Wild Dog Adventure Riding

Riding: Plan, Report and Racing => Racing Section => Topic started by: darthvader on October 29, 2013, 06:35:42 pm

Title: Yamaha WR450F Amageza build
Post by: darthvader on October 29, 2013, 06:35:42 pm
Last year's Amageza was a total disaster.  I totalled my bike(XR650L) on the first day, but at least I managed to get through the qualifying on the Friday unscathed.  On the Saturday, the first day of the race, about 40kms into the race, I high sided the bike and destroyed everything.  Hole in engine casing, navigation tower destroyed, twisted frame and a broken rib.  Broken ego and tail between the legs, I decided to head home and get nursed back to health by my lovely girlfriend.

So a few months back I decided to enter this year's race, the 2013 Amageza Rally.  First priorities was to get fit and build a new bike!  I made myself a deal, that if I could lose 10kgs in 2 months and get my resting heart rate at 50, I would by myself a WR450.  I was about 90% on my way reaching my goal and an almost new 2011 WR450F was advertised on Gumtree.  I decided to take the plunge :

(https://lh3.googleusercontent.com/-QPppi4fFDdM/URQDJ7yv2wI/AAAAAAAAE2o/tQuN83tF-ck/s640/20130207_210721.jpg)

I knew building this bike was going to be a mammoth task, so I approached my very good friend Reynard from Scorch(now Beserker) exhausts/canopies. He knew the history of my 2012 Amageza experience and he offered that I could use his workshop to race prep my bike.

As you can see, the bike was practically new, not a scratch!  Ready for the hacksaw! :
(https://lh6.googleusercontent.com/-g4M7ZZV9Sqc/UdHat-HNT9I/AAAAAAAAFGU/M7LVexwKO64/s640/20130701_131128.jpg)

Then the shock email from Alex: "Amageza 2012 cancelled".  Aaargh, fudge! I spent about 13,000 ZAR on imported Safari tanks, many extra hours in the gym, no alcohol policy and bunny food! So I gave up, well, not really, I just dropped two gears and decided I will prepare the bike for next year's race. No rush.

The tanks arrived and I fitted them :
(https://lh4.googleusercontent.com/-yNO3Cdb_O3Q/UdHXpAQGrEI/AAAAAAAAFEk/F4SMw8ftkI0/s640/20130701_135123.jpg)

and from the back, sexy! :
(https://lh4.googleusercontent.com/-M29z5SkZPJM/UdHXVVC5ZTI/AAAAAAAAFEc/1DvPJ7kr9hk/s640/20130701_135134.jpg)

I had the idea of fitting an oil cooler, but I managed to get in contact with the Australian Safari Legend Rod Fagotter. He said they are running the bikes stock, "you just have to ride fast enough!". The pictures below gives you the idea of the clearance behind and in front of the tank fitted :

(https://lh4.googleusercontent.com/-PNEHWeBcMvc/UdHWv8wfQmI/AAAAAAAAFEM/aJZTlthZSvg/s640/20130701_135156.jpg)

(https://lh4.googleusercontent.com/-90HtHA4FiBM/UdHWfzAfdhI/AAAAAAAAFEE/diNFBQp-G68/s640/20130701_135209.jpg)

A Jagg oil cooler will never fit in there and if it does, it will restrict the air flow, not to mention the bitch of a mission it would be routing the oil lines.  This is why most of the factory rallye bikes have the oil cooler fitted on the navigation tower, just below the headlight.

From the front :
(https://lh5.googleusercontent.com/-DtLvcteQduw/UdHWL174JBI/AAAAAAAAFD8/ytUaXLCNSvg/s640/20130701_135215.jpg)

Also, the radiator braces by PSP racing are essential, as a simple fall on the tank would pop it like a zit to the front.  This came with the bike, so no extra expense there.

The rear tank acts as a widened seat :
(https://lh3.googleusercontent.com/-CjxEGrTQb9A/UdHV-h9bzjI/AAAAAAAAFD0/crruHS-DOBw/s640/20130701_135221.jpg)

I really should have upgraded my seat, it caused major fatigue.  After massive liasons your bum gets so tired, then you tend to stand to fix that problem and that causes sore feet and knees.  The bike was kitted with extra wide pegs, so that helped a bit.

Routing the exhaust was a bit above my skill level(which is none), so I consulted my trusted friend Arrie from Scorch(now Beserker) exhausts/canopies to help me with this task.  It took him a good part of 15 minutes to do this!?! Crazy.  We used a picture from an Australian Safari bike with the same tank setup as a reference.  In fact, it showed us how we don't want to do it  ;D  :

(https://lh6.googleusercontent.com/-R8kNJJD05D4/UdHVMkx6j1I/AAAAAAAAFDc/HCTqoZegAwc/s640/20130701_163009.jpg)

Lets see how it fits along the tank :
(https://lh5.googleusercontent.com/-Mq13FVWaizo/UdHVAgoVriI/AAAAAAAAFDU/h15NiD5xejs/s640/20130701_163015.jpg)

Arrie ducking for a profile shot to see if the lines are right :
(https://lh3.googleusercontent.com/-38uBcnzfsZs/UdHUiU70QjI/AAAAAAAAFDE/ILK4qGw4Q0g/s640/20130701_163105.jpg)

Tacked and fits perfectly, exactly like we profiled it :
(https://lh3.googleusercontent.com/-X0C8KO4U2m8/UdHUEhsXFXI/AAAAAAAAFCw/-qDnjbeeKks/s640/20130701_165344.jpg)

Crazy routing skills! :
(https://lh5.googleusercontent.com/-OqLZtXqwr7U/UdHTrbGa3RI/AAAAAAAAFCg/Mqbcqrp96LI/s640/20130701_165354.jpg)

Very close to the fuel line, but we will make a plan later :
(https://lh6.googleusercontent.com/-wZjE8y0SOKs/UdHTfmUeIkI/AAAAAAAAFCY/C8riFbYR4v0/s640/20130701_165358.jpg)

Exhaust with tank combination :
(https://lh4.googleusercontent.com/-2WsHn7f1BA4/UdHS1Frm-6I/AAAAAAAAFB0/ELkqBx9sWwQ/s640/20130701_165434.jpg)

You'd think that the bike is almost done, but far from it!  I almost fooled myself there for a moment.  

By this time I was still in go slow mode, so I got bored with exhausts and welding, making brackets for exhausts and tanks, etc.  So I started on the navigation tower and the mounting point.  Now, I know there are other people who has done big plates along the side of the bike, for the navigation tower.  I opted for a bigger job, a clamp or mounting point on the frame.  Why? Well, I thought it is going to be much stronger and less friction on the frame.  I started stripping everything of the head :

(https://lh6.googleusercontent.com/-Kn-9t_TfLzI/UdsHEAhyrjI/AAAAAAAAFMo/daf4MM3VEDQ/s640/20130705_083526.jpg)

I marked all the wiring, so I could assemble it all again, or at least reroute it without understanding the wiring(lazy).  It seems that Yamaha have a nice "square" on the head and it is actually square, I checked :

(https://lh5.googleusercontent.com/-Ei71rKbGF9E/UdsG4Wgka-I/AAAAAAAAFMg/WqIZ_LCvBQU/s640/20130705_083517.jpg)

Kaalgat :
(https://lh6.googleusercontent.com/-HKB_pkeZ91I/UdsHrxNDWxI/AAAAAAAAFM4/yqe1bwEBCu8/s640/20130705_090252.jpg)

Kaalgat from the back :
(https://lh6.googleusercontent.com/-H80FMV-vNx8/UdsIA2CT2AI/AAAAAAAAFNA/tBpRbyaSWFs/s640/20130705_090306.jpg)

Next step is to manufacture a bracket.  After a few lessons from my friend toolmaker Reynard, I started milling! This was my first time, but I had a good tutor :
(https://lh3.googleusercontent.com/-IkO9ItBLLzo/UdsGol_pC7I/AAAAAAAAFMY/X9sgrdcROIY/s640/20130705_145525.jpg)

The finished product.  
(https://lh3.googleusercontent.com/-PDsPblOGCik/UdsGMDa3-yI/AAAAAAAAFMI/Nr-dfn7NX9I/s640/20130708_163613.jpg)

My tutor measured it and I passed! Less than a 1/10th of a mm out! Nice!  The clamping will be done with some high tensile steel Allen head bolts with dual washers, a split washer and a Nyloc nut!

Over engineered enough!? :
(https://lh4.googleusercontent.com/-QXkZJOhKdtM/UdsF8EU88aI/AAAAAAAAFMA/7FKpdXTOsZ8/s640/20130708_163615.jpg)

I must admit, I was(and still am) worried about the clamp breaking off the frame when I clamp whatever needs to be clamped.  Whatever goes in between the clamps, needs to be a overly tight fit - we are talking rubber hammer tight.

Another profile picture :
(https://lh5.googleusercontent.com/-Ab85lsoylfY/UdsFsLetIvI/AAAAAAAAFL4/3dxnjCYnrA0/s640/20130708_163618.jpg)

Looking good, now to tack it :
(https://lh6.googleusercontent.com/-_qT4Ao5eBAI/UdsFILbWQQI/AAAAAAAAFLo/zJ7R9g-_ebE/s640/20130708_163640.jpg)

Tacked and ready for the next phase :
(https://lh4.googleusercontent.com/-maWrXDWfM-I/Uef_QfSD8KI/AAAAAAAAFQM/dihw5RarCS0/s640/20130718_152141.jpg)

Square, phew! :
(https://lh5.googleusercontent.com/-0mGnmEJP4Vo/Uef_dhCzWEI/AAAAAAAAFQU/mvcMz7BwUxY/s640/20130718_152148.jpg)

It should do it. Side view :
(https://lh6.googleusercontent.com/-n4uGDsLKm6Y/Uef_ucnZDsI/AAAAAAAAFQc/6qp7uKZMMkI/s640/20130718_152155.jpg)

Then I got the news that the Amageza Rallye is changing to the Amageza Safari and that the race is actually going to happen!  This was awesome news, so I shifted gears again.  Running around like a headless chicken I changed focus and started designing navigation equipment.  It is clear that I have ADD.  Perhaps I just like building things in stages, perhaps it gives me time to ponder about what I have done so far... I give it time to settle ;)  

Back to navigation!  First thing for me was a compass, CAP unit or CAP repeater.  I opted for a standalone z-axis tilt sensitive compass.  Normally you by a RNS, ERTF or ICO repeater, that plugs into your GPS.  This then reads the NMEA sentences and displays the heading.  For the normal guy this might be limiting, since we use our own GPS and that means that the USB port will be used for streaming the headings to the repeater, which in turn means that the GPS cannot be charged while riding.  I did not want this, so, I rolled my own!  After sourcing a serial 7segment LCD from China, I started writing code.  Implementing the "Mean Angle of Circular Quantities" and averaging a few readings, I got a beautiful compass going :
(https://lh6.googleusercontent.com/-QYjYVQQS5H8/UeUVi9a5upI/AAAAAAAAFPo/Bqv2BXxOOTs/s640/20130716_114041.jpg)

It was a bitch to implement, since the serial LCD was "serial", but it did not come with a built-in driver, only a shift register.  The datasheet... well... China... they don't care.  After a few days I eventually got them to send me some code, but it was Assembler.  I have not done Assembler in years, but after an hour or so, I ported it to C.  First flash of the microcontroller and it worked! Awesome!  Unfortunately I ran out of time and I kept popping regulators on the night before the race, so I did not fit it in the little box I sourced  >:(

I also built a GPS tracker, complete with it's own blackberry battery and SD card.  It writes a GPX file and it should have satisfied the organisers.  I even added a Nokia 5110 screen to the whole thing!  This came in well under a 1,000 ZAR :
(https://lh6.googleusercontent.com/-8jmKtT6vtGY/UeTxHHj1f7I/AAAAAAAAFO4/Ux9JlHxkpTw/s640/20130716_085607.jpg)

I am working on building my own ERTF, or a least a close knockoff!  Anyway, both these projects were not done in time.  Everything work, it was just a regulator and housing issue.  Watch this space.

Still not 100% certain that I would get my bike done in time, so being human, you go at 80% of the pace - not sure if one should invest more time, just wasting more time at half the pace  :-\  My girlfriend gave me a lovely peptalk and forced me to commit to this mission again.

Back to navigation, it is a rallye after all.  With the clamp tacked, I could start profiling my tower and equipment tray.  I started with a base member :
(https://lh3.googleusercontent.com/-zRh11ProLwk/Uf_3koodhjI/AAAAAAAAFV0/ZXjFnXBfp1w/s640/20130805_155431.jpg)

Wood is easy to profile with, and it supports the equipment tray with all the gadgets mounted.  This way I can get on the bike and get a feel for the dimensions.  I am going to be doing a lot of jigsaw cutting, fitting, refitting and adjusting, so hardboard for the main members :
(https://lh6.googleusercontent.com/-ZHdoFmjFEXY/Uf_3DZ39O7I/AAAAAAAAFVk/GsmZLNXCKyk/s640/20130805_164507.jpg)

I cut a piece of 1mm aluminium at the same time for the equipment tray.  This was just to make sure that the bender I had could bend the tight angles.  I cut some holes it in, because I wanted to see how everything would look mounted.

The next step was to create a base or main member for the tower.  I used a 25mm piece of HDPE for this.  It was basically a very rough sketch on a piece of paper that I held agains the tower I had built from hard board.  I transferred the drawing to my 25mm HDPE stock.  The milling machine was my new weapon, well, I did not have time to draw parts in Solid Works and get the laser cut.  Good thing, because I made major changes towards the end.  The first rough draught of my part :
(https://lh6.googleusercontent.com/-8KISU34iClM/UkCj7kKDsoI/AAAAAAAAFYg/FyW9sb2G7ao/s640/20130923_141311.jpg)

I then drew a template of the side members.  I just made it up, with no real plan, but with enough to spare space if I wanted to mount extra brackets or shit on the side :
(https://lh6.googleusercontent.com/-NPNZJ0v_1Jg/UkCjh8X-vuI/AAAAAAAAFYY/8no_Q1hpGe8/s640/20130923_141327.jpg)

And this is how you create identical copies :
(https://lh6.googleusercontent.com/-BkSK6v-8XJM/UkCkLR8gWSI/AAAAAAAAFYo/bZ11SEq43Lc/s640/20130923_144009.jpg)

I drilled some strong triangular spaced hole in the main member and moered it into the clamp(remember, rubber hammer) :
(https://lh3.googleusercontent.com/-aO6rXJGTv4U/UkbY3zjhxeI/AAAAAAAAFak/Q3IPacJL8P0/s640/20130928_144622.jpg)

The next workshop tool I needed to master, was the lathe!  I decided to use nylon for the spacers between the side members of my tower.  Got some roundbar stock, decided on a width and turned a few parts.  Well, I piloted a hole first, then cut as many lengths as I needed :
(https://lh6.googleusercontent.com/-bsOvtceqGgA/UkbYwWIqbSI/AAAAAAAAFac/21-HskWXIpI/s640/20130928_144652.jpg)

Nylon is a bastard, if you are not careful, it will snap a drill bit chop chop!

Two identical side members finished :
(https://lh6.googleusercontent.com/-0ew6KUlhCv0/UkbYrcnWpNI/AAAAAAAAFaU/xOj0WZrrJ2o/s640/20130928_144727.jpg)

...and it was ready for first test assembly :
(https://lh6.googleusercontent.com/-cJ96JdXeVIg/UkbYLhAN2DI/AAAAAAAAFZs/DzoF6uAC1ho/s640/20130928_145308.jpg)

The other side mounted; we are getting somewhere :
(https://lh6.googleusercontent.com/-QfE9J1l8Blk/UkbYYs6RJ3I/AAAAAAAAFZ8/LbmLEuGHGVo/s640/20130928_145800.jpg)

Another view :
(https://lh5.googleusercontent.com/-H0VWSeqxVCs/UkbYffhdQfI/AAAAAAAAFaE/ucTBo97wCHU/s640/20130928_145803.jpg)

All the parts mounted, but it looked like a tortoise in heat! mmm... I will check this later with the rest of the stuff taped to the tower.

Tortoise in heat :
(https://lh4.googleusercontent.com/-ZRNOYhpVXYA/UkbX-pCv4hI/AAAAAAAAFbA/0KnEtPkl19o/s640/20130928_145809.jpg)

mmm, lets worry about it later :
(https://lh5.googleusercontent.com/-MHvFn06cWZo/UkbXd8JHC9I/AAAAAAAAFY4/UTyKFYodBoY/s640/20130928_151322.jpg)

To create some rigidity, I needed to add squares or triangles in this design.  The navigation tray needed to be mounted on something strong and the requirement was that this part should be fairly crash proof. I decided to use aluminium for this part and started the manufacturing process.  I took a block of stock aluminium, drilled 3 holes(so I can adjust height) and a gutter for a piece of round bar that the navigation tray will eventually swivel on : (https://lh3.googleusercontent.com/-NBLFNHx10SA/Ukw4oojQ7vI/AAAAAAAAFck/Ep0esIS8-QY/s640/20131002_151529.jpg)

It was a bit on the heavy side, so I made it a bit lighter :
(https://lh3.googleusercontent.com/-hxCbL22rt7o/Ukw4iOkqNlI/AAAAAAAAFcc/cfGWS_mfXT8/s640/20131002_162750.jpg)

I used the lathe to turn a piece of round bar with about 2mm extra on the diameter of the clamps that came with the roadbook :
(https://lh6.googleusercontent.com/-mWPaWDFi7iQ/Ukw4uhgrarI/AAAAAAAAFcs/NCSSePTTSGQ/s640/20131001_170047.jpg)

Welded it together :
(https://lh5.googleusercontent.com/-ACVKRP-lsfw/Ukw4CjYGWOI/AAAAAAAAFb8/9IrTXOWoA4s/s640/20131002_170310.jpg)

Check if we are still ok with widths, etc. :
(https://lh3.googleusercontent.com/-quUy4MUVmGs/Ukw3yeQF5-I/AAAAAAAAFbs/-ne18X0y2WM/s640/20131002_170432.jpg)

Next up was the navigation tray.  Took a piece of 3mm aluminium sheet and replicated a tray on my first 1mm template :
(https://lh6.googleusercontent.com/-tYoo2_i6jyM/Uk2N5mzCBzI/AAAAAAAAFeg/mEB0kMxYNAY/s640/20131003_150226.jpg)

Perfect! :
(https://lh6.googleusercontent.com/-jvndOQrO6Yg/Uk2NuUAPjLI/AAAAAAAAFeY/2NCgkUh8UtU/s640/20131003_170017.jpg)

I clamped it all together :
(https://lh3.googleusercontent.com/-97bR6K8knKc/Uk2NKagkqhI/AAAAAAAAFd4/pvtKASk8WnU/s640/20131003_170745.jpg)

...taped it all up :
(https://lh3.googleusercontent.com/-znLwswDh9Z4/Uk2NCQbEe8I/AAAAAAAAFdw/Jm7GIR6oxqw/s640/20131003_171132.jpg)

... and yes, it does not look right. Shit! OK, so I did some research, looked at factory rally bikes, just to get a feeling for how far forward this tortoise head of mine can be.  I opened Gimp(linux photoshop) and got working.

MUCH better :
(https://lh6.googleusercontent.com/-KUpExEartho/Uk2vtKvQVfI/AAAAAAAAFe4/4GROXHP8T5w/s640/navtower-photoshop.jpg)

Luckily I gave the main member enough room for the whole thing to move back.

I then did a preliminary fitting of the navigation equipment on the tray :
(https://lh4.googleusercontent.com/-rdLgtDl228g/Uk74bCoRuUI/AAAAAAAAFhI/75o70Xr7QCw/s640/20131004_182830.jpg)

The g-clamp still in place, as I wanted as little holes as possible in the 10mm HDPE sides :
(https://lh4.googleusercontent.com/-vroB2vRu5dI/Uk73Yb708MI/AAAAAAAAFg4/QI_nuVkSu2g/s640/20131004_182841.jpg)

It is starting to look like a rally bike!  The tower moved back, with all the nav equipment mounted :
(https://lh3.googleusercontent.com/-kNUMyLc8pKA/Uk72tZ37M2I/AAAAAAAAFgI/U1dc4YaU7Bs/s640/20131004_183422.jpg)

Front view :
(https://lh5.googleusercontent.com/-_v1CkWx1Fd8/Uk72kW7tbSI/AAAAAAAAFgA/tZgQSB28j-A/s640/20131004_183435.jpg)

The main member was too long(mind the pun), so I had to take the tip off :
(https://lh6.googleusercontent.com/-Rfysf0-6vdg/UlEYs3LN5KI/AAAAAAAAFmM/ky7q1AYMgCQ/s640/20131005_104826.jpg)

With everthing disassembled, I decided to add another supporting bolt through the whole tower :
(https://lh5.googleusercontent.com/-KsMEPXDC1o0/UlEYdwocc4I/AAAAAAAAFl8/aFuDkIoF-Hk/s640/20131005_105337.jpg)

The new finished unit with all the main parts :
(https://lh6.googleusercontent.com/-2d64lx0XgVI/UlEYLXCT5zI/AAAAAAAAFls/BPmNCft6Oz8/s640/20131005_110008.jpg)

.... to be continued ....
Title: Re: Yamaha WR450F Amageza build
Post by: zetman on October 29, 2013, 07:20:06 pm
DUDE Dis befok like die build report  :lamer: :ricky:
Title: Re: Yamaha WR450F Amageza build
Post by: Dwerg on October 29, 2013, 07:51:02 pm
Awesome. Sien uit na die res
Title: Re: Yamaha WR450F Amageza build
Post by: the_BOBNOB on October 29, 2013, 08:08:11 pm
brilliant stuff
Title: Re: Yamaha WR450F Amageza build
Post by: BigRED on October 29, 2013, 08:35:11 pm
Wow awesome, can't wait the rest  :ricky:
Title: Re: Yamaha WR450F Amageza build
Post by: darthvader on October 29, 2013, 08:39:53 pm
[EDITED]
Title: Re: Yamaha WR450F Amageza build
Post by: DeeCeeBee on October 29, 2013, 08:44:43 pm
Respect!! Can't wait for more.
Title: Re: Yamaha WR450F Amageza build
Post by: Vance on October 29, 2013, 08:45:50 pm
Wens ek het jou skills. Mooi gedoen. Hou ons op hoogte!
 :thumleft:
Title: Re: Yamaha WR450F Amageza build
Post by: Bossiekop on October 29, 2013, 08:57:20 pm
Definitief Ingeskryf..... :thumleft:  :thumleft:
Title: Re: Yamaha WR450F Amageza build
Post by: darthvader on October 29, 2013, 09:10:44 pm
With everything assembled it looks strong to me :
(https://lh6.googleusercontent.com/-pUVFdDUPWyE/UlEXxmr2msI/AAAAAAAAFlU/jjloxDAcT-4/s640/20131005_110018.jpg)

Mounted back on the bike :
(https://lh6.googleusercontent.com/-l6jddaocCwI/UlEXaBQM4aI/AAAAAAAAFk8/5dAG8SguEro/s640/20131005_110225.jpg)

Drilled the final holes for the navigation tray swivel and mounted it all up :
(https://lh6.googleusercontent.com/-1163kcZysbQ/UlEWZgZuj7I/AAAAAAAAFkU/3sFZKPYeQ0U/s640/20131005_110552.jpg)

Added some Hyde hand guards to the setup :
(https://lh5.googleusercontent.com/-3RNpdbj_wxQ/UlEV0fNG5DI/AAAAAAAAFj8/k1CHEiovC-M/s640/20131005_112325.jpg)

It is not a bad product, but you get better.

ICO and roadbook switch mounted :
(https://lh3.googleusercontent.com/-M9GW-c0BRJA/UlEVPyrmxzI/AAAAAAAAFj0/DE3SQLPN1-s/s640/20131005_115106.jpg)

RB switch(also from Chris @ Desert Lizard) :
(https://lh3.googleusercontent.com/-QZoKLweaFg8/UlEU7SKkb-I/AAAAAAAAFjs/cmUqyyWO92E/s640/20131005_115112.jpg)
Title: Re: Yamaha WR450F Amageza build
Post by: darthvader on October 29, 2013, 09:38:17 pm
The light/indicator/hooter switch was a bit of a problem.  There was just no space for it after I mounted the ICO and RB switches, so I relocated the whole unit to the navigation tray :
(https://lh6.googleusercontent.com/-CwnYy6x81_w/UlEUPg2iUXI/AAAAAAAAFjU/J7ffC43c0EI/s640/20131005_140626.jpg)

I also added 2 waterproof panel pushbuttons.  They had no clear function, but they proved to come in handy later!  The box on the top right was for my digital compass(CAP repeater).  I am still pissed off that I did not make an greater effort in finishing that project.  I would not have gotten lost on the first day if I had that!

I was running out of time and the quality of my workmanship and general creativity plunged a bit.  I neede to refit the original bikini fairing and headlight cluster, so these brackets were born :
(https://lh6.googleusercontent.com/-73UpaiV-BRk/UlETHYYXSmI/AAAAAAAAFi0/xdGizPMeEpU/s640/20131005_145714.jpg)
However, I did strengthen them with a crossbar and 2 small triangles in the initial bends.  They did survive a MOERSE crash on stage 3!  So they are good :)  The only thing I do not like about them, is that it is fairly difficult to create a new part in the field or bivouac.  Anyway, I digress.

Flimsy :
(https://lh3.googleusercontent.com/-Tr0vJFoMKbo/UlES1jwrE3I/AAAAAAAAFis/R6P7okvOr5U/s640/20131005_145940.jpg)

But remember, I did add the crossbar  :-\

Next up! Electrics! I relocated the ignition switch to a really cool spot :
(https://lh3.googleusercontent.com/-KuQfuJvO5LY/UlEPgR-shUI/AAAAAAAAFh4/Ub7S49K13LY/s640/20131005_150800.jpg)

I even shortened the one nylon bus, so that the switch's space could fill the gap, but unfortunately there was just too much wiring and I had to relocate it again.

Before I could do the wiring, I had to take everything off again.  By now I could take the tower off, unplug everything just short of 5 minutes!  Building your own bike is not just satisfying, but it gives you so much confidence in case something goes wrong on race day/night.  You know every weak point and skim point!

Ah, where was I, taking everything off to do the final weld :
(https://lh4.googleusercontent.com/-CkFEEaluK5E/UlMHzg_qiqI/AAAAAAAAFno/h4NXCarDGJk/s640/20131007_180845.jpg)

I had to remove forks, bearings, seats and anything close to that head and heat it up, up to who knows how many degrees(checked it with temp gun, cannot remember).  I was very tense at this stage, but Reynard has welded MANY bike frames, swingarms, prosthetic legs before.  It was quite a difficult weld to do, as there was a moerse big gap that had to be filled... it did not seem to bother Reynard much *shrug*  I can weld aluminium when everything is clean, flush and hot.  If you need serious aluminium or stainless steel welding to do, I highly recommend him!

Partially assembled(check the crossbar between the 2 fairing brackets) :
(https://lh3.googleusercontent.com/-iOk3-7A_OL8/UlMFopDtiyI/AAAAAAAAFmk/bUnlpYuvmQE/s640/20131007_192521.jpg)

I found a Scott steering damper on Gumtree for R2000 bucks.  This really saved my ass multiple times in the race.  I have never ridden with one before, but I knew how to change it for the terrain.  It works!  I had to lengthen the bracket and re-slotted the part that bolts to the frame(painted it black) :
(https://lh6.googleusercontent.com/-MJ6rhq3WnxQ/UlRcdmFfLXI/AAAAAAAAFpc/hzoUOqfv6lI/s640/20131008_143329.jpg)
Title: Re: Yamaha WR450F Amageza build
Post by: Orangejuicepony on October 29, 2013, 09:57:12 pm
Sub
Title: Re: Yamaha WR450F Amageza build
Post by: darthvader on October 29, 2013, 09:58:38 pm
ADD kicked in again.  Not really, I just wanted to hear the bike's engine and before I finished up the electrics, I decided to focus on the exhaust and fuel lines for a few hours.  First up, a bracket to hang the exhaust from the rear tank :
(https://lh6.googleusercontent.com/-5BQ8KAFJ41w/UlWA7c97fNI/AAAAAAAAFqk/72gL1ffuzug/s640/20131009_141755.jpg)

Then, to fix the exhaust mid way to the frame, I turned a small stainless spacer, tapped it M8 and made a diagonal cut.  This I would weld to the exhaust and then a bolt through the frame would pull it nice and tight :

(https://lh5.googleusercontent.com/-164jpW54B_8/UlWAkV2-JJI/AAAAAAAAFqM/ZkEeUiIZZk0/s640/20131009_160106.jpg)

It was such a nice little part, before I had to cut it :(

Welded to the exhaust :
(https://lh3.googleusercontent.com/--fKjnZ9RJ98/UlWAXffQb1I/AAAAAAAAFp8/V8N3srA-NPk/s640/20131009_163630.jpg)

Bolted to the frame :
(https://lh6.googleusercontent.com/-lY9ihf58ayg/Ulep4RK9M8I/AAAAAAAAFs0/sxuqGr-ihso/s640/20131010_183248.jpg)

The fuel lines was not that hard to route.  There are two lines coming from the rear tank and one from the front.  So I drilled two entry holes in the airbox and one exit hole that will go to the carburettor.  I joined the rear lines with a T-piece and then rear and front supplies with another 2piece to the carbs.

Entry(right) and exit(left) on the left hand side of the bike(joining rears with T-piece) :
(https://lh4.googleusercontent.com/-r1uIKwm-L_k/UlWBu2cnhmI/AAAAAAAAFrM/sWA0Mx5-hjI/s640/20131009_132219.jpg)

Entry rear left :
(https://lh3.googleusercontent.com/-N6w-QAaC90g/UlWBDzla7NI/AAAAAAAAFqs/Cpcil-I1I58/s640/20131009_132253.jpg)

Entry rear right :
(https://lh6.googleusercontent.com/-ePI33MtUR3Q/UlerS--L7WI/AAAAAAAAFt8/s2DJSro82UY/s640/20131010_183156.jpg)

Exit left :
(https://lh4.googleusercontent.com/-4EtUCbUWiTU/Uleq9dObKeI/AAAAAAAAFts/vvGE8ZmIjZg/s640/20131010_183210.jpg)

T-piece joining front and rear fuel lines to the carb :
(https://lh3.googleusercontent.com/--Y3YTl9x3ss/UleqSlwpixI/AAAAAAAAFtM/piwqY2eGeiA/s640/20131010_183232.jpg)

Luckly my eye caught this one.  I made two extended tabs that would protect the fuel tank from the nasty shrouds of the radiator.  The ones Safari provided were real crap :
(https://lh3.googleusercontent.com/-7RK0EMHVZl8/UleprKsjuDI/AAAAAAAAFss/Xpusboc673I/s640/20131010_183307.jpg)

To fix the fuel line issue on the right, I used some fibreglass wrapping to shield the exhaust :
(https://lh5.googleusercontent.com/-fMeaYTh2jjE/UllasljNzhI/AAAAAAAAFvM/gvxwNS1kmJU/s640/20131012_100836.jpg)

... to be continued ...
Title: Re: Yamaha WR450F Amageza build
Post by: darthvader on October 29, 2013, 10:20:00 pm
A week before the race I realised that I have not spent one second thinking about my suspension.  So I phone my friend Chris @ Desert Lizard again.  We had a Skype session that evening, planning the weight on the rear suspension and he went scouting for a new rear coil.  I did not have time to phone around, so Chris helped me out.  The next day, my super stiff coil was delivered.  Happy days!

Apparently you can remove the coil without doing this :
(https://lh4.googleusercontent.com/-lj4QbYyhFOI/Ul20IC1-YoI/AAAAAAAAFwA/pyF6IpAk9kE/s640/20131014_114935.jpg)

I did the setup myself, for the first time by the book.  In the race, the bike bottomed out exactly twice!  Saying that, a swiss exercise ball would have bottomed out on those 2 occasions.  Silly speed, not enough flight ;)

I was really not looking forward finalising the electrics, so I fitted a new Michellin Desert in front :
(https://lh3.googleusercontent.com/-6nxRyYJa0GU/Ul2z_aUIpzI/AAAAAAAAFv4/ntF6vVXeFrs/s640/20131015_141122.jpg)

and rear :
(https://lh3.googleusercontent.com/-aKYH_zcg6Sc/Ul2zaNpd6MI/AAAAAAAAFvg/HfQY58C-I70/s640/20131015_141140.jpg)

It took me an embarrassing 37 minutes to remove the rear and fit a new one!  I was not looking forward getting punctures in the Richtersveld!  I got some of that green goo you squirt in your tyre - it works!  Not one puncture and a nasty snakebite that it actually closed!?

This bike was starting to look bitchin! :
(https://lh4.googleusercontent.com/-LncI1ZryiDs/Ul2zmXe1cZI/AAAAAAAAFvo/5VDV0olw0s4/s640/20131015_141145.jpg)

But is/was it all bark an no bite?

.... to be continued ....
Title: Re: Yamaha WR450F Amageza build
Post by: Yami Super 10 on October 29, 2013, 10:30:15 pm
Nice one!!

As a aircraft/helicopter engineer I can commend you on your skills :thumleft:

Electrical and even welding :deal:

Keep it coming! Might even get you to do some mods on my WR450 :pot:
Title: Re: Yamaha WR450F Amageza build
Post by: darthvader on October 29, 2013, 10:46:35 pm
Almost done.  I was really running out of time and steam.  It was late one night and I saw a piece of flexible clear plastic in my "stock box".  This is really shit, it was skew, not symmetrical, but I was not going to redo it :
(https://lh6.googleusercontent.com/-XlBM8chNQcg/UleoqAqqjAI/AAAAAAAAFr0/-gRPWvr6598/s640/20131010_221151.jpg)

Measuring last year's success, I was going to destroy it on the first day anyway!  It just needed to deflect most of the rocks and sand.

I realised the seat was not bolted in and I was struggling to get it to hook on the tank.  I took of the seat and saw that I forgot to make a little bracket for the tank, so this was born :
(https://lh5.googleusercontent.com/-GBOwMuURgBI/Ulgf6qe-tyI/AAAAAAAAFuk/TSyU7U4u01s/s640/20131011_154515.jpg)

Workmanship out the window :p  The little kink is for the loom, otherwise it would chafe against the bracket and short out. I rounded the edges on the sides and surface of the bracket,... just in case.
Title: Re: Yamaha WR450F Amageza build
Post by: BlueBull2007 on October 29, 2013, 10:52:14 pm
Bliksem!! I said it before and I'll say it again: You are an artist, bru. This is a really, REALLY good WR build. Keep it coming.

Neil :paw:
Title: Re: Yamaha WR450F Amageza build
Post by: YamaV on October 29, 2013, 10:55:09 pm
 :drif: Really good stuff, well done!
Title: Re: Yamaha WR450F Amageza build
Post by: alanB on October 29, 2013, 10:56:23 pm
Nice one!!

As a aircraft/helicopter engineer I can commend you on your skills :thumleft:

Electrical and even welding :deal:


+100  :thumleft:

Really great development skills, really interesting thread.

Love to hear more about your electronics development!
Title: Re: Yamaha WR450F Amageza build
Post by: darthvader on October 29, 2013, 10:58:37 pm
I dreaded the final wiring effort.  I knew this was not going to be easy getting all that crap in between my navigation tower's side members.  

So I took off the headlight :
(https://lh4.googleusercontent.com/-6pAWXG0XPFM/Ul20k_pH5pI/AAAAAAAAFwQ/5jTxAWGDy8k/s640/20131015_200600.jpg)

and started planning the wiring f-up.  Before I forget, check the 2 stainless brackets that the headlight is resting on.  I cannot even remember when I did this, I must have been sleep-bike-building.  I was totally exhausted going into this race, which only put more stress on the situation.

OK, wiring! I relocated the ignition switch and that bought me a whole lot of space :
(https://lh4.googleusercontent.com/-j1l6OXSH0y8/Ul20U6IrF4I/AAAAAAAAFwI/akimkKkh8TU/s640/20131015_200607.jpg)

I jammed everthing in there and used a cable tie and that ribbon wrapping plastic to hold everything in place :
(https://lh5.googleusercontent.com/-vN-EZG9Hrvk/Ul7W73qHpVI/AAAAAAAAFxo/7y_y0jDML90/s640/20131016_115655.jpg)

I wired the headlights to the two switches.  I knew they would come in handy.  Don't ask me why.  All I can say is that I thought I knew something about auto electrics... I don't, but this is a area I am going to become a master in.  A new Krog will be born!
Title: Re: Yamaha WR450F Amageza build
Post by: Martin-DR650 on October 29, 2013, 11:00:48 pm
Baie Nice! Het die bike gesien by rynard.

Thanks for the sweet write-up :thumleft: :thumleft:
Title: Re: Yamaha WR450F Amageza build
Post by: darthvader on October 29, 2013, 11:20:57 pm
Vieslik! Check her out! :
(https://lh6.googleusercontent.com/-ktbIeXz1-24/Ul7WKTKG3NI/AAAAAAAAFxI/aKAsToFxmpI/s640/20131016_163833.jpg)

and so! :
(https://lh5.googleusercontent.com/-6YX-ifXhXKg/Ul7Vz4UbxzI/AAAAAAAAFxA/zuASENVIkAs/s640/20131016_163838.jpg)

and so! :
(https://lh3.googleusercontent.com/-inZ7PUGD3eY/Ul7VfFk0ufI/AAAAAAAAFw4/mj14b545je4/s640/20131016_163848.jpg)

This was Thursday.  I then took the bike for exactly the first time off road!? CRAZY!  That is offroad, EVER!  I have only ridden it on tar... but for a very good reason.  I did not want to "dust up" the bike.  I wanted a clean bike to work on.  I took the bike to the big dunes in Atlantis(close to Cape Town) for a first and final shakedown.  The bike was amazing! but still, I had no experience on the bike and I just had to figure out the bike on the race.  Again, CRAZY!  Before this bike, the only thing I have regularly ridden offroad was my KTM 950 SE.

Finished!  Trailered the bike to Grabouw and ready for action Jackson! Parked next to a new friend's bike :
(https://lh5.googleusercontent.com/-zxasNRDEjyE/UmlWOlBx4yI/AAAAAAAAF28/qUJ9XlB7NEg/s640/20131019_154146.jpg)

I got a few frowns and giggles about the look of the bike, but all in good spirit.  I bought a plastic and I kept it a plastic!

Was it all bark and no bite?

NAY!!!

Day 2 at bivouac :
(https://lh3.googleusercontent.com/-6XBsVi0pR3A/UmlVN3QSgsI/AAAAAAAAF2U/PQHkKc9mxaQ/s640/20131021_233607.jpg)

Day 3, Amageza 2013 finisher :
(https://lh5.googleusercontent.com/-1pnrxcWBi-g/UmlTbg-9IhI/AAAAAAAAF1M/oBF47iJyE3k/s640/20131022_153816.jpg)

Totally stoked!  I finished 14th... but I incurred a 6 hour penalty on the 1st day.  Day 2 - 4th, Day 3 - 6th.  I had multiple breakdowns in both of the special stages where I lost valuable time!  I also came of hard on day 3 which took about 20 minutes to get back to race pace.

I learnt so much building this bike and racing it.  To race a bike you built yourself gives you a massive advantage, you know exactly how hard you can push the bike.  On a factory bike, you just worry about things like chains, sprockets and engine.  With a home build, something that was not tested and well researched, you worry about everything, which is a good thing ;)

I will wrap this thread up with what went wrong, what failed/broke in the race, what could have been done different and a damage report on the tower.  I am going to take it apart and inspect the wear on all the holes.
Title: Re: Yamaha WR450F Amageza build
Post by: N[]vA on October 30, 2013, 12:15:31 am
Awesome build and thanks for the thread mate!
Title: Re: Yamaha WR450F Amageza build
Post by: NeilV on October 30, 2013, 08:25:39 am
Awesome build! :drif: Well done finishing 14th!   :thumleft:
Title: Re: Yamaha WR450F Amageza build
Post by: SteveD on October 30, 2013, 09:00:40 am
 :notworthy:  Respect, great build.
Title: Re: Yamaha WR450F Amageza build
Post by: darthvader on October 30, 2013, 09:24:49 am
I see I missed an image.  Just search for "I then drew a template of the side members" on the first page.
Title: Re: Yamaha WR450F Amageza build
Post by: Pleco on October 30, 2013, 09:34:42 am
We need to chat about your GPS tracker. Its been a while since I worked with programming. Assembler was the last time.  :eek7:

Making a purpose built system for Rallye could be the answer for the Amageza. But we will need to build one quickly, and test it for quite a while.

As you saw in this year's run, the GPS tracking is absolutely critical.  :deal:

You need to survive, your bike needs to survive, your nav kit needs to survive, and your GPS needs to track you all the way.
Title: Re: Yamaha WR450F Amageza build
Post by: mtbbiker on October 30, 2013, 09:39:45 am
Awesome build, I wish I had friends with a workshop like that  :thumleft:
Title: Re: Yamaha WR450F Amageza build
Post by: darthvader on October 30, 2013, 09:59:42 am
Ah! That reminds me!  I really want to thank my two friends who helped me build and kit this bike.  I highly recommend both of their businesses and skills :

1. Reynard Schonken - Scorch Exhausts/Berseker Canopies www.scorchdesign.co.za (http://www.scorchdesign.co.za)
 - I can now weld aluminium! sort of... Reynard is a master aluminium and stainless welder!
 - teaching me the basics of tool making
 - letting me use his workshop!!!

2. Chris Barry - Desert Lizard www.desertlizard.co.za (http://www.desertlizard.co.za)
 - sourcing tanks, navigation equipment, suspension, beautiful MotionPro tools
 - just general race and rallye advice, what to pack, what to worry about
Title: Re: Yamaha WR450F Amageza build
Post by: YamaV on October 30, 2013, 10:21:51 am
Hi Darthvader

I'm really motivated by your WR build, well done, its inspiring stuff :)

And of course well done on finishing the Amageza! I did the first Amageza, it was the best riding ever..and using a plastic clipboard as roadbook holder was interesting ;) and downright dangerous!

I'm have also been thinking about getting a WR450 and doing the same as you, but I want to get an idea of the costs involved.

I've seen a couple of 2nd hand WR's available at good prices, but what can you perhaps give me an idea of the costs for all the extras you had to get?

Thanks!
Title: Re: Yamaha WR450F Amageza build
Post by: darthvader on October 30, 2013, 10:36:50 am
I've seen a couple of 2nd hand WR's available at good prices, but what can you perhaps give me an idea of the costs for all the extras you had to get?

Bike 40,000 ZAR to 50,000 ZAR  - for a excellent carburettor model.  I suggest you get the FI, better fuel economy.
Tanks(15L + 10L) - 13,000 ZAR to 15,000 ZAR - crazy :)
Stiffer spring - 1,500 ZAR to 1,800 ZAR - depending on what you get.
Navigation Equipment - 4,000 ZAR to 5,000 ZAR - depending on what you get.
Steering Damper - 3900 ZAR
Bash plate, swing arm protector, clutch protector radiator braces - 5000 ZAR? - That was on my bike, so I am not sure.

Then you have to think about the labour involved.  The stock cost nothing, probably nothing more than 500 ZAR, but the labour could go up to 6,000 to 8,000 ZAR... even more!

Also, tyres, Michellin Deserts are not cheap and I refuse to run anything else.  3,000+ ZAR for a set.

Yes, I could have bought a 2nd hand rally bike, but that was not my mission.
Title: Re: Yamaha WR450F Amageza build
Post by: YamaV on October 30, 2013, 10:38:02 am
I've seen a couple of 2nd hand WR's available at good prices, but what can you perhaps give me an idea of the costs for all the extras you had to get?

Bike 40,000 ZAR to 50,000 ZAR  - for a excellent carburettor model.  I suggest you get the FI, better fuel economy.
Tanks(15L + 10L) - 13,000 ZAR to 15,000 ZAR - crazy :)
Stiffer spring - 1,500 ZAR to 1,800 ZAR - depending on what you get.
Navigation Equipment - 4,000 ZAR to 5,000 ZAR - depending on what you get.
Steering Damper - 3900 ZAR
Bash plate, swing arm protector, clutch protector radiator braces - 5000 ZAR? - That was on my bike, so I am not sure.

Then you have to think about the labour involved.  The stock cost nothing, probably nothing more than 500 ZAR, but the labour could go up to 6,000 to 8,000 ZAR... even more!

Also, tyres, Michellin Deserts are not cheap and I refuse to run anything else.  3,000+ ZAR for a set.

Yes, I could have bought a 2nd hand rally bike, but that was not my mission.

Awesome, thanks
Title: Re: Yamaha WR450F Amageza build
Post by: bonova on October 30, 2013, 10:41:43 am
Dude..... You lost me seriously at BUILDING YOUR OWN GPS and programming stuff!! If the zombies come can I be on your side? Respect!
Enjoying this thread... So awesome to build your own bike up. My efforts with my bike are dwarfed by yours!
Title: Re: Yamaha WR450F Amageza build
Post by: darthvader on October 30, 2013, 10:50:54 am
Dude..... You lost me seriously at BUILDING YOUR OWN GPS and programming stuff!! If the zombies come can I be on your side? Respect!
Enjoying this thread... So awesome to build your own bike up. My efforts with my bike are dwarfed by yours!

Thank you for the kind words man! 
Title: Re: Yamaha WR450F Amageza build
Post by: MaxThePanda on October 30, 2013, 11:08:19 am

Totally stoked!  I finished 14th... but I incurred a 6 hour penalty on the 1st day.  Day 2 - 4th, Day 3 - 6th.  I had multiple breakdowns in both of the special stages where I lost valuable time!  I also came of hard on day 3 which took about 20 minutes to get back to race pace.

I will wrap this thread up with what went wrong, what failed/broke in the race, what could have been done different and a damage report on the tower.  I am going to take it apart and inspect the wear on all the holes.


Was about to ask what went wrong, but then see I'm jumping the gun. Interested about the issues you experienced?

Also intrigued on your view on the choice of WR. For me it looks like option for this kind of event and general hard adventure touring is between KTM 690 (or perhaps Husky 610/630 or BMX) or the 450 class bikes (KTM, WR, CRF, BMW). The loss of another 20kgs from my ride appeals, but an engine rebuild every 10,000km doesn't...
Title: Re: Yamaha WR450F Amageza build
Post by: darthvader on October 30, 2013, 01:06:46 pm
We need to chat about your GPS tracker. Its been a while since I worked with programming. Assembler was the last time.  :eek7:

Making a purpose built system for Rallye could be the answer for the Amageza. But we will need to build one quickly, and test it for quite a while.

As you saw in this year's run, the GPS tracking is absolutely critical.  :deal:

You need to survive, your bike needs to survive, your nav kit needs to survive, and your GPS needs to track you all the way.

Lets have a chat then.  Lets set some deadlines.  Either way, I am going to build a ERTF like unit for myself.  I will help bigtime if you have 2 CAP heading readings(yours and waypoint) and an indicator of how many meters to the waypoint.  I would rather have less features, than trying to mimic the ERTF completely.  It is by NO means a difficult device to build.... trust me ;)
Title: Re: Yamaha WR450F Amageza build
Post by: Pleco on October 30, 2013, 02:07:05 pm
We need to chat about your GPS tracker. Its been a while since I worked with programming. Assembler was the last time.  :eek7:

Making a purpose built system for Rallye could be the answer for the Amageza. But we will need to build one quickly, and test it for quite a while.

As you saw in this year's run, the GPS tracking is absolutely critical.  :deal:

You need to survive, your bike needs to survive, your nav kit needs to survive, and your GPS needs to track you all the way.

Lets have a chat then.  Lets set some deadlines.  Either way, I am going to build a ERTF like unit for myself.  I will help bigtime if you have 2 CAP heading readings(yours and waypoint) and an indicator of how many meters to the waypoint.  I would rather have less features, than trying to mimic the ERTF completely.  It is by NO means a difficult device to build.... trust me ;)

I have a 6 week stint in Zambia to handle, so if you can have something running when I am back in CT it would be great.

In the meantime we can communicate via email. First thing is to get a copy of the international ERTF brackets. It would be best if your unit mounts to those brackets as well. Then the riders only have to buy one set of brackets.

My electronics are way too rusty to be of real help to you, but I might have some ideas. I don not need to see your design and programming. That stays your intellectual property. I do like your idea of over engineering things. It might be good if we can epoxy encase each unit to make sure its bulletproof. Not sure how much heat you are generating.

I have some power supply experience. You can maybe send me that circuit diagram, so that I can try and see why your regulators kept on blowing. I know that if you DC the AC output from the WR, it runs past 30VDC. Blew some expensive LED spots on a friends bike.  :eek7:

There are no ERTF units available for rent in RSA that we know of, so maybe there is some money in there somewhere. As long as Amageza gets a discount for helping.  :thumleft:

lukas(at)bekker.org.za
Title: Re: Yamaha WR450F Amageza build
Post by: darthvader on October 30, 2013, 02:16:29 pm
I know what my problem was with the regulators and I have a robust solution now.  The heat is normal, same as any other unit.  I try to keep it as close to 5V, so I do not need a mother of a regulator.  I try to waste as little energy as possible. 

Anyway :)  I have to electronics and power side of things down, it is more the logic that I am after, i.e. what we need to display on the screen.  I know the ERTF fairly well, so I have some good ideas.

More about this later!

Next up in this thread : "What worked and what failed miserably!"
Title: Re: Yamaha WR450F Amageza build
Post by: SteveD on October 30, 2013, 02:35:53 pm
http://www.ertf.com/photos/training/TrainingGps2B_uk.pps (http://www.ertf.com/photos/training/TrainingGps2B_uk.pps) describes how the ERTF unit works.

Wouldn't it be nice for Amageza to have a unit that shows this info when you arrive at the bivuoac? No post-processing until all hours of the night, no hoping/guessing what penalties you got, no unpleasant suprises.
Title: Re: Yamaha WR450F Amageza build
Post by: darthvader on October 30, 2013, 02:43:01 pm
http://www.ertf.com/photos/training/TrainingGps2B_uk.pps (http://www.ertf.com/photos/training/TrainingGps2B_uk.pps) describes how the ERTF unit works.

Wouldn't it be nice for Amageza to have a unit that shows this info when you arrive at the bivuoac? No post-processing until all hours of the night, no hoping/guessing what penalties you got, no unpleasant suprises.

Exactly.  I have made a list and drawings of all these features.  I will be using a very low cost LCD.  I am currently trying to source the best size and bang for buck.  Gotta love China!
Title: Re: Yamaha WR450F Amageza build
Post by: pietas on October 30, 2013, 02:47:29 pm
This has been a really informative read. I like!
Title: Re: Yamaha WR450F Amageza build
Post by: Bender on October 30, 2013, 03:10:48 pm
One of the best and most informative reads for me in a long time. Good on you :thumleft:
Title: Re: Yamaha WR450F Amageza build
Post by: Hentie @ Riders on October 30, 2013, 03:17:17 pm
Well done  :thumleft:
Title: Re: Yamaha WR450F Amageza build
Post by: wiledog_X on October 30, 2013, 04:30:12 pm
wow, some guys have a lot of talent - very nice to see your skills in action, and a kick-ass end product! keep up the good work!  :thumleft:
Title: Re: Yamaha WR450F Amageza build
Post by: KTMRICK on October 30, 2013, 04:49:17 pm
Really interesting and way above my capability. Big respect for those who can like you. I would appreciate it if you could elaborate on the use of the steering damper a bit more in the various terrains you encountered. I have one on my 640 but am really not sure how to use it properly.
Title: Re: Yamaha WR450F Amageza build
Post by: BlueBull2007 on October 30, 2013, 05:09:13 pm
Again, this is one of the best rally build threads I have seen. I'm stunned at how cheap it was even with the labour. :eek:

Can you post pics of the damage and what you saw that you liked and did not like? The only thing I would have maybe done differently is to route the header under the foot peg away from the engine and fuel tanks, like you can see on the old 690 rally bikes.

http://www.ertf.com/photos/training/TrainingGps2B_uk.pps (http://www.ertf.com/photos/training/TrainingGps2B_uk.pps) describes how the ERTF unit works.

Wouldn't it be nice for Amageza to have a unit that shows this info when you arrive at the bivuoac? No post-processing until all hours of the night, no hoping/guessing what penalties you got, no unpleasant suprises.

Exactly.  I have made a list and drawings of all these features.  I will be using a very low cost LCD.  I am currently trying to source the best size and bang for buck.  Gotta love China!

I have the bracket for the current ERTF so can get pictures and measurements to you. Please keep me in the loop when you chat to Pleco, because I know what the guys are complaining about with this system and this would be an opportunity to build an improvement

nringdahl at geemail dot com.
Title: Re: Yamaha WR450F Amageza build
Post by: JustBendIt on October 30, 2013, 05:32:38 pm
Very well done Bob - that is the ugliest prettiest bike I have ever seen !
Title: Re: Yamaha WR450F Amageza build
Post by: BLK on October 30, 2013, 05:35:02 pm
Nice job.Thks for sharing your work.

 :)
Title: Re: Yamaha WR450F Amageza build
Post by: tok-tokkie on October 30, 2013, 05:58:25 pm
That was really interesting to read.  I liked your writing style very much - fast & friendly conversation.  I so agree with using HDPE for the tower.  If you want to make it ABSOLUTELY indestructible use UHMWPE - readily available from Gartech in Epping.
Title: Re: Yamaha WR450F Amageza build
Post by: darthvader on October 30, 2013, 06:05:00 pm
Very well done Bob - that is the ugliest prettiest bike I have ever seen !

Ek was jou bek uit met seep! When are you getting your fat ass into gear?
Title: Re: Yamaha WR450F Amageza build
Post by: darthvader on October 30, 2013, 06:06:02 pm
That was really interesting to read.  I liked your writing style very much - fast & friendly conversation.  I so agree with using HDPE for the tower.  If you want to make it ABSOLUTELY indestructible use UHMWPE - readily available from Gartech in Epping.

Thy will be done!
Title: Re: Yamaha WR450F Amageza build
Post by: darthvader on October 30, 2013, 06:17:48 pm
Can you post pics of the damage and what you saw that you liked and did not like? The only thing I would have maybe done differently is to route the header under the foot peg away from the engine and fuel tanks, like you can see on the old 690 rally bikes.

Trumpet on! Well, I fixed everything on Day 2 already. Some one the special and some at the bivouac.  I forgot to pick up a new sparkplug, but I should start with maintenance tomorrow.  I will take snaps of the areas that I want to improve on and the wear on the tower.

The damage will be insignificant, but one will be able to extrapolate the damage factor for longer races.

We need to create an essential and rolls royce trommel contents thread or manual.  Chris (REVS) kakked on me for not carrying a spare chain in my trommel!

We also need to create a bike toolkit list. The only thing I did not carry was extra chain and    masterlnks.
Title: Re: Yamaha WR450F Amageza build
Post by: alanB on October 30, 2013, 06:21:14 pm
What do you estimate your nav tower with all its kit on, weighs?

Title: Re: Yamaha WR450F Amageza build
Post by: darthvader on October 30, 2013, 06:42:43 pm
What do you estimate your nav tower with all its kit on, weighs?

I will tell you tomorrow, but weight was not the only motivation for this tower.  The incredible strength and flexibility of HDPE was very attractive to me.
Title: Re: Yamaha WR450F Amageza build
Post by: darthvader on October 31, 2013, 12:20:38 am
Really interesting and way above my capability. Big respect for those who can like you. I would appreciate it if you could elaborate on the use of the steering damper a bit more in the various terrains you encountered. I have one on my 640 but am really not sure how to use it properly.

I am not sure what the rules are, but this worked for me.  I set the steering damper exactly in the middle.  Day 1, SS1, super rocky riverbed terrain, I stiffened it up one full rotation.  Amazing! I am no stranger to rocky terrain and frankly I love it because of the technical challenge.  With the steering damper it made it trivial.  My heart rate never went over 150.  I got lost with some other guys and I was gatvol.  I had to backtrack over the same rocks and stiffened the damper one more rotation.  I was flying over the rocks! No jerking whatsoever.  Back up on the mountain, I toned it down again, back to "zero"/middle/centre.  Technical "slow" sand, like on Day 2 SS1, I set it to zero and then anticlockwise max(negative).  I ride sand almost every weekend and I want full control over the steering - I stand up at low speed sand riding.

Then I joined up with the Amageza 2013 champion, still on sand, but high speed, and I quickly set it back to half way + one full rotation clockwise.  At very high speed you don't want tank slapping, it worked for me.  I left it like this for the remainder of the race, which included uphill rocky tracks and high speed jeep tracks, as well as some super high speed gravel national roads with the odd sand patch.
Title: Re: Yamaha WR450F Amageza build
Post by: darthvader on October 31, 2013, 12:25:33 am
Then I joined up with the Amageza 2013 champion, still on sand, but high speed, and I quickly set it back to half way + one full rotation clockwise.  

En donner, die Vet kan jaag hoor!  Woes!
Title: Re: Yamaha WR450F Amageza build
Post by: pietas on October 31, 2013, 08:35:16 am
Had a look at your navigational setup last night. Some smart thinking there.
Have you seen the following:
http://store.3drobotics.com/products/3dr-gps-ublox-with-compass (http://store.3drobotics.com/products/3dr-gps-ublox-with-compass)

Not that cheap but gps, compas rolled into 4x4cm unit. Used for remote controls. Part of the http://diydrones.com/ (http://diydrones.com/) open environment

I would like to see your setup from close-up

Title: Re: Yamaha WR450F Amageza build
Post by: Yami Super 10 on October 31, 2013, 09:06:48 am
I am sure that having this Thread :deal:

There will be more guys wanting to do it next year...... :peepwall: :pot:
This has even got me thinking :ricky:
Title: Re: Yamaha WR450F Amageza build
Post by: Pleco on October 31, 2013, 10:30:54 am
I had a quick look at Kobus Potgieter's nav tower. It has built in suspension. If you can have a pivot point and two small gas shocks in the back, the Nav tower wil not disintegrate.

Not sure how that works
Title: Re: Yamaha WR450F Amageza build
Post by: darthvader on October 31, 2013, 10:50:03 am
I had a quick look at Kobus Potgieter's nav tower. It has built in suspension. If you can have a pivot point and two small gas shocks in the back, the Nav tower wil not disintegrate.

Not sure how that works

Tell that to Riaan van Niekerk.  His tower disintegrated after an off ;D

I was thinking about that, but I had not leverage.  The cool thing about the setup I have now, is that I can really do anything at the front, any shape or size.  I did notice that Paco Martinez's tower(klx450mx) was actually lower than his handle bars if you lock it to the side.  If I lock my steering, my handlebars go underneath my navigation tray.  That said, Paco is a midget.
Title: Re: Yamaha WR450F Amageza build
Post by: alanB on October 31, 2013, 04:34:17 pm
What do you estimate your nav tower with all its kit on, weighs?

I will tell you tomorrow, but weight was not the only motivation for this tower.  The incredible strength and flexibility of HDPE was very attractive to me.

Ja quite innovative, using something that will bend and not just break  :thumleft:

You did quite well and didn't suffer any sort of failure on the tower so clearly its a workable solution.

But the weight is always an issue for me, especially so high up and far forward, - did you notice any ill effects from all that weight on the front? 

If you can I would be interested in two figures:
1) The weight of all the instruments and switches, wire etc on their own
2) Total weight of the tower with all the supporting members.

The real issue here is how to get all the instruments out front where one can see them while riding.  How far that has to be is the big trade off - far forward and high up is ideal - but supporting that weight out there in such a hostile environment is the big engineering problem.
Title: Re: Yamaha WR450F Amageza build
Post by: N[]vA on October 31, 2013, 04:39:56 pm
What do you estimate your nav tower with all its kit on, weighs?

I will tell you tomorrow, but weight was not the only motivation for this tower.  The incredible strength and flexibility of HDPE was very attractive to me.

Ja quite innovative, using something that will bend and not just break  :thumleft:

You did quite well and didn't suffer any sort of failure on the tower so clearly its a workable solution.

But the weight is always an issue for me, especially so high up and far forward, - did you notice any ill effects from all that weight on the front? 

If you can I would be interested in two figures:
1) The weight of all the instruments and switches, wire etc on their own
2) Total weight of the tower with all the supporting members.

The real issue here is how to get all the instruments out front where one can see them while riding.  How far that has to be is the big trade off - far forward and high up is ideal - but supporting that weight out there in such a hostile environment is the big engineering problem.
I can tell you that having all my nav gear (f2r roadbook, ico & screen + led spot lights) handle bar mounted didn't all that much of a weight difference that I wouldn't happily do it again. I also dont have a steering damper on the bike. It's not THAT heavy

Nice thing about the handle bar mount system is that it rotates on the bar in a crash rather than breaking.

I really enjoyed Rob's ideas on how he built his and am very keenly considering similar for my next build
Title: Re: Yamaha WR450F Amageza build
Post by: darthvader on October 31, 2013, 04:51:14 pm
But the weight is always an issue for me, especially so high up and far forward, - did you notice any ill effects from all that weight on the front? 

Show me a own rolled rally bike that does not have this problem?  Good suspension setup in front and running the fuel from the front tank first makes this bike perfectly balanced for me.  It is actually very light, I cannot imagine it being more than 1.5kg for everything without the navigation equipment.  Aluminium or mild steel will be way heavier for the same strength.

If you can I would be interested in two figures:
1) The weight of all the instruments and switches, wire etc on their own
2) Total weight of the tower with all the supporting members.

It will take a while to get the measurements without the nav equipment, but I will have something ready in the next few days.  It took me 3 hours to clean up my garage after my frantic Amageza packing mission.

The real issue here is how to get all the instruments out front where one can see them while riding.  How far that has to be is the big trade off - far forward and high up is ideal - but supporting that weight out there in such a hostile environment is the big engineering problem.

I can tell you this : Day 2, Liason 1, we had moer big dongas to ramp.  Ask the guys I rode with if I had any problem ;) Koos? Zarin? Donovan? ... we were flying and my bike was an absolute pleasure to ride.  I mentioned before that this was the first time I took a 450cc bike offroad, let alone a "top heavy" rally bike!  I had no time on this bike, I only road it on tar for maximum 3 hours and I still had no problem riding it flat taps with all the nav equipment.

What I am trying to get at, is that this bike, with the 1.5 to 2.5kg weight was very easy to ride.  The bike just felt right up until I had fuel tap problems and I had to run some fuel from my rear tanks first.  My tower is actually very snug up against the handle bars.  I don't think you can get it closer.
Title: Re: Yamaha WR450F Amageza build
Post by: alanB on October 31, 2013, 04:58:55 pm
But the weight is always an issue for me, especially so high up and far forward, - did you notice any ill effects from all that weight on the front? 

Show me a own rolled rally bike that does not have this problem?  Good suspension setup in front and running the fuel from the front tank first makes this bike perfectly balanced for me.  It is actually very light, I cannot imagine it being more than 1.5kg for everything without the navigation equipment.  Aluminium or mild steel will be way heavier for the same strength.

If you can I would be interested in two figures:
1) The weight of all the instruments and switches, wire etc on their own
2) Total weight of the tower with all the supporting members.

It will take a while to get the measurements without the nav equipment, but I will have something ready in the next few days.  It took me 3 hours to clean up my garage after my frantic Amageza packing mission.

The real issue here is how to get all the instruments out front where one can see them while riding.  How far that has to be is the big trade off - far forward and high up is ideal - but supporting that weight out there in such a hostile environment is the big engineering problem.

I can tell you this : Day 2, Liason 1, we had moer big dongas to ramp.  Ask the guys I rode with if I had any problem ;) Koos? Zarin? Donovan? ... we were flying and my bike was an absolute pleasure to ride.  I mentioned before that this was the first time I took a 450cc bike offroad, let alone a "top heavy" rally bike!  I had no time on this bike, I only road it on tar for maximum 3 hours and I still had no problem riding it flat taps with all the nav equipment.

What I am trying to get at, is that this bike, with the 1.5 to 2.5kg weight was very easy to ride.  The bike just felt right up until I had fuel tap problems and I had to run some fuel from my rear tanks first.  My tower is actually very snug up against the handle bars.  I don't think you can get it closer.

Thanks that basically answers my question.  The thick plastic looked quite heavy in your photo's but , 1 or 2 kg's isn't really an issue at all!

Still would be quite interested in the weight of all the instruments on their own, because those have to go any rally bike regardless of the nav tower solution.

I think you did fantastically well given the lack of time to get used to the bike  :thumleft:

I also think the balanced front/rear fuel tanks help a lot.
Title: Re: Yamaha WR450F Amageza build
Post by: husky on October 31, 2013, 05:02:13 pm
Nice work; particularly the GPS.  Most impressive.

I know BB has seen it but the AdvRider Nav tower thread has at least one HDPE tower.
Title: Re: Yamaha WR450F Amageza build
Post by: darthvader on November 04, 2013, 06:54:03 pm
I am running a bit behind on my build dissection, but I am currently doing tests on various thread locking products and viscosities & strengths. 

To my surprise, I found out that the "high strength" Loctite(TM) thread locking glue actually break down under extreme vibrations.  I used Würth-medium-strength on the last stage that I got from the KTM Cape Town mechanics and that seemed to work.  What other products do you suggest?
Title: Re: Yamaha WR450F Amageza build
Post by: Kenisis on November 04, 2013, 07:03:46 pm
Awesome Build.

Whilst at speed did you have any problems with vibrations of the plastic head end?

Cheers

Al
Title: Re: Yamaha WR450F Amageza build
Post by: darthvader on November 04, 2013, 07:06:48 pm
Visually, no.  Give me 10 minutes and I will go loosen up the main bolts and tell you if there was any wear and/or tear on any of the members of the tower.
Title: Re: Yamaha WR450F Amageza build
Post by: darthvader on November 04, 2013, 07:33:46 pm
Visually, no.  Give me 10 minutes and I will go loosen up the main bolts and tell you if there was any wear and/or tear on any of the members of the tower.

I removed two main support bolts(refer to the construction), the top bolt of the bottom triangle and the bolt I added afterwards.  They had no visible wear on them.  I did test their torque just before I removed them and I could give each nut an extra full rotation!  

There are two and a half theories at this point.  The first would be that the nyloc was damaged and it vibrated loose.  Nylocs work best if used once, obviously(you damage the plastic insert each time you turn/rotate the nut).  The other part to this is that I did not torque it enough when I finally assembled the tower. For this very reason, I am going to use high tensile bolts for the tower as well, not just the base.  I can then torque it until it bleeds! B.T.W., I used stainless bolts?!!? vreemd!  The other reason for the "looseness" could be that the HDPE compressed enough although I doubt it.  

I have no mechanical or plastics engineering background, so please chip in.  If you did not read the whole thread, I used nylon for the spacers and HDPE for the sides.
Title: Re: Yamaha WR450F Amageza build
Post by: alanB on November 04, 2013, 09:34:38 pm
I personally doubt if the nyloc nuts vibrated loose.  I re-use them all the time and never have issues with them loosening.

Possibilities are:

1) Maybe some sort of creep in the plastic (including the spacers) - meaning it sort of flowed away from the highly /stressed compressed areas (creep is a function of time and stress, exacerbated by vibration).  This is the most likely explanation IMO.   
2) I've had poor results with stainless bolts - often bend and loosen, especially when subject to heavy vibration and stress. 

Those would be my guesses anyway.

PS did a quick search for HDPE compressive creep and it seems that could indeed be the issue.  Although that's hardly conclusive.
Title: Re: Yamaha WR450F Amageza build
Post by: darthvader on November 04, 2013, 09:42:57 pm
Creepy...  ;D  I checked the thread on the stainless bolts after the post and they are fine(no stretched threads)  There are zero signs of "creep" on the thickness, and if there are, we are talking micrometers, way less than one rotation.

I also noticed that the nylocs are way easier to loosen and tighten, so it is without a doubt  the nyloc nuts that loosened.  Again, stainless.  If I have used high tensile bolts, I would have torqued it much more.
Title: Re: Yamaha WR450F Amageza build
Post by: darthvader on November 04, 2013, 09:45:24 pm
Creepy...  ;D  I checked the thread on the stainless bolts after the post and they are fine(no stretched threads)  There are zero signs of "creep" on the thickness, and if there are, we are talking micrometers, way less than one rotation.

I also noticed that the nylocs are way easier to loosen and tighten, so it is without a doubt  the nyloc nuts that loosened.  Again, stainless.  If I have used high tensile bolts, I would have torqued it much more.

O, and for final assembly, I would use new nylocs and some medium strength thread locking glue.
Title: Re: Yamaha WR450F Amageza build
Post by: alanB on November 04, 2013, 10:07:17 pm
Creepy...  ;D  I checked the thread on the stainless bolts after the post and they are fine(no stretched threads)  There are zero signs of "creep" on the thickness, and if there are, we are talking micrometers, way less than one rotation.

I also noticed that the nylocs are way easier to loosen and tighten, so it is without a doubt  the nyloc nuts that loosened.  Again, stainless.  If I have used high tensile bolts, I would have torqued it much more.

If the plastic did creep then the bolts wouldn't still be be stretched and then the nuts would seem loose, and thus easy to loosen - just saying.

But I'm really guessing at creep being the culprit. 

But in any event, using stronger bolts, new nuts and loctite will at least eliminate those possibilities next time  :thumleft:
Title: Re: Yamaha WR450F Amageza build
Post by: darthvader on November 04, 2013, 10:09:28 pm
I hear your, but, what I am saying, the nut can be turned by hand(removed from the rig completely)... before there was no way.
Title: Re: Yamaha WR450F Amageza build
Post by: BlueBull2007 on November 05, 2013, 12:51:04 am
We should change this thread to engineering banter. ;) ;D

Keep it coming boys!
Title: Re: Yamaha WR450F Amageza build
Post by: Pleco on November 06, 2013, 09:34:37 am
Visually, no.  Give me 10 minutes and I will go loosen up the main bolts and tell you if there was any wear and/or tear on any of the members of the tower.

I removed two main support bolts(refer to the construction), the top bolt of the bottom triangle and the bolt I added afterwards.  They had no visible wear on them.  I did test their torque just before I removed them and I could give each nut an extra full rotation!  

There are two and a half theories at this point.  The first would be that the nyloc was damaged and it vibrated loose.  Nylocs work best if used once, obviously(you damage the plastic insert each time you turn/rotate the nut).  The other part to this is that I did not torque it enough when I finally assembled the tower. For this very reason, I am going to use high tensile bolts for the tower as well, not just the base.  I can then torque it until it bleeds! B.T.W., I used stainless bolts?!!? vreemd!  The other reason for the "looseness" could be that the HDPE compressed enough although I doubt it.  

I have no mechanical or plastics engineering background, so please chip in.  If you did not read the whole thread, I used nylon for the spacers and HDPE for the sides.

Check your torques and use a good torque wrench. The torque is supposed to stretch the bolt so that it acts like a spring. Too little and there is not enough pull to keep the nuts tight. Too much and the bolt looses its spring tension all together, then you might as well toss the bolt unless you weld the nut in.

A once torqued Nylok nut should not come loose. Ride it for the first day, back the nut off half a turn and retorque. Then everything would have settled nicely. You can always put some silicone onto the nut and exposed thread after the re torque. The nut wont come out, and you can get the silicone off easier than thread lock. Don't use stainless bolts, its too soft. Allen cap.

HT bolts and nuts with spring washers, torqued correctly with some silicone afterwards will work just as well. Otherwise you need to keep spare nyloks.

This worked well on my extreme 4x4 trips. 
Title: Re: Yamaha WR450F Amageza build
Post by: Kenisis on November 06, 2013, 06:02:26 pm
I hear your, but, what I am saying, the nut can be turned by hand(removed from the rig completely)... before there was no way.
What about expansion and contraction? The SS bolts will expand differently to the plastic possibly less so than the plastic and then when warm it compresses it causing your looseness?

* Warning * I am no Plastics scientist!
 
Title: Re: Yamaha WR450F Amageza build
Post by: darthvader on November 06, 2013, 08:46:34 pm
UPDATE : I have measured my spacers(vernier calliper) and the thickness of the sidewalls(eyeballed it in light and no dents or warps), they are all 100% the same thickness.  SO, Stainless and Nyloc damage was my problem.  I have to use HT bolts and galvanized Nyloc nuts(I am not sure you get HT Nyloc nuts) for my tower.

Silicone, yes, good plan, but I do think that a good design should not really need that much "glue" on the navigation tower.  Eventually any epoxy glue will fail if there is too much stress on the fix points.

I have studied the factory Honda and KTM Rallye bikes(photos and amageza, etc.)  Normal bolts should suffice... I also suspect Yamaha used the exact KTM tower and brackets, see the pic :
(https://lh5.googleusercontent.com/-QpPZhYrVmIA/UnqGqcVVAYI/AAAAAAAAGCA/_4ooYcCekkU/s640/P20130530085145052.jpg)

Look very closely... zoom in!  Then!  I have built my own bike, nice, cool, Darth, you are the best, blah, but! Check Cyril's bike, it is a 100% garage build.  I so want him to finish top 10 with this bike, because that would just prove you can build a low cost bike and win.

His tanks probably cost 1000ZAR in material ;)  His exhaust is routed brilliantly ... and all the exhaust sections parts are sleeved, with springs! Super easy to fix at the bivouac.  If Yamalube pulls this off, it will reset history.

I am going to test my bike in the next 2 mounts with it full rally party dress.  Lets see if the girl holds up!
Title: Re: Yamaha WR450F Amageza build
Post by: darthvader on November 06, 2013, 08:53:53 pm
I have fitted a new x-ring chain(it makes much more sense to me?), so lets see how it goes. 

Then, I have changed my front sprocket from a 13 to a 14; I just had way too much torque in 2nd and 3nd.  I have way more control in my wheelies  :biggrin:  Atlantis will give me the final stamp of approval.

The new chain guide is a TM Designs UHDPE guide, so that should help a bit.
Title: Re: Yamaha WR450F Amageza build
Post by: darthvader on November 06, 2013, 09:06:34 pm
I so want him to finish top 10 with this bike, because that would just prove you can build a low cost bike and win.

His tanks probably cost 1000ZAR in material ;)  His exhaust is routed brilliantly ... and all the exhaust sections parts are sleeved, with springs! Super easy to fix at the bivouac.  If Yamalube pulls this off, it will reset history.


I am sure the suspension is worth 100K ZAR on Cyril's bike, but the rest of the parts are all within a frugal budget's reach.
Title: Re: Yamaha WR450F Amageza build
Post by: alanB on November 06, 2013, 10:45:58 pm
UPDATE : I have measured my spacers(vernier calliper) and the thickness of the sidewalls(eyeballed it in light and no dents or warps), they are all 100% the same thickness.  SO, Stainless and Nyloc damage was my problem. 

OK  :thumleft:

I wouldn't think you need to torque that thing until your eyeballs bulged so I wouldnt get too carried away with HT bolts etc.  Just get some new nyloc nuts and some normal steel bolts and some nice big/thick washers and it should be fine.

Cyril's bike looks really good - I really like the idea of the exhaust moving to the back and the FI feeding from the top/front - just makes so much sense!
Title: Re: Yamaha WR450F Amageza build
Post by: darthvader on November 06, 2013, 10:52:11 pm
I wouldn't think you need to torque that thing until your eyeballs bulged so I wouldnt get too carried away with HT bolts etc.
Stainless bolts are just not good enough and HT bolts are the next level up at my local bolt store... they are a bit heavier, but it does not make a difference.  Stainless just strip so easily, so HT bolts it is.

Cyril's bike looks really good - I really like the idea of the exhaust moving to the back and the FI feeding from the top/front - just makes so much sense!
Totally!

And zero fairing.... 2 simple panels from the tower to the tanks, with quick releases.

I am happy with my bike.  I have 2 major structural fixes, one on the exhaust and one patent pending navigation tower fix ;)  ... ok, no, I promised it to be open source, so, I will release cad pics of the plastics soon.
Title: Re: Yamaha WR450F Amageza build
Post by: Aquatic on November 07, 2013, 03:00:36 am
Brilliant read! Thanks

I wish I had the time
Title: Re: Yamaha WR450F Amageza build
Post by: alanB on November 07, 2013, 07:24:28 am
Just one other thing I thought of last night.

You may want to consider making the spacers out of aluminium.  I imagine the current nylon one's will compress/flex quite a lot under pressure/stress (no matter how tight you tighten the bolts) which may be part of the problem.  A metal spacer will compress/flex less and thus hold everything that much more rigidly.

Just a thought.


And zero fairing.... 2 simple panels from the tower to the tanks, with quick releases.


Ja I've been saying for a long time that I did'nt quite see the point of the huge tower and fairing - so like the less is more approach on that bike. :thumleft:
Title: Re: Yamaha WR450F Amageza build
Post by: Kenisis on November 07, 2013, 01:28:59 pm
I so want him to finish top 10 with this bike, because that would just prove you can build a low cost bike and win.

His tanks probably cost 1000ZAR in material ;)  His exhaust is routed brilliantly ... and all the exhaust sections parts are sleeved, with springs! Super easy to fix at the bivouac.  If Yamalube pulls this off, it will reset history.


I am sure the suspension is worth 100K ZAR on Cyril's bike, but the rest of the parts are all within a frugal budget's reach.

An interesting thing that I was told by Coma and Despres mechanics at last years challenge is that the  only stock item on the KTM is the clutch casing. There is nothing the same compared to stock 450`s.

I think Cyrils bike has some adjustments made to it in order to compete.
Title: Re: Yamaha WR450F Amageza build
Post by: tau on November 09, 2013, 05:10:07 pm
Well done. The wiring was my biggest issue. Ended up making them robust not pretty.
Title: Re: Yamaha WR450F Amageza build
Post by: BlueBull2007 on November 10, 2013, 09:07:50 pm
I so want him to finish top 10 with this bike, because that would just prove you can build a low cost bike and win.

His tanks probably cost 1000ZAR in material ;)  His exhaust is routed brilliantly ... and all the exhaust sections parts are sleeved, with springs! Super easy to fix at the bivouac.  If Yamalube pulls this off, it will reset history.


I am sure the suspension is worth 100K ZAR on Cyril's bike, but the rest of the parts are all within a frugal budget's reach.

An interesting thing that I was told by Coma and Despres mechanics at last years challenge is that the  only stock item on the KTM is the clutch casing. There is nothing the same compared to stock 450`s.

I think Cyrils bike has some adjustments made to it in order to compete.


Agree 100%. For example I know on the KTM Cyril had his footpegs turned 5-8 degrees forward, and am sure would have done the same on his Yammie
Title: Re: Yamaha WR450F Amageza build
Post by: XRV-Boy on November 25, 2013, 08:25:46 pm
awesome build boet
Title: Re: Yamaha WR450F Amageza build
Post by: REVS on November 30, 2013, 06:52:43 pm
Great build pics, well done boet!!! :thumleft:
Title: Re: Yamaha WR450F Amageza build
Post by: zebra - Flying Brick on November 30, 2013, 08:05:07 pm
Inspirational stuff, well done!  :thumleft:
Cheers
Title: Re: Yamaha WR450F Amageza build
Post by: darthvader on December 02, 2013, 09:00:08 pm
Thanks guys.

So, the following are for those who praised me as some engineering genius :)
http://www.wilddog.za.net/forum/index.php?topic=93663.msg1878624#msg1878624 (http://www.wilddog.za.net/forum/index.php?topic=93663.msg1878624#msg1878624)
http://www.wilddog.za.net/forum/index.php?topic=93663.msg1893456#msg1893456 (http://www.wilddog.za.net/forum/index.php?topic=93663.msg1893456#msg1893456)

My build from last year ;)
Title: Re: Yamaha WR450F Amageza build
Post by: darthvader on December 02, 2013, 09:01:37 pm
Thanks guys.

So, the following are for those who praised me as some engineering genius :)
http://www.wilddog.za.net/forum/index.php?topic=93663.msg1878624#msg1878624 (http://www.wilddog.za.net/forum/index.php?topic=93663.msg1878624#msg1878624)
http://www.wilddog.za.net/forum/index.php?topic=93663.msg1893456#msg1893456 (http://www.wilddog.za.net/forum/index.php?topic=93663.msg1893456#msg1893456)

My build from last year ;)

Oops, ignore the "rakkie" on the back, that is still pretty cool :-D
Title: Re: Yamaha WR450F Amageza build
Post by: Woestynhond on December 02, 2013, 09:31:53 pm
Dartvader, the safari rear mounted tank, what is the width where it fits over the rear mudguard/ back portion of the seat?

Am really interested in fitting one to my DR , Willing to make modifications  curious to see if it will fit over the sub frame.  Have mailed Safari but no reply.....
Am also in the process of building a rally fairing sort of like this one to go along with the 20l Acerbis tank.

Damn nice build!
Title: Re: Yamaha WR450F Amageza build
Post by: darthvader on December 02, 2013, 09:35:39 pm
Dartvader, the safari rear mounted tank, what is the width where it fits over the rear mudguard/ back portion of the seat?

Am really interested in fitting one to my DR , Willing to make modifications  curious to see if it will fit over the sub frame.  Have mailed Safari but no reply.....
Am also in the process of building a rally fairing sort of like this one to go along with the 20l Acerbis tank.

Damn nice build!

Draw me a picture or show me on a photo in my build what you mean.  Mark it with photoshop or something similar.
Title: Re: Yamaha WR450F Amageza build
Post by: Woestynhond on December 02, 2013, 10:26:49 pm
DV, like im the picture. 
Title: Re: Yamaha WR450F Amageza build
Post by: darthvader on December 03, 2013, 08:16:51 am
DV, like im the picture. 

Cool, I will take some measurements tonight.
Title: Re: Yamaha WR450F Amageza build
Post by: darthvader on December 03, 2013, 09:31:17 pm
DV, like im the picture. 

145 - 155mm

I think the tank is over 7000ZAR, so it is quite an expensive chance to take.  I am almost 100% sure that the tank won't fit over a DR's frame.  As it is, it fits quite tight over the WR's frame ;)
Title: Re: Yamaha WR450F Amageza build
Post by: N[]vA on December 03, 2013, 10:10:14 pm
oi DV when we doing an Altantis day?
Title: Re: Yamaha WR450F Amageza build
Post by: darthvader on December 09, 2013, 08:33:19 pm
I have tested a few things out after the race and the first was sprocket configuration.  Now my bike topped empty, at 155km/h.  The downside is that you get totally f-up on 160km/h+ sections, but the technical sections this is king!  I bought a stock 14tooth sprocket and it is a total fu(c)kup, I am going back to 13 on the front.  The bike just feels a tad lazy with the 14...

@audience : What do you run on your 450 on the back and front?
Title: Re: Yamaha WR450F Amageza build
Post by: Pleco on December 09, 2013, 08:45:56 pm
For what its worth,  I ran one tooth smaller in the front and one size bigger in the back on the klr. It completely transformed the bike. It topped at 100kph at 5000rpm which was perfect for last years rules of 100kph max on the gravel roads.
Title: Re: Yamaha WR450F Amageza build
Post by: darthvader on December 09, 2013, 08:57:29 pm
Yeah, I am over it, 13 it is, tomorrow.
Title: Re: Yamaha WR450F Amageza build
Post by: BlueBull2007 on December 11, 2013, 05:25:06 am
I have tested a few things out after the race and the first was sprocket configuration.  Now my bike topped empty, at 155km/h.  The downside is that you get totally f-up on 160km/h+ sections, but the technical sections this is king!  I bought a stock 14tooth sprocket and it is a total fu(c)kup, I am going back to 13 on the front.  The bike just feels a tad lazy with the 14...

@audience : What do you run on your 450 on the back and front?

In my experience what you had on is the best combination. Maybe 14/48 is a little better but if I remember correctly gives the same result. 155km/hr
So while its frustrating being passed by guys doing 168 on their 690's at least you are still on a lighter bike and will catch them when the miss the turnoffs and the technical stuff. The 2012 450 RR gets up to about 163, and the 2014 450 RR with Efi can get up to 185 (it did on the Marroc). I think it will be while before we see that kind of tech on bikes for us mere mortals, maybe another couple of years.

You get what you pay for I suppose

A WR is a great, affordable bike for rallies, even though it is not as fast as 690, it is almost as fast as a factory KTM machine, and is lighter than both (at least until we saw next year's KTM). Anyway, 155 is pretty damn fast in a special stage! Chances of a serious high-speed crash are high, but it exponentially higher at greater speeds.

My 2c
Title: Re: Yamaha WR450F Amageza build
Post by: BlueBull2007 on December 11, 2013, 05:27:32 am
I forgot to mention my ICO clocked a top speed of 162 on one stage in Brazil by  tucking myself in behind the fairing to reduce drag. Dont remember if it was on a downhill, probably was.
Title: Re: Yamaha WR450F Amageza build
Post by: cheesy on December 15, 2013, 01:51:50 pm
Thank you for posting this most informative project. This will surely inspire many more to consider the challenge. I admire your courage and skills to "go it alone" in the build of your machine. Congratulations on your achievement. Certainly one of the better posts.
Title: Re: Yamaha WR450F Amageza build
Post by: BlueBull2007 on December 15, 2013, 04:56:45 pm
So Darth, what is next?
Title: Re: Yamaha WR450F Amageza build
Post by: darthvader on December 15, 2013, 05:13:42 pm
Took the bike out on the dunes with the 14 sprocket and it is 100% certain that it doea not work as well as the 13.  In the whoops and technical sections I could not find the right gear. On the tar the bike tops out at 165!

I think I am going to do the Namakwa rally next year. The only thing that I worry about is the roadbook of this race. On day three of the Amageza I totally trusted the roadbook and road the shit out of my bike; one mistake on that roadbook and I would have kakked hard :) I am going to put my life into the hands of somebody with no rally-event experience and I hope he gets the roadbook right!
Title: Re: Yamaha WR450F Amageza build
Post by: Orangeswifty on December 16, 2013, 11:31:12 am
I read your entire build from the first post bud :deal:
duly impressed! :thumleft:
I have contemplated doing same for the Namakwa with a 530 KTM but i don't have even a tenth of your technical knowledge and machining capabilities.
Well i suppose if you can't do it yourself you gotta pay someone to do it for you?
Very interesting read!
Very well done!

I came past you on an SE in the 2012 Amageza just after you had crashed with your Honda.
I felt as broken for you as you must have been yourself!
Well done on the 2013 achievement! :thumleft:
Title: Re: Yamaha WR450F Amageza build
Post by: darthvader on July 14, 2014, 10:22:58 am
Got this done this weekend :

(https://lh3.googleusercontent.com/-mE1dpJLPHVQ/U8OD-lyJJaI/AAAAAAAAHGs/TvTHxVp8A_E/s800/20140714_082803.jpg)

Side view :

(https://lh4.googleusercontent.com/-xC0EcGI1G_8/U8OEF-FtKUI/AAAAAAAAHG8/JWZ4Lm0kCpk/s800/20140714_082756.jpg)
Title: Re: Yamaha WR450F Amageza build
Post by: darthvader on July 14, 2014, 10:30:12 am
So the next task is to reinforce the exhaust bracket.  There are two extra holes which I can use to add another bracket, the existing one is quite shitty.

I am also fixing up my roadbook situation, I want to see if I can lower it about 50mm.  That does unfortunately mean it would need to move forward with 40mm.

If there is time, I am going to try and make a lexan screen for the whole tower.  I have spoken to some of the other competitors this weekend about the bike's water situation.  I do not really want to carry it in a PVC pipe, but push comes to shove, that will be my last resort.  I am going to try and model a tank from polystyrene and integrate it with the bashplate.
Title: Re: Yamaha WR450F Amageza build
Post by: SteveD on July 14, 2014, 11:25:22 am
What you also need to do is find and eliminate whatever it was that caused your GPS to stop logging on Day 1 last year. High priority task!
Title: Re: Yamaha WR450F Amageza build
Post by: darthvader on July 14, 2014, 11:27:50 am
I will look into that ;)
Title: Re: Yamaha WR450F Amageza build
Post by: N[]vA on July 14, 2014, 03:34:42 pm
sigh now I wanna race again >.<

she is looking great dude  :thumleft:
Title: Re: Yamaha WR450F Amageza build
Post by: BlueBull2007 on July 15, 2014, 02:49:58 pm
I agree. That seat is awesome.
Title: Re: Yamaha WR450F Amageza build
Post by: bonova on July 15, 2014, 09:33:16 pm
Looking great bud! Need to still sort my seat and water too... Problem is that my seat has a big petrol cap inset for the rear tank and I dunno if it can be made to look nice with a new cover and foam. hahahaha. I'm getting a new better bashplate as mine took a beating last year, and gonna get a water tank built into it. Did you get that cap repeater of yours sorted?
Title: Re: Yamaha WR450F Amageza build
Post by: ruger1 on July 15, 2014, 09:49:39 pm
Your bike is looking awesome.

Who done your seat for you, looks great, would like to get my seat to look as cool and comfy as that. I just bought a 2013 husquvarna TE511 for the amageza adventure and the seat is not comfy so would like to upgrade
Title: Re: Yamaha WR450F Amageza build
Post by: darthvader on July 16, 2014, 09:01:37 pm
Your bike is looking awesome.

Who done your seat for you, looks great, would like to get my seat to look as cool and comfy as that. I just bought a 2013 husquvarna TE511 for the amageza adventure and the seat is not comfy so would like to upgrade


Eric from Nithrone.  Be sure to mention my name as reference! I want to show commitment.  He is probably the only guy in the Western Cape that can design a build a quality seat like this.

His service is impeccable!  We had 47 messages back and forth, not one phone call!!!  I sent him pictures; he said : "Cool! Thanks! Easy!" and I picked up my seat from him at Zone 7 five days later.
Title: Re: Yamaha WR450F Amageza build
Post by: darthvader on July 16, 2014, 09:07:12 pm
Actually, his service is so good that I do not want to take advantage of it!  Quality vendor and person.
Title: Re: Yamaha WR450F Amageza build
Post by: ruger1 on July 17, 2014, 10:41:00 am
Thanks, I will give him a call
Title: Re: Yamaha WR450F Amageza build
Post by: darthvader on July 20, 2014, 10:43:41 pm
OK, so, 3mm polycarbonate (http://en.wikipedia.org/wiki/Polycarbonate (http://en.wikipedia.org/wiki/Polycarbonate)) ... guess what that is going to be used for!  and then good old HDPE (http://en.wikipedia.org/wiki/High-density_polyethylene (http://en.wikipedia.org/wiki/High-density_polyethylene)) ... I just call it "strong as f_ck!"
(https://lh3.googleusercontent.com/-aF-zy3hRBfY/U8wi7fKNlBI/AAAAAAAAHHc/unxnAjV8Lxc/s800/20140720_220034.jpg)

A good fuel tap from DesertLizard(Chris) - not sure if I am going to use it, but it will go into my backpack and, plus, fuel filters!

300ZAR for a tube of medium(semi viscose - rubbery) Loctite! Crazy price!

Two super cool spotlights - got them in 2013 at R700 a piece and I believe they are going for R900 bucks now.  I am not really sure how I am going to manage them in my current configuration, but we'll see how it pans out.  I might have to build some cooling/heat friendly area, cause the HDPE is strong as f_ck but it hates heat!  These spots generates tonnes of heat!  Saying that, in the Amageza I do not think I will run them for more than 90 minutes at a time. *shrug*
Title: Re: Yamaha WR450F Amageza build
Post by: darthvader on July 20, 2014, 10:51:19 pm
O, I forgot, 3mm poly, 8mm HDPE, 25MM HDPE.  Rebuilding my tower completely.  I am going to move the roadbook down and forward, more or less to the middle of the front wheel.  I hit my (head)helmet a "kak hou" on the road book in the Richtersveld on day three!  Still don't really know what happened, but it could have been avoided.  There is just way too little room for moving with the tower that high and over/close to the handle bars.

Ideally you want your head in the exact position the roadbook is, in attacking position.  My roadbook/nav tower as it is at the moment is directly under my chin, which is totally wrong.
Title: Re: Yamaha WR450F Amageza build
Post by: Rolling Stone on July 20, 2014, 11:27:50 pm
Looking great bud! Need to still sort my seat and water too... Problem is that my seat has a big petrol cap inset for the rear tank and I dunno if it can be made to look nice with a new cover and foam. hahahaha. I'm getting a new better bashplate as mine took a beating last year, and gonna get a water tank built into it. Did you get that cap repeater of yours sorted?
I am doing this with the water, tools. Etc.
Does not nether me when I ride at all.
Took it loaded on a Maraisburg run with no problems at all
Title: Re: Yamaha WR450F Amageza build
Post by: darthvader on October 20, 2014, 01:19:37 pm
Same problem, same race, different year!

I need heat shielding for my fuel line!  I am going to cable tie this away from the exhaust(also fibreglass wrapped) somehow, but I need some shielding to go over that fuel line.  See the pic below.

(https://lh6.googleusercontent.com/-ePI33MtUR3Q/UlerS--L7WI/AAAAAAAAFt8/s2DJSro82UY/s640/20131010_183156.jpg)

I need something that can slip over the fuel line.  Where can I get something like this in Cape Town?
Title: Re: Yamaha WR450F Amageza build
Post by: N[]vA on October 20, 2014, 01:24:07 pm
That ceramic tape I got for the exhaust header did a serious treat, I have loads of aluminium tape if that would help? (no idea if it would to be honest)
Title: Re: Yamaha WR450F Amageza build
Post by: darthvader on October 20, 2014, 01:27:00 pm
It possibly could, but I am looking at something that I can slip over the fuel line.  Please ask around, I am running out of time and true to form, I am a "Sunday evening homework" guy!
Title: Re: Yamaha WR450F Amageza build
Post by: Aquatic on October 20, 2014, 01:32:40 pm
It possibly could, but I am looking at something that I can slip over the fuel line.  Please ask around, I am running out of time and true to form, I am a "Sunday evening homework" guy!

https://www.google.com.au/?gws_rd=ssl#q=fuel+line+fire+sleeve (https://www.google.com.au/?gws_rd=ssl#q=fuel+line+fire+sleeve)

We use this on firetrucks. To protect all critical lines - fuel, oil, electrical
http://firesleeve.thermaguard.com.au/products/fire-sleeve?gclid=CM-J5tSRu8ECFVgjvQodnwgAqQ (http://firesleeve.thermaguard.com.au/products/fire-sleeve?gclid=CM-J5tSRu8ECFVgjvQodnwgAqQ)
Title: Re: Yamaha WR450F Amageza build
Post by: darthvader on October 20, 2014, 01:37:48 pm
Yes, google has all sorts of nice things  :biggrin:

...but where can I get something in Cape Town / South Africa.
Title: Re: Yamaha WR450F Amageza build
Post by: BlueBull2007 on October 20, 2014, 01:45:54 pm
Yes, google has all sorts of nice things  :biggrin:

...but where can I get something in Cape Town / South Africa.

Get some extra for me please boet! :deal:
Title: Re: Yamaha WR450F Amageza build
Post by: darthvader on October 20, 2014, 01:52:14 pm
Get some extra for me please boet! :deal:

I will, when one of our comrades help us out.
Title: Re: Yamaha WR450F Amageza build
Post by: Aquatic on October 20, 2014, 02:09:10 pm
Get some extra for me please boet! :deal:

I will, when one of our comrades help us out.

Ask 1 of these guys -
http://www.fireraiders.co.za/contacts.asp (http://www.fireraiders.co.za/contacts.asp)
http://www.firefightingequipment.co.za/contact.htm (http://www.firefightingequipment.co.za/contact.htm)
http://www.forestry.co.za/fire-fighting-equipment-africa/?cat=5746 (http://www.forestry.co.za/fire-fighting-equipment-africa/?cat=5746)
Title: Re: Yamaha WR450F Amageza build
Post by: JustBendIt on October 20, 2014, 02:10:53 pm
Get some extra for me please boet! :deal:

I will, when one of our comrades help us out.

Closest to you in the CBD is to go to Powerflow Exhausts in Salt River - ask Dick / Andrea for some "marglass" - tell them Justin sent you

It is a fabric with a shiny silver reflective side - made by bosal exhausts and used to shield fuel and electrical lines from exhaust heat.

Measure and cut a strip - fold it over and staple the two ends together with a normal stapler - silver side must be on the outside facig the heat source to reflect the heat and shield the fuel line
Title: Re: Yamaha WR450F Amageza build
Post by: darthvader on October 20, 2014, 02:18:13 pm
Sorry for cross posting, but I had to cast the net a bit wider.

Thanks for the advice Jagsding.
Title: Re: Yamaha WR450F Amageza build
Post by: BlueBull2007 on October 20, 2014, 02:43:27 pm
Jagsding you beauty!! :thumleft:

Title: Re: Yamaha WR450F Amageza build
Post by: JustBendIt on October 20, 2014, 05:50:39 pm
Sorry for cross posting, but I had to cast the net a bit wider.

Thanks for the advice Jagsding.

Did you come right Robbit ?
Title: Re: Yamaha WR450F Amageza build
Post by: B2B on October 20, 2014, 09:34:29 pm
You can get braided fuel line from Hosefit in Paarden Eiland (021) 510 4299 that should do the trick.
Title: Re: Yamaha WR450F Amageza build
Post by: darthvader on October 21, 2014, 08:09:58 am
This is what I got, perfect!  Thank Jagsding!

(https://lh4.googleusercontent.com/-WbE_V0r85eI/VEWEpoDE_4I/AAAAAAAAHT0/JuRLystSP4w/s720/20141020_211510.jpg)
Title: Re: Yamaha WR450F Amageza build
Post by: darthvader on October 21, 2014, 08:25:14 am
Added a new 3mm Polycarbonate screen last night.

Template :
(https://lh6.googleusercontent.com/-l5U7F-A-eMk/VEWE0q4O2-I/AAAAAAAAHT8/Sja_ps1Iz2s/s720/20141020_211459.jpg)

Heatgun'ed it to give it a curve.  I tried the oven method and it works well, very well, but I did not have time last night and I did not really have anything to bend it around.  I could also not find my piece of felt to bend it on.
(https://lh5.googleusercontent.com/-8NJg4yNYSLo/VEWD6ewyy3I/AAAAAAAAHTc/_X7btovlrcc/s720/20141020_220100.jpg)

Anyway, it came out well.
(https://lh3.googleusercontent.com/-KGkgWweQFac/VEWDt_qWPWI/AAAAAAAAHTU/XIpNN9vGKEk/s720/20141020_223712.jpg)
Title: Re: Yamaha WR450F Amageza build
Post by: darthvader on October 21, 2014, 08:31:30 am
To do on my list :
Title: Re: Yamaha WR450F Amageza build
Post by: SteveD on October 21, 2014, 08:39:05 am
To do on my list :
  • Mount the CAP/compass (if I am happy with it's durability)

So you finished your custom CAP repeater?
Title: Re: Yamaha WR450F Amageza build
Post by: darthvader on October 21, 2014, 08:49:06 am
So you finished your custom CAP repeater?

Follow this link : https://picasaweb.google.com/105198938841665329174/WR450?authkey=Gv1sRgCLTprvL80928PQ#6052880400230017890
Title: Re: Yamaha WR450F Amageza build
Post by: bonova on October 21, 2014, 08:50:16 am
To do on my list :
  • Mount the hooter
  • Mount the spot
  • Wrap fuel line and pull it away from exhaust with a cable tie.
  • re-wrap the exhaust and use tie wire to keep it nice and tight.
  • Wheel bearings
  • Front break pads
  • Figure out something with the GPS
  • Mount the CAP/compass (if I am happy with it's durability)
  • Change tyres and tubes, ultra-heavy duty
  • Bathe the bike in lock-tite

Nice one! Looking forward to burning some sand with you again bud!
Title: Re: Yamaha WR450F Amageza build
Post by: darthvader on October 21, 2014, 10:24:16 am
I have two questions :
1. X-ring or O-ring chains for rally?
2. 14/50 sprockets with a 2007 5-gear gearbox?  I really like the 13, but I want to save the engine and the chain guide.



Title: Re: Yamaha WR450F Amageza build
Post by: darthvader on October 21, 2014, 10:28:10 am
Ah, one last question! :)

Oil or wax for rallye? Which one and what brand?
Title: Re: Yamaha WR450F Amageza build
Post by: JustBendIt on October 21, 2014, 10:39:51 am
Buy the best chain you can get - the most expensive o - ring will be better than cheap x - ring - look for DID - I love those chains

Wax lube / dry lube - wurth make an excellent chain lube / also try white lightning dry conditions mtb chain lube - I use that
Title: Re: Yamaha WR450F Amageza build
Post by: darthvader on October 21, 2014, 10:42:22 am
Buy the best chain you can get - the most expensive o - ring will be better than cheap x - ring - look for DID - I love those chains

Wax lube / dry lube - wurth make an excellent chain lube / also try white lightning dry conditions mtb chain lube - I use that

So... I buy the most expensive X-ring then?
Title: Re: Yamaha WR450F Amageza build
Post by: bonova on October 21, 2014, 11:07:20 am
DID x-ring. Otherwise I know some people swear by the EK chains.
O-ring is not just a different seal... the metal is thinner and weaker. Stretches faster and breaks easier

Title: Re: Yamaha WR450F Amageza build
Post by: JustBendIt on October 21, 2014, 06:16:10 pm
Buy the best chain you can get - the most expensive o - ring will be better than cheap x - ring - look for DID - I love those chains

Wax lube / dry lube - wurth make an excellent chain lube / also try white lightning dry conditions mtb chain lube - I use that

So... I buy the most expensive X-ring then?

Yes ROBBIT - but phone around and don't be shy to ask for discount - Trac Mac Paarden Eiland and Craig's Maitland will give you big discount if you ask nicely
Title: Re: Yamaha WR450F Amageza build
Post by: whitedelight on October 21, 2014, 11:41:34 pm
Buy the best chain you can get - the most expensive o - ring will be better than cheap x - ring - look for DID - I love those chains

Wax lube / dry lube - wurth make an excellent chain lube / also try white lightning dry conditions mtb chain lube - I use that

So... I buy the most expensive X-ring then?

Yes ROBBIT - but phone around and don't be shy to ask for discount - Trac Mac Paarden Eiland and Craig's Maitland will give you big discount if you ask nicely

Yep speak nicely to Dave at TracMac in Paarden Eiland
Title: Re: Yamaha WR450F Amageza build
Post by: darthvader on October 22, 2014, 07:15:00 am
So I settled on a DiD X-ring, but the thinner chain.  It is actually stronger than the wider chain and it was developed specifically for MX and SuperCross.

Hope it works. Any objections?
Title: Re: Yamaha WR450F Amageza build
Post by: africanSky on October 22, 2014, 08:28:06 am
Apologies for the hi-jack, also need some chain advice: I recently had a new DID X-ring chain fitted, but the back wheel is waaay forward, is it possible to lengthen the chain to get a bit more clearance between the tyre and swingarm?
Title: Re: Yamaha WR450F Amageza build
Post by: darthvader on October 22, 2014, 08:42:57 am
So I settled on a DiD X-ring, but the thinner chain.  It is actually stronger than the wider chain and it was developed specifically for MX and SuperCross.

Hope it works. Any objections?

I also bought a PBR sprocket set, anybody had bad experiences with these?
Title: Re: Yamaha WR450F Amageza build
Post by: BlueBull2007 on October 22, 2014, 02:05:27 pm
Apologies for the hi-jack, also need some chain advice: I recently had a new DID X-ring chain fitted, but the back wheel is waaay forward, is it possible to lengthen the chain to get a bit more clearance between the tyre and swingarm?

Hi, Yes it is, you just need a short length of chain.
Title: Re: Yamaha WR450F Amageza build
Post by: adamktm on October 22, 2014, 02:44:10 pm
So I settled on a DiD X-ring, but the thinner chain.  It is actually stronger than the wider chain and it was developed specifically for MX and SuperCross.

Hope it works. Any objections?

I also bought a PBR sprocket set, anybody had bad experiences with these?

Nothing wrong with PBR sprockets. They are good. One thing you must keep in mind with an MX chain is that they stretch a lot more than the thicker ones. As long as you keep your tension right you should be fine!
Title: Re: Yamaha WR450F Amageza build
Post by: darthvader on October 23, 2014, 08:09:36 am
Last night I re-wrapped my exhaust with fibreglass and the fuel line with Marglass I got from Jagsding's connection at Powerflow Exhausts Salt River :
(https://lh6.googleusercontent.com/-FjLbTPC3gRI/VEiZA79uzdI/AAAAAAAAHUU/rB2LPq9ptEU/s640/20141022_214823.jpg)

I got some good clearance :
(https://lh4.googleusercontent.com/-_-Nrvpprfm0/VEiZFBuvLHI/AAAAAAAAHUc/uq327v9UAQg/s640/20141022_214833.jpg)

and a view from the bottom :
(https://lh6.googleusercontent.com/-Xwpa-ojaAXo/VEiZIxPaYqI/AAAAAAAAHUk/Q_MyMvv6Awk/s640/20141022_214914.jpg)
Title: Re: Yamaha WR450F Amageza build
Post by: darthvader on October 23, 2014, 09:04:45 am
I am finishing this guy on Sunday :
(https://lh5.googleusercontent.com/-UG_XLulR3uA/VAAlYxX9p0I/AAAAAAAAHLc/bKJkkuobQC4/s640/20140827_220020.jpg)

I am taking a GPS as backup though  :-\  I did not really have time to print and manufacture a PC board.  The component cost was :
Title: Re: Yamaha WR450F Amageza build
Post by: MaxThePanda on October 23, 2014, 11:24:00 am
Very cool! While the rest of us just do wiring, change tyres and bolt on accessories. I'm feeling super lazy all of a sudden.

There's a guy on ADV Rider that's developed something similar looking. Was talking about mass producing them for a lot less than the price of the ICO CAP (and with extra features) but I can't find the post right now....
Title: Re: Yamaha WR450F Amageza build
Post by: Rolling Stone on October 23, 2014, 07:14:39 pm
I am finishing this guy on Sunday :
(https://lh5.googleusercontent.com/-UG_XLulR3uA/VAAlYxX9p0I/AAAAAAAAHLc/bKJkkuobQC4/s640/20140827_220020.jpg)

I am taking a GPS as backup though  :-\  I did not really have time to print and manufacture a PC board.  The component cost was :
  • Enclosure : R75
  • IPV5 Push-button
  • LCD : R100
  • Microcontroller : R200
  • Compass : R250
  • Regulator components : R85
Very cool
Title: Re: Yamaha WR450F Amageza build
Post by: whitedelight on October 24, 2014, 05:34:34 pm
Nicely  :thumleft:
Title: Re: Yamaha WR450F Amageza build
Post by: JustBendIt on October 24, 2014, 06:52:15 pm
Last night I re-wrapped my exhaust with fibreglass and the fuel line with Marglass I got from Jagsding's connection at Powerflow Exhausts Salt River :
(https://lh6.googleusercontent.com/-FjLbTPC3gRI/VEiZA79uzdI/AAAAAAAAHUU/rB2LPq9ptEU/s640/20141022_214823.jpg)

I got some good clearance :
(https://lh4.googleusercontent.com/-_-Nrvpprfm0/VEiZFBuvLHI/AAAAAAAAHUc/uq327v9UAQg/s640/20141022_214833.jpg)

and a view from the bottom :
(https://lh6.googleusercontent.com/-Xwpa-ojaAXo/VEiZIxPaYqI/AAAAAAAAHUk/Q_MyMvv6Awk/s640/20141022_214914.jpg)


well done ROBBIT !!!
Title: Re: Yamaha WR450F Amageza build
Post by: Rolling Stone on October 24, 2014, 11:30:40 pm
Did you need to do anything special with the stator to get enough power to run all the kit on a rally bike?
Title: Re: Yamaha WR450F Amageza build
Post by: onderbroek on February 20, 2018, 08:56:45 pm
I know its been a while but a lekker read anyway. Very informative
Title: Re: Yamaha WR450F Amageza build
Post by: darthvader on February 20, 2018, 09:06:18 pm
I know its been a while but a lekker read anyway. Very informative
I miss that ugly praying mantis


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