TollyFab MK2 MOD01 - first bike

[T0lly]

Great forum here, has helped my first project greatly.
The TollyFab MK2 MOD01
I started with a Grubee Skyhawk 66cc kit. Bike is a Schwinn Skyliner. I had planned to use a Trek 820 but it was too small and needed frame mods to fit. I was skeptical when I ordered the kit, but it has met my expectations. I quickly threw this together a couple days ago and have some tweaking to do. I had to modify the intake and move carb to side to clear the frame. The bike has grip shifts on it, so I couldn't use the twist throttle. I robbed a thumb trottle off a mini atv I had in the shop. The Muffler would not clear the pedals so I cut it off and will relocate. After the first test ride I am hooked, these are a blast. I have a small metal fab shop and look forward to making some custom rides. So here is a sneak peek of my first one, more to follow.

[Salty Gator]

Originally Posted by T0lly

Great forum here, has helped my first project greatly.
The TollyFab MK2 MOD01
I started with a Grubee Skyhawk 66cc kit. Bike is a Schwinn Skyliner. I had planned to use a Trek 820 but it was too small and needed frame mods to fit. I was skeptical when I ordered the kit, but it has met my expectations. I quickly threw this together a couple days ago and have some tweaking to do. I had to modify the intake and move carb to side to clear the frame. The bike has grip shifts on it, so I couldn't use the twist throttle. I robbed a thumb trottle off a mini atv I had in the shop. The Muffler would not clear the pedals so I cut it off and will relocate. After the first test ride I am hooked, these are a blast. I have a small metal fab shop and look forward to making some custom rides. So here is a sneak peek of my first one, more to follow.

Excellent build Tolly....you faced the same exact issues I had....having to fabricate a side draft intake.....my pedals hit the muff pipe too.. ( easy fix ...just vice it and bend )......and you're rigtht. these *SCREAM*. LOL. have fun mate !


Laters,
Salty

[Nicholas Marker]

How do you actually bend the muffler? Do you heat it up???

Thanks

Nicholas

[Salty Gator]

Originally Posted by Nicholas Marker

How do you actually bend the muffler? Do you heat it up???

Thanks

Nicholas

Not at all....just vice it at it's greatest length...( the pipe not the actual muffler ) and GENTLY push it the direction you need it to go......... don't force it .....take your time.....patience is a virtue

Good luck,
Salty

[T0lly]

Looks like I can post my video link now.
This is the very first test run, just minutes after installing the kit.
YouTube - Motorized bicycle mk2 mod01 01

[T0lly]

Well after the first run I found a list of things I wanted to change. So I tore the bike down and started modding.
I did not like the stock clutch cable setup, it had a bad angle and set the cable against the engine.
I made a bracket that set the cable higher and away from the engine case.



I threw it together quick and already plan another version, but I will run this for a while.

[T0lly]

The stock exhaust did not fit well so that was next on the list. I started by cutting up the exhaust manifold. I noticed the hole ID on the flange did not match the pipe ID. So free performance upgrade just opening up the flange a bit.
Before

After

It is not great but hopefully better.

[Saddletramp1200]

Great job Like your work!

[Salty Gator]

The sheer ingenuity of everyone in here never fails to impress me......


Thanks,
Salty

[T0lly]

On the exhaust I cut and rotated the tubing, added and extension, and then added a turnout on the end. This put the muffler along the centerline of the frame tube, away from the pedals. The turnout is to keep the hot gases off the tire.


I am not real happy with how it looks, more function over form.
Do you think I need to add a support for the muffler?