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Z3n's Project Barn

Managed to knock out a few shift knob installs for my friend's Element and NSX:
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My Einstar arrived, and true to superfastmatt's video, it is excellent.
Here's the bike stripped down for scanning:
pMXEGwOl.jpg

And in the scanning software:
yKNij6yl.png


I checked the axles and the wheelbase was basically dead on spec, so their accuracy targets are pretty good. Definitely good enough for design work like I want to do.

I got the mesh imported into Gravity Sketch, and this took me about 4 hours to do, including some time learning the toolchain:
0cnCSbxl.png


Started over once I got a sense of the tooling, and my second 4 hour session ended up with this:
0L8PkSal.png


Just gotta draw the rest of the owl now! Hopefully I'll be able to finish up the designs in Gravity Sketch this weekend, and then it's time to figure out the process for transferring the fairings from Gravity Sketch to something I can 3d print.
 
Last edited:
I'm good at computers, totally.

(thanks, fixed!)
 
That is interesting.

Besides frame specs what else is the goal with the new software??
 
Having 3d scans of the bikes makes making everything a lot faster and cheaper.

For example, I can scan the 350 frame and motor assembly, scan the KTM Rally fuel tanks, put the whole assembly in the CAD software I use, line everything up, and then design every part digitally, instead of having to mock it up by hand and then test fit. I can validate fit with 3d printed parts, and then do all of my finals in the material that fits the use case (probably aluminum, sometimes it'll be carbon, or TI). There's some stuff you have to look out for, like clearance on moving parts, but that's all relatively easy.

Basically, should just be easier to build stuff faster, which means more projects done and more time riding them :)
 
I feel like that amount of self image would be destructive. :laughing
 
Okay, been a long time since updates, but haven't been idle, just haven't had a chance to update!

Let's see what we've got:
Picked up some Nepros thin ratchets while waiting for my replacements from Craftsman to show up.
3FvegpCl.jpg

This is a 10mm deepset on the 3/8ths drive ratchet, very low profile:
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Printing thin / narrow things with the 3d printer didn't go great:
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I realized that joining these surfaces was going to be pretty time consuming to get good fit up, so figured I'd deal with 3d print problems latter. Little experimentation with some wrapping:
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Tried to do some dampers on the box van, unfortunately, the axle swap meant these didn't fit how I'd hoped:
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Did manage to get my lightbar installed:
xq44RNnl.jpg


Some test fit work on an 890 OEM tank shroud on the RC890:
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Brake booster swap in the pontiac:
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Did some testing of a SpeedBox cam on my buddy's 890, which delivered the promised +7 HP after some cleanup on tuning and power:
yaZByh9.mp4


Quick welding break to make a t-post adapter for my demo hammer:
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And then it's back to the old way of building assemblies - patterns and bent sheet aluminum:
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Quick break to pick up a Stark Varg (I'm not keeping it - a buddy wanted my preorder, I wasn't in a place to buy it, and Stark wouldn't pass my pre-order on, so I just bought it and immediately sold it to him):
MNSlFwBl.jpg


Quick ride review, though, these things are incredible. I did a little roll around and it doesn't have the issue my KTM FreeRide had of just digging a hole the moment the rear loses traction, the suspension felt really good, slides cleanly and progressively, chassis is wonderful, and all around just a wonderful motorcycle. I'll head down to his place and shred around on it more in depth at some point, but what a killer bike. Wish it made sense for me to keep it.

It's the alpha model, and I took it on a quick spin up the street and mother of god, it started doing a rolling burnout at 50mph that didn't stop until 75mph when I let off, and looking at the power spike, it only needed 62hp delivered to the rear wheel to make that happen. 80HP in that thing is un-usable without supermoto wheels.
 
Anyways, at this point it's about 3 days before the first trackday of the season, and it's time to kick into high gear on fixing everything to get it ready. As you can see from the last picture, the rear tail assembly is floating in space, so need to slide a little titanium under that guy to support me.
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Don't judge my messy workspace, I have a process:
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Took me a while to sort getting the pipes fit up properly, but nothing a little extra welding rod couldn't fix.
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Ended up with this:
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And after a little bit of vinyl wrap, here we were at the track:
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Trackday went great, no mechanical issues, no problems with the new subframe, bike ran great, bike felt great, was back within 1.5 seconds of my PB at Ridge by the end of the day with old tires and plenty of places where I could easily regain time.

Bike has a couple of small items to sort out, and then it's time to rip the interior out of the box truck and set it up for moto-hauler / repair / welding duties, finish up the KTM 300 / Electric Motion E-Pure Race powertrain swap, and start in on building the rally bike. And help some friends with their 790 / 890 tunes, a couple of trips out of state to see friends, and some camping with the wife. Busy busy, but absolutely can't complain. Next trackday is ORP weekend with 2Fast in May, some offroad riding weekends, getting everything set up to start selling exhausts and tunes, and onwards and upwards!
 
Holy shit you have been busy!!! :wow

Glad the bike worked for ya at the track. :thumbup

Nice blurg on the SV too. :Port
 
Yeah I’m real happy - it’s taken a lot of work to get to the point where I can do something like that and come out with a reliable outcome (knock on wood, of course :laughing ).

Traveling to see family but will be back at it soon, have some house projects that I elided that are on the stack to finish up too :)
 
Back from travel, managed to get out yesterday to rip around on the dirtbike a little:
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Also spent some time this weekend helping a friend with their van builds, teaching a buddy to weld, and otherwise just enjoying the change of the season towards summer.

Today managed to fit a hitch to the box van, which has let me install a MotoTote:
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Gone this weekend camping, ORP next weekend, probably wont make much progress on any of the projects, too busy out enjoying time with family and friends. Might be able to rip out the E-moto enough to bring it out this weekend, that'd be fun if I have enough time to get it all together. Clock is ticking on the Rally build too...
 
Amazing stuff!

Geek head on, I love those Nepros ratchets - where did you find them?
 
Thanks!

I ordered the ratchets directly:
https://neprostools.com/collections/drive-tools

Check the dimensions to make sure you're getting the style you want. I went with:
1/4 drive:
https://neprostools.com/collections/drive-tools/products/a000074
3/8 drive long:
https://neprostools.com/collections/3-8-sq/products/a000162

If I were to order again I'd consider getting the slightly longer 1/4 drive one:
https://neprostools.com/products/a000075

175mm vs 125mm.

I found them because my buddy who owns the NSX was researching the tools used to work on the NSX and KTC makes the plastic spudger that's recommended for removing the NSX fairing panels. There's also some incredible stuff floating around on their site in terms of "display" tools:
https://neprostools.com/collections/urushi/products/b000290

I'd used my Craftsman stuff through 2 rebuilds for a decade plus, figured it was okay to drop ~$200 on new ratchets. I also picked up the Gearwrench set, these aren't 4x the niceness of the Craftsman replacements or the Gearwrench stuff I snagged for beating on, but they're definitely nice enough that I'm always happy when I reach for them :)
 
Very nice. I really like Japanese hand tools. I've had a mild fetish ever since getting a set of Vessel Megadra Impact screwdrivers...so useful.
 
I also have a set of Vessel screwdrivers, critically useful during the rebuild of the CBX :)
 
Well, it's been a hot minute. What have I been up to since then?

ORP was...a trip of extremes. Got the bikes prepped, 890 in the box, mototote on the E350 with the supermoto on the back:
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Rolled out with the box van, van was feeling a little down on power in stop and go traffic - right up to the point where I lost the brakes on the freeway in stop and go traffic. Managed to limp it to the shoulder, saw this:
Wrm6onNl.jpg

Of course, being an old Ford 460, once it stopped while heat soaked, it didn't want to restart. After letting the brakes cool down, wailing on them with a pipe wrench for a bit (what, it is what I had), I got the brakes reasonably unstuck. Finally it started back up, and as I got prepared to carefully proceed back on to rejoin the freeway, the engine died again and I ended up rolling backwards down the shoulder with no brake booster. Slammed it into park, fully engaged the ebrake, and after a heart stopping few seconds, it came to a stop with a giant hop of the rear wheels. I wondered if in that moment I lunched the transmission, but when I got it restarted again, it moved forward and I was able to limp it to a local auto parts store, where a combination of mechanical persuasion, grease, etc, managed to get things unstuck and running again.

Proceeding up the mountains towards ORP, everything was pretty fine, although I stopped at the top of the grade to check the brakes were still fine, which they were, and it wouldn't restart again. After a bunch of coaxing, I managed to get it to the freeway onramp, when one of my friends calls me, asking if he'd just driven by me on the side of the road. I mention what's going on, he waits a little ways ahead, and I get it rolling down the hill and cooled down enough to run normally again. With the two of us in caravan, I'm feeling okay about things, and head onwards to the racetrack.

Day saved! I've been delayed by a few hours, but so goes it. Except...about 60 miles from the track he calls me and says the truck is smoking. I don't notice any loss of power, all guages are normal, everything seems fine. He couldn't quite tell what color the smoke was, so I was thinking maybe it was running a bit rich, perhaps sucking some gas or oil past the rings? After about 15 seconds, the smoking dissipates, so I just cross my fingers that I only need to go a bit farther and we'll be all good.

Another 20 miles or so later, another big puff of smoke. It again, dissipates after a bit, and so we just decide to try and make it to the track as is, because stopping means it probably won't restart for awhile again, and I'd really like to make it to the track.

And then at about 35 miles from the track, I apply the throttle, and the revs climb but the truck doesn't go forward. I pull over into a convenient turnout, and ATF is pouring out of the transmission. Fuck, I can't fix that on the side of the road. I call my friends, and we start pulling stuff out of the box van so I can get to the track before they close.

Did I mention it's the weekend where the Aurora Borealis is showing up? Pretty surreal to be pulling your stuff out of the back of a van and swapping everything to another vehicle under the lights:
dNNvnKal.jpg


With my friends showing up, we tow the box van to a better spot, and sprint towards the track so we can get there before the gates close at midnight.

Bonus image from my friends at the track, while I was dealing with a blown up box truck:
fqYQM77l.jpg


Anyways, I figured I'd just deal with the box truck when I got back. From here on, it's trackday time.

First day, everything goes pretty well. I don't love the CW configuration of ORP, but things are going pretty smoothly. Then my buddy's SV650 makes a weird noise, and suddenly doesn't want to idle. Because I've spent too much time screwing with SV650s, I figure it's running on one cylinder - because they're even firing V-twins, one cylinder cutting out at idle doesn't create a super obvious problem, it just won't idle. I discover it's no problem to grab the front exhaust header when it's running, so that's the cylinder that's not firing. Injectors spray, spark plug fires, maybe lost compression for some reason? With the spark plug pulled, blocking the spark plug hole with my finger causes it to get blown out under compression, so we figure the next thing to check is timing. Maybe the cam hopped a tooth somehow?
or2B1Jxl.jpg


Ahh, yes, it hopped a lot of teeth. Our assumption is because this motor was in a pretty severe front end crash, with the front valve cover being damaged, and we think it's quite possible that it actually caused a break in the cam chain that eventually gave up the ghost. But hey, it still ran, and if the valves are shut, and the motor hasn't seized, the front cylinder is just an airspring now, right? Rip the cam chain out, crank the idle, and let's ride the SV325:
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Totally worked just fine, honestly, just extremely down on power. If you'd like to see what an SV325 can do on track:

After a productive day, time to enjoy the sunset:
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Can't argue with round two of the Aurora:
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So, on to Day 2, in my favored configuration. Things are generally going pretty well, when our other friend takes his 675 offroading, and when getting back on track, it is smoking heavily - he gets black flagged, pulls off, parks it in the dirt. Figure we've lost that motor too, but we can sort that out later. Managed to do reasonably well for myself at Superpole, 5th fastest overall for the day, and the fastest 600 class bike:

I also had a great time looking at my data traces on my friend's Racebox, so I figure it's time to invest in some proper datalogging, more on that later.

We go to drag the 675, and discover that it has converted itself to a drag bike:
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In his offroading session, it snapped the lower linkage, and all the smoke was from the rear tire eating itself alive on the exhaust. But hey, he didn't crash it!

So after all that, it's time to sort out the box truck coming home. After some significant arguments with AAA as to what is a motorhome vs what is a box truck, they finally agree that it is what it is registered as (a motorhome), and they'll tow it...except that it is mothers day, and that means a $3300 tow, of which they'll cover $500. I decide I'll work my local network instead and see if I can get someone else to tow it back in. Finally, the next day, we manage to get that sorted, and at 2AM it arrives home:
XUanoXjl.jpg


What a weekend. After all of this, I also realized I wasn't going to be able to make it to COTAH, so canceled my registration for that, unfortunately.

Went to spectate a buddy at Oregon Trail Rally, was super fun. Loved this little Ford:
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bDVo6OFl.jpgl

Can't argue with the famous Ferrari swapped Subaru:
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And a quick break for some dirtbiking in the woods:
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And then it was time to build an exhaust for Minimoto, and do some final work on the bike for the 6 hour NW Minimoto endurance race:
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Unfortunately, we also discovered that a mis-installed rotor meant that the keyway was totally destroyed, and the rotor wouldn't hold position anymore:
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May as well try to weld the hell out of it and see if it holds up. No time for a proper solution, no time to get a replacement motor, just gotta cross our fingers and see what happens.
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Sadly, it doesn't hold up, and we end up riding the B bike. In spite of all of the travails of the race, we end up taking first in class and 3rd overall, which we were pretty pleased with.
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With the endurance race in the books, it's time to get after the datalogging. After some research, I splash out for an AIM Solo 2 DL, as it seems to support everything I want, namely pulling data from CANBUS to add to data traces.
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With some research, internet sleathing, and a bit of swearing, I ended up with this:
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For this particular trackday, all I really wanted was the ability to see my TPS settings and lean angle. With those pulled from the ECU, I felt like I was pretty good to go. I had also finally destroyed my ceramic knee sliders I'd had for approximately 17 years, so picked up some of the Held Timber sliders for giggles, figured it'd be a fun diversion if nothing else.

I don't exactly end up having the best first day at the track, it dawns wet and pretty marginal, but we manage to shake off the cobwebs and get some good tracktime in. I also get the chance to play a little on my buddy's Kramer, which is quite the experience.
XDVAkyIl.jpg


Setting up for the second day, I have a pretty good back and forth with a ZX10R, thanks to the new datalogger, you can also see my TPS settings. Thanks to the new datalogging setup, you also get overlays.

The funniest part of it all to me is that I would have sworn that I was basically flat out through Turn 9, but the reality is I back off to about 70% throttle for about 1.5 seconds every time. As it turns out, I spent a lot of money on datalogging to be called a liar and coward, but hey, how else are you gonna improve?

We had a pretty wonderful session where I was on the Kramer with my friends, the best video of that comes from my friend following me on his 890:

The Kramer is just such an unbelievable joy to ride, it's one of those bikes that is just sublime in terms of what it lets you get away with, how it communicates to you, the freedom of line choice, and the confidence it inspires. Such a wonderful bike, if you have the chance to ride a Kramer 690/890, or RC8C, god, take it up. They're truly unbelievable trackbikes, as evidenced by my easily running a 2:01 on a my third session ever on the bike, just 4 seconds off my PB times with a ~50hp deficit over the 890.

Wooden slider review: Quite nice. Watch out for splinters.
Awoh5A1l.jpg


Also, after this trackday, I really missed the box truck. I'd been having dreams of swapping in a Ford Ecoboost 3.5 twin turbo motor, as I absolutely adore that motor, but I realized that'd be a ~2 year project, and even then, I'd still have an ancient chassis, so maybe it was time to just suck it up and spend the money. My spouse had been telling me to just spend the money on the nice thing for ages, but I'd never really been able to convince myself it was worth it. And then I stumbled upon basically the perfect boxtruck - the cabover I'd always wanted, with the new Vortec 6.6, ~45k miles on it, 16 foot box, and a fully set up interior with more E track than I've ever seen, folding worktables, an inverter, a side door, all the nice creature comforts (AC, cruise, carplay, etc), and a rear liftgate for loading and unloading bikes. After chatting with the dealership, I drove down south, and picked it up.
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I was pretty sure I was going to enjoy the experience of driving a cabover, but I wasn't quite prepared for how much I really loved it. Incredible visibility, plenty of power, just a delightful rig as a whole.

Obligatory stickers:
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I'll need to decide on what I'm doing for setup on the interior, but it's perfectly fine and functional as is right now. I'll throw a bunch of random supplies in there and slowly build out the modular interior of my dreams, no reason not to with the flexibility in the interior:
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Most recent project is setting up some Ohlins forks in my buddy's SXV forks. Ohlins doesn't make cartridge kits for these guys, but with some digging, I was able to discover they do make kits for the 48mm Sachs fork the Aprilia uses, because it was also used on certain GasGas and KTM models. My friend was willing to take a flier on it, so we blind ordered the kit, hoping that I'd be able to make the appropriate adapters for it, and with some prototyping, ended up with this:
krxWIAml.jpg


From the bottom:
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And with the fork cap installed:
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Top threads straight in, as the upper is the same. The adapters will show up in aluminum shortly, and I'll be able to throw them back together with SKF seals and ship them down to my friend. Just need to figure out the rear shock.

Besides that, the purchase of the box truck has put a bit of a hole in the bank accounts, so it's time to simplify, sell a bunch of bikes, settle down on what I'm going to be doing for parts manufacturing. Also on the list is: Finish up the datalogging for the 890, do some more dirtbiking, go to some kart tracks on the sumo, maybe try to sneak in an adventure trip or two, some longer trips working from the box van, more trackdays...no shortage of stuff to do!
 
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wow, you have done more stuff in the past 2 years then I have in 10, amazing stuff!!! imma pm you about your 890r build
 
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