BonusParts' Genesis Astra 29er Build

BonusParts · Jan 23, 2014

New build time!

Seeing as i blammed a deer on the huffy (video link) I decided to build a brand new bike.

I settled on the Genesis Astra Cruiser walmart sells for 185. (bike link)

It's a 29er, has V-brakes, all aluminum. I've checked it out in the store and its a solid bike that just needs a quality assembly to be long lasting.

Seeing as I'm getting it shipped direct I have the joy of assembling it myself from the start. I will post pics of the bike and how it gets built once it ships/arrives.

The goal with this bike is to achieve 50MPH - and yes on a single speed. Also am seeking to make it as reliable as possible within the confines of the design.
I will update the thread with pics and such as the bike arrives/gets built etc. Also will update with GPS accurate speeds and longevity reports!

Here are the build plans (there will likely be changes later - and I'll update)

66cc Stage 2 Fred Motor w/ Stuffed crank.
- New copper base and head gaskets (.025" base, .016" & .025" head (to vary compression)
- upgraded intake/exhaust gaskets
- long intake tube
- nt speed carb (or the dellorto clone (ive got one just need jets))
Lightning CDI
KX80 or similar expansion chamber
Pirate cycles freewheel sprocket adapter & 36T sprocket
revised tensioner for drive chain
2+ gal motorcycle tank
hd thorn resistant tubes
revised clutch arm system (havent decided on cable drawn linkage or a roller guide)
front and rear racks
2x 1200 lumen LED headlights (wide angle)
homebrew junction box for headlight, battery and charging.
new led rear lights
replacing ALL hardware that attaches the fenders to 12.9 metric w/ locking washers and flange nuts.

I started this post earlier and then walked away, and now I haven't the slightest clue what else I had to post. I'll be back when i gather myself together again.
Matt

BonusParts · Jan 29, 2014

Update.

The bicycle is here - HOORAY!
My bike stand is here... holding above mentioned bicycle.

Here's the order sheet so far:

New clutch (big bevel wheel) assembly
clutch puller
suspension fork
front and rear rack
SBP front engine mount and HD air filter for NT
JuiceMotoParts.com head, base, intake and exhaust gaskets
motorcycle throttle assembly and grips
shock seatpost
seatpost clamp with rack mounting eyelets

Thats what i've purchased thus far. Boxes should start streaming in as of tomorrow!

I have the handlebars mocked up - just using a 23" mountain bike bar with a low rise. Seeing as the stem is adjustable I've got plenty of room to adjust. Need to wait for my seatpost to come to finalize my seat height and pick a bar position.

Revised my mounting situation for the headlights as from manufacturer it is certainly pitiful.

I'll post photos in a couple hours - gotta run with the fiance to the grocery store.

Matt

BonusParts · Jan 29, 2014

Here are some photos to accompany.

when the bike arrived...

unwrapping it a tad

getting everything down to the workshop... still waiting on my stand at this point....

so i figured I'd lay some paint down on my handlebars...

and once i finished that started taking the bike apart and ended up with this...

BonusParts · Jan 29, 2014

And then the stand showed up....

and to show you what all i've got going on - its a mess of bikes everywhere

so at this point its waiting for parts, so i took my fred motor and got busy!

And after some sanding and paint this is my fred motor. improved visually

BonusParts · Jan 31, 2014

More stuff came in today!!

Still waiting on the fork, i/e gaskets, the gas tank, clutch/brake levers, couple things.

BonusParts · Feb 19, 2014

Wow, really behind on updates. I'll hafta do that tonight. I've made some solid progress

BonusParts · Feb 21, 2014

so here are some bits of progress...

mounting brackets for my phone holder

here are a few mock up shots, the tank isnt mounted yet.

More pics coming. wish the upload allowed 10 attachments

BonusParts · Feb 21, 2014

And here are the pics of my switchbox some of you may have seen. I got carried away but it came out nice.

BonusParts · Feb 21, 2014

here is the finished switchbox with its 4 plug in harness ends. Nice and modular.

The wiring for the battery itself is not yet finalized. but it does all work

Stay tuned. More progress en route! I should be having my fuel tank mounted in the next week, as well as my exhaust attached. Using the SBP exhaust from my other bike, just so happens to fit! I was going to use a KX80 exhaust, but with this frame its just more work than its worth to do.

BonusParts · Mar 12, 2014

My brake light LED's are here, the work LEDs are here, and my special surprise kit has arrived. all are happily powered simultaneously without killing my SLA battery. That includes 1.0a out for a USB charger. Woot!

snelson203 · Mar 20, 2014

I have the same bike- just scored it at Wal-Mart for $139 on sale. Pulled all the stickers off and am going to motorize it next. Couple of questions: The rack on the back of yours, what brand and where did you get it? #2: I see you replaced the quick turn seat clamp. What kind of clamp is that and where did you get it? Thanks.

BonusParts · Mar 21, 2014

The rack I sourced from ebay. Its a sunlite. Rated for 55lbs.

The seat clamp i also sourced on ebay. they list under "rack mount clamp" or "seat post clamp mount"

I could have just used a standard bolt for the original seat clamp, but I like the idea of a dedicated set of bolts to attach my rack to!

Good luck with your project, Stay tuned because I think mine ought be running soon.

In other news -

The SBP chamber has been HACKED and made to be a bit more useful.

Pics to follow.

Mungface78 · Mar 26, 2014

Nice build you got

BonusParts · Mar 28, 2014

Well today ended up being a relatively productive day.

I affixed my rear lights to the pannier bags, that was a nice handful of small zip ties - very discrete.

I also took advantage of all my peripherals being off the bike to finalize locations and mount my multiple led strip setup. I went a tad overboard trying to keep the wires hidden, but overall its a clean job and they follow existing cables as not to attract extra attention.

My phone case arrived and that is mounted on the handle bars - its AWESOME. will have heads up GPS etc on my bars

.

beyond that I am down to only a couple "significant" projects.

-mount the tank
-find headlight battery enclosure
-finalize expansion chamber and mount it

I will try to get some photos soon but my basement makes a crappy backdrop.

BonusParts · Mar 31, 2014

Some pictures to catch you up!

BonusParts · Mar 31, 2014

BonusParts · Mar 31, 2014

SPECIAL FEATURE LOL

snelson203 · Mar 31, 2014

That gas tank is out of control. You will have a 600 mile range on one tank of fuel. Maybe more!! Looking good

BonusParts · Mar 31, 2014

snelson203 said:
That gas tank is out of control. You will have a 600 mile range on one tank of fuel. Maybe more!! Looking good

I wish i could say i believe you but its only 2.5 gallons. I have a hard time seeing how i'll near 200mpg at 40mph lol
- I guestimated it to be about 225 miles as my "working" range. ~90mpg
Thank you for the kind words !!

BonusParts · Apr 7, 2014

Alright, SHOULD BE RUNNING this week. Im going on a vacation soon so I need to finish before I depart.

I just got the TurboBuick tensioner and its AWESOME. AWESOME. catch that? AWESOME.

Could nearly run without a tensioner at all, but the addition of the roller wheel and nice PROPER bearings make it a silent machine

BonusParts' Genesis Astra 29er Build

Member

Member

Member

Attachments

Member

Attachments

Member

Attachments

Member

Member

Attachments

Member

Attachments

Member

Attachments

Member

New Member

Member

New Member

Member

Member

Attachments

Member

Attachments

Member

Attachments

New Member

Member

Member