Rotten Orange build - Gary Fisher Aquila shifter buildup!
- Thread starter datz510
- Start date
Tonight, I got the cable housing cut and installed for the rear derailleur. Also found out that my derailleur hanger was severely bent. Got it bent back close to where it should be, but its still not right. Have a new one coming in the mail now. 
For now, I can use my old one, but am lacking top gear.
Its looking like I'll have the bike on the road for a test ride soemtime this weekend if all goes as planned.
For now, I can use my old one, but am lacking top gear.
Its looking like I'll have the bike on the road for a test ride soemtime this weekend if all goes as planned.
HI,
Just though of something you mentioned earlier about plumbing the fuel pump into the intake to take advantage of the intake pulses to operate the pump.....
If you use a boost bottle as you mentioned you may, would the pump idea still work?....I say this because the purpose of a boost bottle is to smooth the pulses...possibly resulting in not enough of a pulse to drive the fuel pump?
Nice job on the tank!....I liked some of the input concerning the "sight tube" to check the level in the fuel tank.....That brought me to the next level in thinking....How about a totally clear tank?....Now THAT would be wild....Fuel levels at a glance and you can even see if there is dirt in there!
Andrew
Just though of something you mentioned earlier about plumbing the fuel pump into the intake to take advantage of the intake pulses to operate the pump.....
If you use a boost bottle as you mentioned you may, would the pump idea still work?....I say this because the purpose of a boost bottle is to smooth the pulses...possibly resulting in not enough of a pulse to drive the fuel pump?
Nice job on the tank!....I liked some of the input concerning the "sight tube" to check the level in the fuel tank.....That brought me to the next level in thinking....How about a totally clear tank?....Now THAT would be wild....Fuel levels at a glance and you can even see if there is dirt in there!
Andrew
There still should be enough of a pulse to run the fuel pump. I am going to start out without a boost bottle and see how it does. I have a boost bottle ready to install once I get the pump going. I'm interested to see how the fuel pump running off the intake is going to cause the engine to behave.
The other possibility would be to tap the crankcase and use the pressure from the engine's intake cycle to run the pump. Granted, that would require doing a complete teardown of the engine, which I dont really want to do since this one is broken in nicely now.
I almost bought all the stuff to install a sight gauge, then decided at the last minute to just leave the tank as it is. (I am kinda diggin' the simplicity of it right now) I could always add one in later.
The other thing I could do is drill the bottom of the fuel cap to accept a dipstick to easily see the fuel level when the cap is removed.
I'm thinking a glass window in the side of the tank would be really cool for a sight gauge. I wonder if anything like that is available.
The other possibility would be to tap the crankcase and use the pressure from the engine's intake cycle to run the pump. Granted, that would require doing a complete teardown of the engine, which I dont really want to do since this one is broken in nicely now.
I almost bought all the stuff to install a sight gauge, then decided at the last minute to just leave the tank as it is. (I am kinda diggin' the simplicity of it right now) I could always add one in later.
The other thing I could do is drill the bottom of the fuel cap to accept a dipstick to easily see the fuel level when the cap is removed.
I'm thinking a glass window in the side of the tank would be really cool for a sight gauge. I wonder if anything like that is available.
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Finished the tank mount tonight and started on the front engine mount. Should have the engine mounted tommorrow morning.
I'm currently in the process of sealing the tank with a tank sealing system I got from KBS. Stop Rust - Outperforms POR-15 - Gas Tank Sealer - KBS Coatings - RustSeal in Colors This will seal up any potential pinhole leaks and prevent any rust from occuring in the tank in the future.
Also picked up a fuel filter, fuel line, and some parts to get the bike running.
Biggest thing after the front engine mount will be fabrication of an intake manifold to get the Dellorto carb sitting in the right position, as with my frame configuration, I can't use the stock intake manifold. Then its just getting an exhaust on it to go take a test ride.
I'm currently in the process of sealing the tank with a tank sealing system I got from KBS. Stop Rust - Outperforms POR-15 - Gas Tank Sealer - KBS Coatings - RustSeal in Colors This will seal up any potential pinhole leaks and prevent any rust from occuring in the tank in the future.
Also picked up a fuel filter, fuel line, and some parts to get the bike running.
Biggest thing after the front engine mount will be fabrication of an intake manifold to get the Dellorto carb sitting in the right position, as with my frame configuration, I can't use the stock intake manifold. Then its just getting an exhaust on it to go take a test ride.
HI,
As far as a glass window on the side of the tank that sounds fairly easily doable....I located this site and they talk about clear plastics....seem pretty durable/ strong / and hopefully gasoline resistant too (Physical Properties of Plexiglas, Lucite, Perspex Acrylics).
You're doing a great job on your build....I look forward to your progress!
Andrew
As far as a glass window on the side of the tank that sounds fairly easily doable....I located this site and they talk about clear plastics....seem pretty durable/ strong / and hopefully gasoline resistant too (Physical Properties of Plexiglas, Lucite, Perspex Acrylics).
You're doing a great job on your build....I look forward to your progress!
Andrew
Here are some photos of the mounting system I came up with for the tank. I also finished the tank sealer process, which took about 3 hours total time to do. The tank will get painted tommorrow. Unfortunately, I cant put any fuel in the tank for 96 hours after the sealant is applied, so I may not get to run the bike this weekend, but I can say it'll be darn close to ready to run.
In this photo, the tank is sitting on the filler end. The flat bars will work as a clamp to hold the tank to my rear rack. Amazingly, I just kinda eyballed everything. Did a couple of mockups on the bike to see where the rack rails would sit, but this was just all done by eye:
Here is the tank from the rear. The bolts are welded in place:
On the bike. I plan on slicing a couple peices of fuel line hose lengthwise and slipping it around the rails of the rack where the tank sits. This will help hold it in place a little better and provide for some vibration dampening:
The welding on the bottom of the tank. I drilled a couple of holes in the plate and did a couple of rosette welds for a little more strength:
In this photo, the tank is sitting on the filler end. The flat bars will work as a clamp to hold the tank to my rear rack. Amazingly, I just kinda eyballed everything. Did a couple of mockups on the bike to see where the rack rails would sit, but this was just all done by eye:
Here is the tank from the rear. The bolts are welded in place:
On the bike. I plan on slicing a couple peices of fuel line hose lengthwise and slipping it around the rails of the rack where the tank sits. This will help hold it in place a little better and provide for some vibration dampening:
The welding on the bottom of the tank. I drilled a couple of holes in the plate and did a couple of rosette welds for a little more strength:
Today, I ran into some problems locating the proper diameter tubing to make a new intake, so called it an early day after getting the tank finished. I used some 3/8" ID black vinyl tubing to sleeve the rack where the tank mounts on the bike:
Here are some new photos of the tank, finally painted and installed on the bike:
Also got all the SBP shifter kit brackets painted and installed. Need to tension the chain a little more before I finish up welding the front mount.
http://www.piratepathy.com/misc/gastank39.jpg
I used a bit of old bike innertube inside the motor mounts as well. These peices will be glued in place permanently to hopefully reduce vibrations a little.
Here are some new photos of the tank, finally painted and installed on the bike:
Also got all the SBP shifter kit brackets painted and installed. Need to tension the chain a little more before I finish up welding the front mount.
http://www.piratepathy.com/misc/gastank39.jpg
I used a bit of old bike innertube inside the motor mounts as well. These peices will be glued in place permanently to hopefully reduce vibrations a little.
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Also, Here are some photos of the fixed chain guide that I installed. This is going to work very well for this bike. The bike is sitting in 1st gear in these photos. I've set the guard so that the chain clears by about 1mm:
http://www.piratepathy.com/misc/gastank42.jpg
http://www.piratepathy.com/misc/gastank42.jpg
The rear rack is very strong. I found it on the Niagara Cycle Works website. The weight capacity on it was something like 110lb! It is made for pannier bags, but I thought it would look pretty cool on the 'Orange.
As far as the chain guard, I'll probably just leave it open. Whenever I got a bike as a kid, the first thing I did was pull the chain guard off. I like living dangerously I guess.
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Thanks!!! If you can weld, you can easily make one too. The most expensive part of it was the filler & cap ($30), but you could cut up a china tank and use the filler/cap off one of those. The rest of the tank cost me about $10 to make:WOW
that is, by far, the coolest gas tank ive ever seen.
Moroso Filler cap and neck: $30 (from JEGS High Performance - Your source for Edelbrock MSD Holley Mr. Gasket Moroso )
1/8" female NPT weld-in bung: $3 (from McMaster-Carr )
2 4" pipe caps: $4.50 total (from McMaster-Carr )
Nuts and bolts: $1 (from Home Depot)
6"x4" diameter exhaust pipe scrap $free (from my scrap pile)
4"x5" 1/8" steel plate $free (from my scrap pile)
I also bought a tank sealer kit from KBS Coatings that will easily do 8-10 of these tanks. Cost me about $40 for that, but I can reuse it for quite a few more tanks, so I'm not really counting the cost.
I will be posting up a Build-A-Tank thread soon with links to all the parts (and optional parts) one would need to make their own cylindrical gas tank.
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Being concerned with comfort after having a back injury a month ago, I ordered up a Brooks B67 saddle today in black. After reading reviews, the B67 definitely takes the cake as far as a comfortable saddle goes. Saw a lot of reviews that stated it works well for those with back pain. This will be nice, especially since I now must ride in a more upright position than in the past. Plus, I think it'll look great on the bike too!
It'll need breaking in, but that hopefully shouldn't be too bad. Mine is a new black version of this one:
It'll need breaking in, but that hopefully shouldn't be too bad. Mine is a new black version of this one:
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Datz, this is turning out to be quite the impressive machine. Can't wait to see it all buttoned up and running well.
I am envious of people that are able to take the time and care like this when they do things. I'm usually in a hurry for one reason or another. I'm also jealous of all the fun tools, that's for sure
I am envious of people that are able to take the time and care like this when they do things. I'm usually in a hurry for one reason or another. I'm also jealous of all the fun tools, that's for sure
Thanks for the comments!
I've put together my collection of tools over the course of about 10 years for working on cars. In the last 7 of those years, in my free time I've done a ton of fabrication work for offroad rock crawler trucks. I've designed and built truck suspensions, steering systems, etc. So, I aquired tools as I needed them.
My father has always told me that a challenging project is always a good excuse to buy a new tool. So, I saved my money and bought all the tools I needed over time.
Since I refuse to take my cars to a mechanic (you know the saying "you want it done right, do it yourself!") anytime work needed to be done on my cars, i picked up a few more tools here and there as needed to do the jobs, So, I ended up with a fixed car and the tools and knowledge for future use for less than what it would have cost to take the car somewhere to have it done.
I'm used to working with heavier steel, which is a lot easier to weld and work with, so scaling everything down to suit a bicycle has been a challenge for me. I've done exhaust work before, but the tank was something entirely new for me as well. And now I know how to make and seal one.
I'm a very patient person, and since I had been layed up for the last month after injuring my back, I had plenty of time to research and figure things out while I slowly put the bike together.
I've put together my collection of tools over the course of about 10 years for working on cars. In the last 7 of those years, in my free time I've done a ton of fabrication work for offroad rock crawler trucks. I've designed and built truck suspensions, steering systems, etc. So, I aquired tools as I needed them.
My father has always told me that a challenging project is always a good excuse to buy a new tool.
So, I saved my money and bought all the tools I needed over time. Since I refuse to take my cars to a mechanic (you know the saying "you want it done right, do it yourself!") anytime work needed to be done on my cars, i picked up a few more tools here and there as needed to do the jobs, So, I ended up with a fixed car and the tools and knowledge for future use for less than what it would have cost to take the car somewhere to have it done.
I'm used to working with heavier steel, which is a lot easier to weld and work with, so scaling everything down to suit a bicycle has been a challenge for me. I've done exhaust work before, but the tank was something entirely new for me as well. And now I know how to make and seal one.
I'm a very patient person, and since I had been layed up for the last month after injuring my back, I had plenty of time to research and figure things out while I slowly put the bike together.
Absolutely! I'm looking forward to getting this thing on the road. How is your bike doing?
