Popular Post Vintage Grumble Posted May 19, 2019 Popular Post Posted May 19, 2019 So I met this guy Dave my last year of high school. A year or so later he came into my work (wreckers yard) looking for a fan for his off roader, which he had just purchased from his little sisters boyfriend (who had purchased it from a work mate, who had originally built it in the 90s) He said I should come see it sometime. I went to have a gork at it some time later, but it was out of action due to the steering rack being broken (steering geometry was all wrong) Dave had worked on it on and off for years, but never got it drivable again. I'd had a crush on it ever since I first laid eyes on it, and pined hard to go for a hoon in it. The off roader then spends most of it's time hidden in a shed, I see it now and then due to me ending up married to Dave's little sister (who I wouldn't have met if I hadn't gone to see said off roader, and started hanging around with Dave) 18+ years after I first saw it, Dave loses interest and decided to sell, so I snap it up. One little problem though, I've never been able to drive it, because it's always been broken, and because my 6'4" ass don't fit in it. That's the first thing I'll sort, so I have cut the front off it, and will extend it about 120mm. It's a bit of a kit set at the moment, due to Dave starting on fixing a few of it's design issues but not finishing them, and from me stripping the front to extend it. I want to get it drivable pretty quickly, and then will work on modifying/upgrading a few things I don't like. A few pics. Just before cutting the front off, Boxes full of bits, Like all cool things, it has a live rear axle, with a gay ass 4x motorbike shock set up, one of the things I want to change. It's powered by a late 80s GSZ600 engine, that makes about 80hp. It also came with a spare engine, which I hacked out of this bad boy, I've had this in the shed for quite a while, but haven't let myself touch it until I finished a few other projects, and sold off a few other things. Super excited about getting stuck into this, and one day being able to hoon it after nearly two decades of pining. Regards, VG. 18 1 Quote
Vintage Grumble Posted May 19, 2019 Author Posted May 19, 2019 55 minutes ago, kyteler said: SHS chassis? It's basically a Ferrari. Unlike a Ferrari, the Barry that built it used imperial SHS, I had to by a full 5.5m length to get the 480mm of 1.1/4" SHS I needed for the extension. 3 Quote
Bling Posted May 19, 2019 Posted May 19, 2019 Any reason you didn't just stretch out the frame, like you do hose? Looks like a sweet project though! 1 Quote
Vintage Grumble Posted May 19, 2019 Author Posted May 19, 2019 7 hours ago, Bling said: Any reason you didn't just stretch out the frame, like you do hose? Looks like a sweet project though! I considered this, but thought the chassis would get too skinny when I pulled it longer. 1 Quote
glen Posted May 20, 2019 Posted May 20, 2019 Nice, looks like it could be based off an Edge Mini Sprint. Get IRS and class 10 registration 1 Quote
Vintage Grumble Posted May 20, 2019 Author Posted May 20, 2019 8 minutes ago, glen said: Nice, looks like it could be based off an Edge Mini Sprint. Get IRS and class 10 registration Aww chur, I'll have to look up the edge mini Sprint. Yeh, they shocks are on my list of things to replace (along with a bit of the rear end framing) but not sure I can be arsed changing the rear to IRS. I'll see how shit it is to drive, and decide from there. The main problem with shocks is they are so friggin expensive! Quote
glen Posted May 20, 2019 Posted May 20, 2019 Could get some great/terrible aliexpress spec shocks https://images.app.goo.gl/Rzyu7FbExECzS8J96 Quote
Vintage Grumble Posted May 20, 2019 Author Posted May 20, 2019 30 minutes ago, glen said: Could get some great/terrible aliexpress spec shocks https://images.app.goo.gl/Rzyu7FbExECzS8J96 Some of those look pretty tempting actually/good enough for this basic old heap. The cheapest option I've found in a known brand would be these fox air shocks https://www.ridefox.com/filter.php?m=offroad&t=shocks&f1=type&v1=Air Shock Not cheap, but not crazy. Well until you add freight I guess. Quote
Popular Post Vintage Grumble Posted May 25, 2019 Author Popular Post Posted May 25, 2019 So I fixed the main problem, I now fit in it. I made up little 120mm extensions, with a bit of tube hammed into them, to add a bit of strength. Welded them into the frame, and then added side and bottom cross braces. I just have to sort out the top pipes now. A few of the problems this thing had, that Dave sorted out, were the steering rack that kept snapping rack ends due to bung geometry. It had a rack out of some grotty old english car originally, so Dave shortened a KP60 starlet rack to suit, He also made new knuckles to fix the bung geometry. The next big problem was it was way over geared. Apparently they hardly ever got out of second. So we got a big ass sprocket for the back, which should cause it to top out at 140ish kmh. It also used to have a motorcycle brake disc and calliper, which didn't work so well, so Dave made a hub to take a car disc, and calliper to suit. Apparently it also never quite ran right, which they put down to it not having an air box. They made up a plenum, with little trumpets inside. Another thing Dave made, was a double layer heat shed with an air gap, to stop the exhaust melting the seat. I'll probably make a top shield to protect the driver from the fuel tank, thats located behind your head. I'll start putting the front end together next, so I can finish off the steering gubbins. Regards, VG. 22 Quote
Vintage Grumble Posted June 1, 2019 Author Posted June 1, 2019 I need to flip this thing on it's lid, so I can finish welding up the frame. I got it running, to heat up the oil pre draining, it was running like a hat full of vagina's, but It's probably only run like 5 times in the last 18 years, so that's understandable. When I drained the oil it seemed to be mostly petrol, so I guess a float is stuck. Whipped the carbs off for a clean, hopefully that will help it run better. Regards, VG. 9 Quote
Popular Post Vintage Grumble Posted July 24, 2019 Author Popular Post Posted July 24, 2019 So I've done a bit more on this dirty Berty. I flipped it over to finish off the frame extension, and cut off a few unneeded bits. Seeing as it wouldn't rev or idle with no choke, I cleaned the carbs out, they had sea weed growing on the float needle things. I also welded up the plenum, and played around with restricter sizing (had to go down to a 35mm opening) this resulted in it running waaaaay better, and revving out like it should. I also removed all the washers that had been put under the needles (they were trying to make up for them not lifting due to lack of vacuum) and it ran even betterer again! I needed some way of mounting the air filter, and remembered I still had some silicon left over from the hektik Hilux, it was perfect, and pretty! Little vid of it running betterer, the linkage was a bit sticky, hence the high idle then dieing out at the end. Then I took the wrap off the headers as it was fucked, and cleaned the headers up a bit. Then I changed the muffler out for a prettier one, it's from a GSX1200, so even though it has one chamber (the other was straight through) it has a larger outlet than the original, so should flow well. I had a sprocket that needed boring and keying, but decided to go with a plate wheel and bolt it to the original sprocket hub. Bit bigger than the OG one. I then put the back end together, and ran a brake line up to the slave cylinder. Got a few hoses from the wreckers, this female - female clutch line from an AE100 Corolla made life easy, used the mounts and all. Then I made a new gear shifter linkage, as the old one was fucking rank. I also moved it forward a bit to suit me. Next was sorting the steering wheel/shaft/rack. This was a bit of a mission, but it worked out well. Managed to mount the wheel on top of the bar it used to be below, and move it forward a bit, so I can pilot the vehicle, with the added bonus of being able to get in and out of it. Also put the front suspension back together, so I could work out the pedal position, and the position of the bar that mounts the steering bearing, clutch and gas cable mounts, and the brake master thing. The brake master has to be in this funny frame thing to miss your legs and still fit under the hood. Once all that was done, I crimped the cables, but they were too short due to me lengthening the frame, so I made little extension doofers out of D shackles. Now the back ends done, all the controls are pretty much done, and it's running better, I'm getting onto doing the front steering knuckles and tie rod ends. Still much to do, but progress is being made! Regards, VG. 24 Quote
felixx Posted July 24, 2019 Posted July 24, 2019 The 20 year wait is almost over, I remember waiting 10 years to have a hoon once. I hope you have a better experience than mine. In the 10 years the chassis had sagged, there was gravel rash and excessive piston slap. Mind you I only got a bottle of Marque Vue into her as prep, you have done the full rebuild. Well done Sir! 2 1 2 Quote
Popular Post Vintage Grumble Posted August 1, 2019 Author Popular Post Posted August 1, 2019 Progression. I drilled the steering knuckles out on a 20 deg angle, and then fucked around for aaaaaagggggggeeeeeees playing with different hights and angles on the struts, trying to get the best all-round set up. Once decided, I welded the piss out of them with Mr Miggins, and then put the front end together. It's got some decent steering angle, I just hope the racks quick enough. It's 3 turns lock to lock, and the steering is nice and light. Looking more like an offroader, I also did some highly scientific suspension testing, It's got about 5 inches of travel in the front, and 7 in the back, which is not too bad really. I started it last weekend and managed to free up the clutch (was seized from sitting so long) by standing on the brake while powering on in first gear, so pretty stoked that worked. Excellent. Regards, VG. 19 Quote
Popular Post Vintage Grumble Posted August 20, 2019 Author Popular Post Posted August 20, 2019 Got a little bit more done. Got an out of date unused 6 point harness, modified it to be 5 point, and fitted that. Just had to make a mounting bar for behind the seat. Then I got a small car battery (will have electric reverse + winch + lights in the future, so didn't use motorbike spec battery) and set about making a shitty mount for it. It used to be in the nose, but got the bash, so I've mounted it on the side. I might have to make a cover to stop it getting owned by debris in the future. I recycled a bit of seat belt and buckles, but couldn't get it tight, so changed it to good old fashioned rods N nuts. I also put a speed sensor on the front wheel for the trailtech dash. I just have to reroute some wiring and mount the magic electrical boxes, and it's ready for a gentle shake down run, hopefully this weekend weather permitting. If all goes well, I'll make a new front bash plate thing, as the old ones a bit rooted, Then paint all the bits that need painting (probably just rattle can it, as shit will keep getting modified) then start fitting all the alloy panels. I also have to make a dash that the bonnet will join up to. Hopefully the next post will have evidence of a successful test run. Regards, VG. XOXOX 23 1 Quote
Popular Post Vintage Grumble Posted August 29, 2019 Author Popular Post Posted August 29, 2019 So it took longer than expected to sort the wiring, which still isn't finished, as I need to make a dash plate and get some new switches n shiz, before I can finish the wiring off. I've been having problems with my trailtech dash giving weird rpm values, and I was darned if I could figure out why. Turns out Dave, being the Barry he is, installed solid copper leads on the motor, so I get an rpm signal even when the wirings not connected to the trailtech, so much zap, lewlz. I might have to put standard leads on it, as I kinda need the rpms to read correctly. Anyways, this evening I halfassedly finished the wiring and put cable ties all over the place, and decided it was a good idea to take it for a quick test drive. In the dark. With no lights. Up my residential street. It was quite exciting. All the controls work well, which is nice, but the motor is not running correctly. I think it's leaning out up in the revs, not that I know how many revs it's doing, so I will have to play with the tune. The gearing seems good, it's definitely not over geared now. After a couple of rips around the neighborhood, I had a quick look over it, and noticed one of the rear sprocket grub screws had stripped out, so I had to pull the rear end to bits so I can drill the 8mm grubs out, and upgrade to 10mm. I'll loctite the piss out of them too. I'll try sort a few issues out, and hopefully take it somewhere this weekend for a second test drive, to see if things are better. But yeh, not too bad, but still lots to do. At least it's now moved under its own power for the first time in nearly two decades, so that's a win. Regards, VG. xoxox 12 1 Quote
Popular Post Vintage Grumble Posted September 1, 2019 Author Popular Post Posted September 1, 2019 BEST DAY EVER. I got new leads, fitted the new plugs that came with it, and headed for the hills/forest. First off it ran like absolute shit, I was cursing the new leads/plugs, but with @keltik 's help we determined I was a dingus, and had put two leads around the wrong way. Correcting this made things much better, but it wouldn't pull past around 5.5k rpm. We removed the restrictor plate, which made things bettererer, but still couldn't get past about 8k rpms. I then half covered the intake pipe with duct tape, and BINGO, spot on. It will pull happily into the late 10k rpms, which is about what this old donkey is meant to do. Fucking stoked to get it running well so quickly. And shit me, 75ish hp seems like a lot in this thing, it's quite scary. Thrashed around in it for a few hours with pretty much no issues, apart from grub screws in the drive sprocket coming loose. There's a few small improvements to be made, but pretty minor. I took a couple shitty vids which I'll slap up in a min. Pretty stoked it didn't disappoint me after all these years! 12 Quote
Popular Post Vintage Grumble Posted September 1, 2019 Author Popular Post Posted September 1, 2019 Also, it tops out at 120kmh, but that feels plenty fast enough at the moment. 12 1 Quote
Recommended Posts
Join the conversation
You can post now and register later. If you have an account, sign in now to post with your account.