New full suspension build

old motorbike · Jul 7, 2009

I sold my old china girl and I'm building a full suspension home build.
Want to rear mount the engine this time.
Pocket bike motor, cvt transmission, dual disc brake bike.
Like last build, don't know how it will work

Technocyclist · Jul 7, 2009

I'm also looking forward to a full supension build. I still plan to use an in-frame engine from Manic Mechanic with a shifter kit and internal gear hub. Problem is - I can't find anybody who can build a steel frame like this. And using leaf spring instead of carbon chain stays. If there is someone here who can build frames like this. Just send me a PM... Thanks...

sdol · Jul 7, 2009

Technocyclist said:
I'm also looking forward to a full supension build. I still plan to use an in-frame engine from Manic Mechanic with a shifter kit and internal gear hub. Problem is - I can't find anybody who can build a steel frame like this. And using leaf spring instead of carbon chain stays. If there is someone here who can build frames like this. Just send me a PM... Thanks...

Look for a GT LTS 4 or 5 from the mid to late 90's They were a steel front triangle and aluminum rear triangle very similar to the frame you have linked to above. They also made the same frame in aluminum as well. I'd provide a link to a photo but it's not allowed in my current status.

sdol

ocscully · Jul 7, 2009

With luck here are some photos of similar bikes The first one is an AL GT LTS and the Second is a Steel Specialized FSR Giant also made a Steel Frame full suspension frameset about this time Mid 90's that would work for frame mounting as well.

ocscully

old motorbike · Jul 7, 2009

I decided to buy a bike with all the suspension done. My second one works great with just front suspension.

Goat Herder · Jul 8, 2009

Thats looks like a cool project check out Neat Times post he did some CVT rear mount builds. I do enjoy watching these builds go up!

old motorbike · Jul 8, 2009

goat herder said:
Thats looks like a cool project check out Neat Times post he did some CVT rear mount builds. I do enjoy watching these builds go up!

Thanks g h,
I'm so anxious myself to get started. I just got the transmission tonight. I have so many projects to finish before I can start. I have about 3 weeks 'til the bike, motor etc. arrives.
Neet Times really motivated this build.
Hope all the other projects are done and out of the way. This build will hopefully give acceleration, cruising, and more comfort.

old motorbike · Jul 22, 2009

Most all the components are here. The bike came with a bent rear wheel and hole in the tube.
That's fixed now.
Picked up a small trailer fender to make the engine- trans mount. Also some angle steel for braces.
My biggest challenge is how to make 2 freewheels to run the right drive on the wheel. I got an extra wheel and may use the old hub to cut off and weld an extra set of threads on the wheel to hold the 2nd freewheel.
Want to use the chinese gas tank painted to match.

Hot Wheels · Jul 22, 2009

did you make the exhaust ? that looks awesome ! ! !

old motorbike · Jul 22, 2009

Thanks, The exhaust on my 2d build is a pocket bike exhaust cut and re-welded to fit.

Hot Wheels · Jul 23, 2009

I Found The Pipe On Ebay Only 11.99. Thank You For Writing Me Back To Let Me Know What It Was From.

old motorbike · Jul 24, 2009

Hot Wheels said:
I Found The Pipe On Ebay Only 11.99. Thank You For Writing Me Back To Let Me Know What It Was From.

Hope you have success with it. I started using the pocket bike engines rather than the china girl engines for better performance. The pipe is thick enough to cut and re-weld easily.

Hot Wheels · Jul 25, 2009

here's a killer pipe on ebay item# 370182775234 only 11.99 + 14.95 shipping

old motorbike · Jul 25, 2009

I need to find a different one for the new build as it's a rear mount.

old motorbike · Jul 26, 2009

Working on the double drive right side challenge. Found a freewheel with a bike sprocket for 1 freewheel. Don't need multiple gears for the motorbike pedals. took an old wheel and removed the hub. Then machined down the old hub with the threads. Notched the end so it matched with the 4- way on the new freewheel. Machined the hub at the end so a bearing could be inserted for more support.
Another freewheel with sprocket installed on the 2nd one. All spaced and preloaded the wheel was fitted on the bike. The gear changers were removed and won't be needed. The chain was fixed with a re-linker.
Next: motor mounting.
Tank painted to match the bike.

old motorbike · Jul 26, 2009

My "machine shop" die grinders etc.
Now with wheel on bike and tank pictures.

old motorbike · Jul 26, 2009

Worked on it tonight some. Fitted the fender (engine mount) to the power train. Notched it to fit to align with the sprocket. tried to figure rear suspension travel. mounted the engine and ran out of energy.
Tomorrow, one more day off.

old motorbike · Jul 28, 2009

One last day off so I did as much as possible to attach the motor and brace it. Used my cheap wire welder to fabricate some brackets. Still needs a few more, but getting more rigid.

old motorbike · Aug 3, 2009

Finally got it running this weekend. Other than a bad sparkplug, the engine runs great.
Almost made it around the block then something broke in the drive sprocket. Back to the wheel again.
Hope I can figure it out so I can finish it.

old motorbike · Aug 4, 2009

Had a bearing failure and couldn't find one the right size. Now without a lathe, need to fabricate a bushing to fit with my hammer and chisel.
This has been the loneliest thread, Maybe I'm doing something wrong?

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