SuzukiSavage.com - The Project: Phase 4

MotoBuddha Serious Thumper Offline Let's roll! Posts: 1416 Charlotte, NC	Re: The Project: Phase 4 Reply #90 - 10/20/11 at 10:51:04 LANCER wrote on 10/20/11 at 10:46:12: Does RYCA use them ? I don't remember right off hand. No. And I'm going to use them just for looks, not function. This time.
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Gyrobob Serious Thumper Offline Posers ain't motorcyclists Posts: 2571 Newnan, GA Gender:	Re: The Project: Phase 4 Reply #91 - 10/20/11 at 11:10:35 MotoBuddha wrote on 10/20/11 at 10:51:04: LANCER wrote on 10/20/11 at 10:46:12: Does RYCA use them ? I don't remember right off hand. No. And I'm going to use them just for looks, not function. This time. There could be some cool ways to use them for the side panels and maybe the seat.
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spacepirates

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Re: The Project: Phase 4
Reply #92 - 10/20/11 at 11:25:50

Before you go spending another $50 on filters, you might see if you can rig up something else for cheap first, like an angled air intake system.

I think there are some pvc fittings that measure pretty close to the carb inlet diameter. Maybe if you got a rubber coupler for a few bucks you could slice and dice and make something work? I can't really see what kind of space you have from these pics (and i'm too lazy to look through the thread to find them). You could try a 90 degree elbow and point the filter down (or out the side, i guess).

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Gyrobob

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Re: The Project: Phase 4
Reply #93 - 10/20/11 at 13:27:29

spacepirates wrote on 10/20/11 at 11:25:50:

Before you go spending another $50 on filters, you might see if you can rig up something else for cheap first, like an angled air intake system.

I think there are some pvc fittings that measure pretty close to the carb inlet diameter. Maybe if you got a rubber coupler for a few bucks you could slice and dice and make something work? I can't really see what kind of space you have from these pics (and i'm too lazy to look through the thread to find them). You could try a 90 degree elbow and point the filter down (or out the side, i guess).

There's just not enough room between the cyl head and the RYCA battery box for any angle adaptors etc.

I'm working the same problem myself times 2. I think I have a solution. I'll post pics in a day or two.

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wombat

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Re: The Project: Phase 4
Reply #94 - 10/20/11 at 15:33:19

Forget buying another K&N. I've used a small clamp-on chrome pod filter from UNI. Fits with "almost" no cutting.

MotoBuddha wrote on 10/20/11 at 09:31:58:

As you can see, I started cutting up the battery box and frame (wish I had something other than an angle grinder) in order to get the air filter to sit properly. I thought I had it close enough to the correct position the other day after bending up part of the cross piece, but the carb wasn't completely seated in the intake boot.

http://i280.photobucket.com/albums/kk182/motobuddha/74ea4d67.jpg

So first I cut off the part of the crosspiece I'd bent up. That didn't help. It was hitting the battery box. So I cut back part of the box. That's when I saw the filter might be hitting the bolts. Some button head bolts would gain me a wee bit more, but not enough. (There are short screws in the photo, because I got tired of removing and replacing the long ones.)

http://i280.photobucket.com/albums/kk182/motobuddha/6f4933ca.jpg

The filter was still angled like this.

http://i280.photobucket.com/albums/kk182/motobuddha/9b3472cc.jpg

So I've decided to scrap the filter and try this cone shaped one.

http://www.knfilters.com/search/product.aspx?Prod=RC-1250

I was hoping K&N had a suitable size with an angled flange, but no.

Again, since I'm using a compact lithium battery, I'll have room for the end of the filter. If I need to, I'll move the rectifier elsewhere, like the inside back of the battery box.

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MotoBuddha Serious Thumper Offline Let's roll! Posts: 1416 Charlotte, NC	Re: The Project: Phase 4 Reply #95 - 10/20/11 at 17:57:27 A UNI is looking like a good solution. Thanks for the tip. I can only find them in a 2-pack. Does someone want the extra one?
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MotoBuddha

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Re: The Project: Phase 4
Reply #96 - 10/21/11 at 09:13:31

Paid a visit to the painter. The bodywork is in progress.

The tank originally had some dings where the windscreen mounting brackets hit it.

The stock cap was also in bad shape, so I decided to replace it with the old standard twist-on style. The old neck was cut off and a new one welded on.

We used some Caswell epoxy-based sealer on the inside to deal with any rust. The stuff dries clear and shiny, like bar top varnish.

You can see that we welded the ignition/lights plate to the tank and now he's smoothing in the seam.

By the way, here's his website: http://www.bdscycles.com/examples.htm

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« Last Edit: 10/21/11 at 11:25:56 by MotoBuddha »

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RpNSht

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Re: The Project: Phase 4
Reply #97 - 10/21/11 at 13:38:03

MotoBuddha wrote on 10/21/11 at 09:13:31:

Paid a visit to the painter. The bodywork is in progress.

http://i280.photobucket.com/albums/kk182/motobuddha/99bc6937.jpg
http://i280.photobucket.com/albums/kk182/motobuddha/cffd6ddd.jpg

The tank originally had some dings where the windscreen mounting brackets hit it.

The stock cap was also in bad shape, so I decided to replace it with the old standard twist-on style. The old neck was cut off and a new one welded on.

We used some Caswell epoxy-based sealer on the inside to deal with any rust. The stuff dries clear and shiny, like bar top varnish.

You can see that we welded the ignition/lights plate to the tank and now he's smoothing in the seam.

By the way, here's his website: http://www.bdscycles.com/examples.htm

i was going to have the ignition plate welded to the tank as well but decided not to after realizing how big of ordeal it would have been to get it completely flush with the rest of the tank. your tank is going to look awesome and cant wait to see it finished

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Gyrobob Serious Thumper Offline Posers ain't motorcyclists Posts: 2571 Newnan, GA Gender:	Re: The Project: Phase 4 Reply #98 - 10/22/11 at 18:02:54 Remember when I said I was going to work on the air filter fitment issue? Well,... they don't call me "Follow Through Bob" for nuttin' See reply #121 in Double RYCA build for the full story.
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MotoBuddha Serious Thumper Offline Let's roll! Posts: 1416 Charlotte, NC	Re: The Project: Phase 4 Reply #99 - 10/22/11 at 19:47:45 Yeah, I saw your thread. I fiddled with some things today. I think I might end up moving the rectifier to the exterior right side of the battery box, cut away most of the front and let the Uni filter stick through.
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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: The Project: Phase 4 Reply #100 - 10/22/11 at 22:14:23 Nice lookin job, good welds,, lots quicker & easier than a wedge shaped spacer.
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MotoBuddha

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Re: The Project: Phase 4
Reply #101 - 10/26/11 at 11:24:24

I got a PK-92 UNI filter and it solves all my problems. The carb is properly attached to the engine and the filter clears everything. The diameter is less than the K&N that Ryca supplies, but it's also longer, so it allows at least as much airflow, if not more. And since it's flexible (foam over a coil spring) it's easier to deal with.

As you can see below, there's no contact with heads of the battery box/tank/seat mounting bolts. It also clears the rectifier and the main part of the battery box.

It might have been unnecessary to cut the frame crossmember, and I obviously didn't need to cut away as much of the battery box. I'll go with this for now. Someday, when I'm feeling flush, I buy another battery box and have someone with more tools than me make the perfect clearance cuts.

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Gyrobob Serious Thumper Offline Posers ain't motorcyclists Posts: 2571 Newnan, GA Gender:	Re: The Project: Phase 4 Reply #102 - 10/26/11 at 17:38:38 What are you going to do about a crankcase breather?
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MotoBuddha Serious Thumper Offline Let's roll! Posts: 1416 Charlotte, NC	Re: The Project: Phase 4 Reply #103 - 10/26/11 at 18:01:02 It would probably be easy to cut a hole in the side of the UNI filter and then seal the end of the hose with silicone. But I'm also looking for a small catch can. And there are filtered plugs the size of the tube. I might do that. Oh, I have a second UNI filter because they only come in 2-packs. Does anyone want it?
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Built2Last Serious Thumper Offline Tempt Fate Posts: 1447 FTF Gender:	Re: The Project: Phase 4 Reply #104 - 10/27/11 at 06:53:00 How many cuts do you have to make to get it to fit? If not many, I'll take it
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