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Old 11-17-2015, 11:47 AM   #371 (permalink)
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Visionary, have you considered hub centre steering. I realise that this would be a project on it's own, but it has many advantages over telescopic forks. With your fabrication skills it may be the easiest and most cost effective way out of your current predicament.
I was invited to a gathering of the UK FF'ers recently, and I happen to know that one member has several new hub centre steering setups in his workshop. I don't know whether he is prepared to part with one, e-mail me if you're interested and I'll pass his details on.

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Pete.

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Old 11-17-2015, 10:35 PM   #372 (permalink)
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Hi Visionary , I love the way your project is progressing !
Do you have any photos of your door slide setup? I've been planning to use draw slides but your approach looks a lot neater .
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Old 11-18-2015, 12:04 AM   #373 (permalink)
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I was wondering what happened to you guys!
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Old 11-18-2015, 05:36 AM   #374 (permalink)
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I'm just hanging around ( building a boat) and waiting for the new Australia Post 110cc efi bikes to come up for auction second hand ... I can't buy a new one ! They're very similar to a Honda Innova and I reckon they will be the perfect base bike for me and far better than the standard CT 110

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Old 11-18-2015, 03:38 PM   #375 (permalink)
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Hi Frank, I'm still around and still running the Dreamliner, I'll post an update soon.
Peter, as you said a perfect base for your project, better suspension than the Cub, 4 gears and Efi, I'm sure you can acheive the much coveted 200 mpg.
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Old 11-18-2015, 05:02 PM   #376 (permalink)
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200 mpg IMP (165 US) or 1.4l/100 km is certainly possible with that bike, gets less ham 2l /100km standard.

It's a much smoother machine than the CT110 Ironside, almost everything about it is better and smoother. I look forward to your update !
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Old 11-18-2015, 07:18 PM   #377 (permalink)
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200 mpgUS with that new Postie would be possible with streamlining. I wonder how fast it could go then.
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A stock Innova gets 130 mpgUS. As far as that goes, I can get 130 mpgUS with my CBR250R if I did a long run at under 40 mph.
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Old 04-25-2016, 07:17 PM   #378 (permalink)
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Update 21 Still working at it!

Although my rate of posting updates has fallen off (apologies to those following) I have been able to maintain a regular pace of work, which I suppose averages out at 10hrs/week. I’m working on a final list of jobs before presenting to the DVLA for registration, and as I work my way through the list, I’m posting significant completed jobs

Front fork modifications
This part has been one of the most technically challenging jobs, not least because it’s been months between taking things apart and putting them back together, which coupled with my lack of familiarity with telescopic fork internals, has made me proceed cautiously (read: slowly). In the picture below you can compare the old and new bodywork solutions


The latest bodywork solution (nearest camera) features a smooth hood line (Bonnet in UK), which is actually a sectioned Ford Fiesta panel. The original body design was forced to allow protrusion of the CBR600 telescopic forks through the top. The image below shows the tight clearance under the hood and the modified fork yolks (Triple Trees US). The lower yolk is a two-part fabrication with significant offset to retain tyre clearance on full bump.



The new version features Kawasaki ZX6R front forks from a 99/00 model year, which I believe are “Showa” units. I stripped them down (one at a time to avoid confusion) and tested the spring rates (it’s a dual rate spring) before cutting 100mm out. I retested the spring once modified, so I know what changes have been made, but its all guesswork because nobody knows how this type of vehicle should be engineered. I’ll find out how good my guesses are when it hits the road!



The outer fork tubes also need shortening by the same 100mm and the internal damping rod and valve adjuster rod by the exact same amount, all so the original function can be retained. Refilling with oil requires some thought, as the volume measurement cannot be used, so the “air-gap” method is used.


The steering mechanism is now fully finished, including the steering damper and a nice steering bar. This just needs the crash protection cover, smart phone mount, and leather wrapped grips.
From the images you can see that I have chosen to revert to the original Honda CBR600 headlamp unit, from the twin aftermarket units fitted to the original. I prefer the twin lamps but the MSVA Test is quite specific about the method for beam adjustment. The factory Honda unit has a great system, and my homemade mounts are a bit “Heath Robinson”, and since its all about getting a registration then function beats form, this time!
The nose height is even lower on this version, but the lamp is still within UK legal height limits. I have the turn signal lamps to mount and the front side sections of bodywork to construct – still lots left to do! But I can see it making it onto the road for late summer, fingers crossed.
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Old 12-30-2016, 02:32 PM   #379 (permalink)
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Has there been any progress on the bike in the last 8 months, or has it been "resting" the way so many of my projects tend to do?

cheers,
Michael
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Old 01-01-2017, 08:39 AM   #380 (permalink)
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Hi Michael, thanks for enquiring about progress.
Yes is the short answer!
I still manage around 10hours per week on average, but unfortunately Ive got out of the habit of posting up news. I'm not really sure why that is because I enjoy the comments and insights that forum members provide.
I think the problem comes from the fact that most of my work seems quite slow to take shape. In the early days, everything was progress, but now I seem to spend so much time going over things and perfecting their operation. Quite often it feels like I'm going backwards

The bike is ready again for another test run, which I will video. I hope to complete this in late January and post up for all to see.
In the meantime I will post a few still images this week.

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