gazguy Posted March 29, 2021 Share Posted March 29, 2021 Lately Ive been having a clearout of stuff that I really dont need, that includes unfinished projects. So to help things along I bought an old CT90 frame and front end. Plans for the bike are to strip it to bare minimum, Lifan it and ride the fuck out of it at the waimak tracks. There will be some small bits of fabricating but nothing too extreme and keep it quite simple and tasteful. The theme of the bike is The Pork Chop Express from the 80s movie Big Trouble in Little China. I have a thing for 80s movies, I named my poo brown C50 after Sexual Chocolate from Coming to America 8 Quote Link to comment Share on other sites More sharing options...
gazguy Posted March 29, 2021 Author Share Posted March 29, 2021 A while back I cut and machined some 25x50 RHS to make a swing arm, just to see how it would work out. So I jigged it up and glued it together. I still need to notch the brace to allow for more movement as it currently hits the frame under full load. Ive got a pair of Aliexpress Ohlins knock off shocks to go on too 6 Quote Link to comment Share on other sites More sharing options...
RUNAMUCK Posted March 30, 2021 Share Posted March 30, 2021 MBike can do a CG110 front fork with disc brake for not much. ChrisQCR has one on his CT. (I plan on getting one for my K0) 1 Quote Link to comment Share on other sites More sharing options...
GuyWithAviators Posted March 30, 2021 Share Posted March 30, 2021 7 minutes ago, RUNAMUCK said: MBike can do a CG110 front fork with disc brake for not much. ChrisQCR has one on his CT. (I plan on getting one for my K0) I’ve been waiting for mine for 6 months now. They do look good though. 1 Quote Link to comment Share on other sites More sharing options...
RUNAMUCK Posted March 30, 2021 Share Posted March 30, 2021 Oh, they did mention a big shipment was arriving soon? I'm miles away from ordering one myself tbh. Quote Link to comment Share on other sites More sharing options...
Popular Post gazguy Posted April 2, 2021 Author Popular Post Share Posted April 2, 2021 Today I was planning on welding up some patches on my vauxhall but the weather turned to shit, so I thought I'd do some work on my ct90. 1st I cut some 41mm tube to make a double downtube, but because its above the downtube does that make it the top tube? Then i trimmed up some 18g steel, drilled some holes ready for dimple dies then put a small brake on the edges so it sits better on the tube. At 1st i was going weld the plate to the tubes but wondered how I'd remove dirt that would gather inside. So I flagged that idea and now it will be held on with button head cap screws. Ill change the position of the holes as theyre messing with my OCD. Its held on with clecos at the moment, I'll repeat the same for the other side. To give the bars some strength i added a crossbar, the same as BMX bars and cut of the indicator mounts. I used my tube notcher to cope the 22mm tube, its from Machinery House and is branded as their own, it took some dicking around to get it centred as it was cutting on the wank. Its the same as a harbor freight unit just a different colour and stickers A few nights back I notched the brace in the swingarm to get more movement, and I mounted one of the shocks to see what it would look like. 12 Quote Link to comment Share on other sites More sharing options...
gazguy Posted August 17, 2021 Author Share Posted August 17, 2021 After contemplating on what engine to put in I decided on a manual Lifan 125. The mounting holes are different and some minor cutting around the mounts was needed to make it fit snug. I left the top hole as is but redrilled the frame to accept the bottom mount and reinforced it with a heavy washer welded to it. I dropped the frame and other parts off to the blasters the frame came back a little worse for wear. various amounts off peppered metal which were cut out and replaced with new steel. Even though its an offroad hack I still like to have my bikes looking half decent. I got a replacement swingarm cheap that needed some surgery due to the previous owner running the rear wheel loose. 2 Quote Link to comment Share on other sites More sharing options...
Popular Post gazguy Posted August 17, 2021 Author Popular Post Share Posted August 17, 2021 Once all the welding and body work was completed I painted the frame, swingarm, mudguard and tank with epoxy gloss white enamel, no flash paint here! just a 1L tin from Bunnings I wasnt too happy with the look of the bars either so i cut the cross brace I made and replaced it with a removable item made from stainless round bar and a stainless shackle cut in half. The bars and bashguard were then powder coated at work. When i went to put the original CT forks back on the bike I noticed the seals were leaking due to the fork tubes being very pitted, so I tried on some CB forks ive had stashed away for a few years along with NOS fork shrouds, which I'll either paint white or black. I'll get the wheels sandblasted as theyre a little scabby and get them powder coated also 11 Quote Link to comment Share on other sites More sharing options...
gazguy Posted August 18, 2021 Author Share Posted August 18, 2021 I got given these footrests from a mate, the sidestand mount had snapped off so i made up a new one and fizzed it on. When I went to paint the foot pegs the small tube that the clevis pin goes through had detached from both of them so I fizzed them up too. A lick of epoxy enamel later and they are good to go. When i was over in one of the sheds I grabbed a spare 19inch wheel and tyre I had on a CT185 and put it on temporarily while I get the wheels blasted and powdercoated. The fork shrouds were painted and fitted today as well. Having them both painted the same colour made the front end look longer than it was so i painted the headlight mounts hammered finish silver to match the dimple died panels and the lowers satin black. I'm really happy with the outcome 7 Quote Link to comment Share on other sites More sharing options...
Chris.QCR Posted August 18, 2021 Share Posted August 18, 2021 The 19" looks great and would make for better handling on the Maungatapu Track on the Molesworth road in the NY 2 Quote Link to comment Share on other sites More sharing options...
xsinclairx Posted August 18, 2021 Share Posted August 18, 2021 That project is coming along nicely! Very cool! 1 Quote Link to comment Share on other sites More sharing options...
Popular Post gazguy Posted August 31, 2021 Author Popular Post Share Posted August 31, 2021 More progress has been made over this lockdown. I'm moving soon so I thought getting this bike into a roller will make it easier move around. I threw the tyre on the rear and managed to pinch the tube. Anyways I had a go at making the exhaust, the header part at least. It's full stainless including the flange that clamps to the head. To take a break away from working on the bike I knocked a few stands for my BMX's so theyre not leaning against anything and everything in the garage. The yellow one weighs as much as the ct90, I'm not kidding! 10 Quote Link to comment Share on other sites More sharing options...
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