
PostPosted: Tue Nov 06, 2012 9:40 am 
[quote="Studflucker"]Update: 11-03-12

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Digging the look of this seat frame! good work mang! :banger:


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Needs Training Wheels
Needs Training Wheels

Years on TR

Posts: 13
Location: Hutchinson, KS.
Gender: Dude

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 Post subject: Re: Ground up build of "The Catalyst" 10-1-12 thru 4-6-13
PostPosted: Mon Feb 04, 2013 12:36 pm 
Finally got an update worth posting. It's been a rough several weeks on the money front, but I got the ball rolling again this last weekend and finally got a rolling chassis.

Got my new wheel and hub with some cheapo spacers just for now.
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I'm planning on going orange and white as a theme, so the wheels will be powder coated from what they are now.
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The front and rear frame with the front end put on. Will be replaced ultimately with new forks and handlebars. These handlebars were only just laying around and useful to handle the frame. New wheel will be on there later on of course.
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Getting ready to align the motor/wheel and tac the motor mounts.
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Air compressor came in for the air ride.
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Testing out the new air valves.
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11-pole stator, rectifier, and flywheel in the mail, gotta power that damn compressor
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Back to aligning the motor/rear wheel and the frames. (the poor man's way, the only way I know how)
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I have to go to Vegas this weekend :banger: so I won't be doing anything this weekend, which sucks because I ordered all of the rest of the stuff for the air ride, which will most likely be here before this weekend, but I guess I will just have to wait a week till I get to install it. till then, peace.

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One of Us
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Location: Minnesota
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 Post subject: Re: Ground up build of "The Catalyst" 10-1-12 thru 4-6-13
PostPosted: Mon Feb 04, 2013 1:14 pm 
:popcorn: :popcorn: :popcorn: :popcorn: :popcorn: :popcorn:

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Needs Training Wheels
Needs Training Wheels

Years on TR

Posts: 13
Location: Hutchinson, KS.
Gender: Dude

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 Post subject: Re: ***THE CATALYST*** EFI Air Ride etc... 10-1-12 thru 4-6-13
PostPosted: Wed Feb 06, 2013 10:09 am 
Got some new parts in today :twisted:

All my parts that came in.
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New intake manifold
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Clocking flange
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Compression fittings for the air lines
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Better camshaft
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Stainless steel air cylinder for the air ride in the rear
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Rod end for the cylinder
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Have to wait till next weekend to test this stuff out :headbashing:

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