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Author Topic: Suzuki DR650SE - the bottomless thread  (Read 15252 times)

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Offline Eisbein

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Re: Suzuki DR650SE - the bottomless thread
« Reply #160 on: November 27, 2007, 09:16:11 pm »
:D :D

Boolean operators: AND OR NOT etc ...

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Offline Poffmuis

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Re: Suzuki DR650SE - the bottomless thread
« Reply #161 on: November 28, 2007, 07:58:03 am »
1 + 1 = 1
1 + 0 = 1
1 . 1 = 1
1 . 0 = 0

hehe
 

Offline LuckyStriker

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Re: Suzuki DR650SE - the bottomless thread
« Reply #162 on: November 30, 2007, 03:45:12 pm »
I started work on the bash plate a while ago

My designs started out simple


I went through a few until I settled on this:


So yesterday I bought a 500mm x 500mm aluminium plate for R150.00
the plate is 4.5mm thick which will hopefully be strong enough. It certainly feels rigid and tough.

Learning from Welsh's thread, I decided to redraw the plate on paper and then transfer it to the alu plate


Unfortunately the angle grinder makes quite a racket so I'm limited to working on weekends lest my neighbours complain
Oh a farm, a farm. My kingdom for a farm


I'll start cutting on Sunday when my neighbours are all catching a nap
will keep you posted
 

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Re: Suzuki DR650SE - the bottomless thread
« Reply #163 on: November 30, 2007, 05:54:52 pm »
4,5 mm!  That is going to be strong.
However it depends on what grade you got.  Pure aluminium is soft.  'Marine' grade is much harder but some of it can not be bent much.  Marine grade is local terminology for 5xxx series usually.  I made mine from 3mm 5000 series which is plenty strong but it cracked slightly at the 22 degree bends.
 

Offline mountainboy

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Re: Suzuki DR650SE - the bottomless thread
« Reply #164 on: December 02, 2007, 08:00:46 am »
Luckystriker, how far is that bash plate. always keen to learn DIY's
I love my bike..................
 

Offline lecap

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Re: Suzuki DR650SE - the bottomless thread
« Reply #165 on: December 02, 2007, 09:27:17 am »
A jigsaw will work much better on aluminium.

Don't use a "steel" disc on the angle grinder. Get one for billet alli & cast alli
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Re: Suzuki DR650SE - the bottomless thread
« Reply #166 on: December 02, 2007, 05:03:32 pm »
Luckystriker, how far is that bash plate. always keen to learn DIY's

I dont think LS will be able to work on it today. ::)
I've seen him this morning, and he looked worse than me... >:D ;D ;D ;D
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Re: Suzuki DR650SE - the bottomless thread
« Reply #167 on: December 04, 2007, 09:18:20 am »
 :useless:

Where's the update
« Last Edit: December 04, 2007, 09:18:41 am by newguy »
 

Offline LuckyStriker

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Re: Suzuki DR650SE - the bottomless thread
« Reply #168 on: December 04, 2007, 09:37:56 am »
Triumphs and setbacks!

After no more than 5minutes of cutting with the angle grinder I decided to switch to the jigsaw. Not only is it quieter but it‚??s also much easier to control. It even cuts quicker than the angle grinder.


Cutting out the shape proved quite easy. I couldn‚??t help but admire my own handywork‚?¶that would all change later‚?¶


4.5mm aluminium is very rigid. In retrospect I think I should have used 3mm. Be that as it may, the stuff had to be bent and I had already decided that I would do as much of the fabrication as I can.


So I clamped it down and heated up the metal with an oxylaser.


Bending the metal was still difficult and my garage quickly turned into a sauna. The heavy garden gloves barely kept the heat away from my skin.


After a few experiments I realized that bending the cold metal was not much more difficult than bending it heated. I suspect the gas in the oxylaser simply can't generate enough heat.
I spent all of Friday night bending it into shape. I even implored my pregnant wife to sit on one end while it pull on another. She glared at me with a cold eye when she realised I intended to use her extra weight to shape sheet metal.
I was in a hurry to progress since the next day was kaboef‚??s bachelor‚??s party (and I had a sneaky suspicion that I‚??d be incapacitated for the whole of Sunday).

Sunday came and went with no productivity‚?¶as expected. Fortunately almost all the preparation had been done. On Monday morning I took the plate to an Alu welder in Kuilsriver.


R100.00 later and back in my garage.


The weld tracks (or whatever you callim) came out quite nice.


And then I got out the drill and the hole saw‚?¶
The first hole went okay.
During the cut of the second hole, the drill became vibey.
On the third hole the drill began to vibrate and suddenly jumped into hammer mode. It chewed up the aluminium something fierce!!
The centre bit snapped and the hole saw began to run amok.
I reset the drill, cleaned the teeth of the hole saw, installed a new bit and tried again.
Within seconds the bit bent and the fourth hole turned into a disaster.


You can clearly see the awful damage.


After taking a break and staring at the damage, I relaxed and figured out how to effect repairs. Unfortunately it would have to wait until the next day.

So I proceeded with rounding off the corners with the angle grinder and hand file.


And smoothing the edges‚?¶


I will start repairing the holes tonight. Check out this thread tomorrow to see if I was able to fix the damage.
 

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Re: Suzuki DR650SE - the bottomless thread
« Reply #169 on: December 04, 2007, 10:14:46 am »
Looks very nice LS.
AS for the damage, I'm sure you will be able to make nice with some filing and sanding.
Otherwise Beemerman might have a magic potion for it ;D
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Offline Poffmuis

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Re: Suzuki DR650SE - the bottomless thread
« Reply #170 on: December 04, 2007, 12:08:29 pm »
looking good, dont know if id worry about the scratches too much. Its a bash plate afterall  :D
whats the latest on the headlight mountings?


 

Offline LuckyStriker

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Re: Suzuki DR650SE - the bottomless thread
« Reply #171 on: December 04, 2007, 12:19:56 pm »
whats the latest on the headlight mountings?

I've been reprioritising and relegated them to third position

First the bash plate (90% complete)
then the rear carrier rack (should be complete before this weekend)
then the headlight mountings (next week)

the order could shift without warning...I can like to be fickle
 

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Re: Suzuki DR650SE - the bottomless thread
« Reply #172 on: December 04, 2007, 02:55:35 pm »
Hey LS

When cutting the holes gooi cuttingpaste or fluid (buy from brights) sommer baie and bobs your uncle, driled some holes 25mm in 4 mm alum checkerplate, and karked to do the first two, then did the above, like butter through a knife  ;)
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Re: Suzuki DR650SE - the bottomless thread
« Reply #173 on: December 04, 2007, 04:01:40 pm »
To cut ally, use spirits (bloutrein) as cutting fluid. And use a drill press. I never use a hole saw in a handheld drill. Nearly took my foot off once.
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Re: Suzuki DR650SE - the bottomless thread
« Reply #174 on: December 04, 2007, 05:55:56 pm »
And use a drill press. I never use a hole saw in a handheld drill. Nearly took my foot off once.
+1 The shape of the bashplate may make it difficult to use the drill press (ideally should have cut the holes before bending the bashplate), just get the wife to spray lots of Q20 while you drill.
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Re: Suzuki DR650SE - the bottomless thread
« Reply #175 on: December 04, 2007, 07:49:40 pm »
Jislaaik LS ek het nie geweet jy is so handvaardig nie...

Gebruik 'n chassis punch vir daai gate ;)
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Offline Captain Zef

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Re: Suzuki DR650SE - the bottomless thread
« Reply #176 on: December 04, 2007, 07:58:16 pm »
oi Stiker, nice job on the fork pics. Just want to know where you bought your Pro-Taper bars and 4 roughly how much?

cheers

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Offline Welsh

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Re: Suzuki DR650SE - the bottomless thread
« Reply #177 on: December 04, 2007, 08:10:44 pm »
And use a drill press. I never use a hole saw in a handheld drill. Nearly took my foot off once.
+1 The shape of the bashplate may make it difficult to use the drill press (ideally should have cut the holes before bending the bashplate), just get the wife to spray lots of Q20 while you drill.

I know I have access to facilities, but it is best to lay it out, get an Autocad style programme to draw it, and laser cut the beast.

It will cut all holes you want, we cut the holes in Disc disc rotors with it!!!

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Re: Suzuki DR650SE - the bottomless thread
« Reply #178 on: December 04, 2007, 08:44:38 pm »
Welsh when you draw the drawing on Cad does the laser cut operator use the drawing to do the cut or is it preprogrammed into somthing like CNC and then automatically cut??

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One Bash Plate coming up!
« Reply #179 on: December 05, 2007, 09:31:40 am »
Thanks for the advice guys.

Repairing the damage turned out to be easier than I thought.
Two things did the trick: Cutting paste and elbow grease.

After the holes were drilled (carefully), I filed down the jagged edges. I then proceeded to sand the edges with one of those grinding stones you attach to the front of your drill (I think you use them to clean up bad welding and sharpen lawnmower blades).
Lastly I used the hand held file and smoothed everything over.

The result was satisfying. Theplate didn‚??t look factory made (as I would have liked) but if you look at the breakdown of costs at the bottom of this post you will see that it came out great for the price and effort.

The holes have no practical function. They only serve to make it look nicer. Total mass saved by cutting six holes: about the weight of a toothbrush!

After polishing the bash plate with Autosol and MrMin, I attached it too the bike. Yay!

As you can see it is completely smooth where it counts, the only protrusions being the two bolts at the back that hold it to the bike frame (will have to watch them for damage and possible protection).
You may notice that there is no access to the sump plug. The whole plate will have to be removed if I want to drain the oil. I am undecided if I should keep it as smooth as possible or cut a hole for the socket to fit through.
Opinions from you will be welcome.


A side-on view shows that the foot peg mounts are protected by the bashplate. The cavity caused by bending part of the bashplate up to form a mounting point to the frame, should not snag too much.
The exhaust does not touch the plate even though it appears that way in the pic. There is about 2cm clearance.


The plate offers little or no side-on protection except for the oil filter which is adequately protected against frontal hits IMO.

What did it cost me?

Labour: approx 8hours

Metal: R150.00
Welding: R100.00
Longer centre bolt for engine mount: R10.00
Total: R260.00

But of course I have to include some tools and consumables that I bought for the project:
27mm Hole saw blade: R43.00 (reusable)
Hole saw arbor: R39.00 (destroyed)
Hole saw arbor: R39.00 (replacement, reusable)
7pc Grinding stone set: R30.00 (reusable)
Oxylaser & gas: R157.00 (oxylaser reusable, gas depleted)

If I don‚??t ad the reusable items the cost of this bash plate came to: R309.00


But now I'm feeling a little gatvol of power tools. I'm taking today off and will only start work on the carrier rack tomorrow.