The cycle is now SHOW-READY!
Does that mean it is totally done? Heck no. I still have to do the headlight/tail-lights/horn/turn-signals wire harness and the DC/DC converter to power it.
But nobody looking at the cycle at the energy fair needs to know that!
Anyways, here's what I did today...
Had to take out the top batteries to get the middle section of battery rack out. I had to take that out because yesterday I managed to pop a weld. I snapped off the little ring of pipe that holds the middle rack to the lower battery and the frame.
I reground it, re-welded it, painted..... Waited for hours for paint to dry, then put it all back together.
At least I had other things to do while the paint was drying.
Since I had the middle rack out anyways, somebody mentioned to weld my two stacks of three washers to make spacers. I finally did that!
See! Washers, now welded together!
I also did not yet have the return spring for the rear brake. It turns out that the spring hooks onto a peg that's on the MUFFLER! Well, there's no muffler anymore, so it's time to FABRICATE something!
The muffler would have mounted below the right passenger foot peg, so I made a small metal plate with two holes, one for the foot peg bolt, and one for a 1/4-20 bolt for the spring to hook on. I put the small bolt through, welded it, then ground off the head (It wouldn't have fit otherwise.)
After that, it was time to work on the chain guard. I found a hunk of aluminum computer rack server rail. It was about the right thickness for a big spacer between the motor mount plate and the side of the cycle. I cut it 9" long and ran it vertically. Here, you see it left of the motor.
I then went to work trimming some salvaged plexiglass to the right size, with cut-outs to go around the bolt-holes and odd shapes on the right. The server rack material featured threaded holes, so I just found the right size screws and drilled a couple matching holes through the plexiglass.
I also cut a narrower piece of plexi for the top. I am still not sure of the best way to attach it. Right after I took the following photo, I just ran a piece of electrical tape over the corner of the two pieces. It actually looked pretty good... I might just use some clear silicon or something to finish that corner.
I don't know if it comes through in the photo or not, but it looks like the chain and sprocket are in an aquarium.
Here's the cycle again, once I finally got it back together (but before I got my tools put away!)
Here's the other view, with horrible orange background lighting.
Here's where I will be for the next four days! Hope you can make it too! Look for me, I'll be the guy by the motorcycle in the "Open ReVolt" shirt
