Popular Post gazguy Posted January 7, 2022 Popular Post Share Posted January 7, 2022 So 2021 was a bit of a shitter for me, recovered from collarbone surgery after being hit by NZ Post on my C50, broke up with my long term girlfriend and finally moving house twice! So to keep me from getting anymore depressed I like to my mind occupied so that means fucking around with small Japanese bikes. After selling my 2 Honda CBX250RS and 2.5 Kawasaki KV75 I had some spare coin so I thought I'd do what alot of others do on here and thats buy another project before finishing the others. The others being the white CT90 I was building. To be honest I wasnt really feeling the CT and have really been thinking of building a chaly since my accident. So I put the feelers out for a Chaly, there were few on trademe but they were a bit spendy for me and it was a shame to do to them what I wanted to. Anyways a mate hit me up with a frame he had the he was going to convert to electric, a deal was struck and I paid him what he paid for it. I'm sure this frame has passed through a few hands of people here in CHCH. Overall the frame was in OK condition. At some point someone has removed some of the paint causing heavy pitting but no terminal rust causing me to have to get the welder out. Within the space of a week I'd managed to piece together parts to try and get it in to a roller. Wheels, mudguards and swingarm were sourced from my mate Jeremy and the forks are a disc front end from the guys MBike. The overall quality of the forks wasn't too bad but the strength of the headlight ears was really average. I didnt like the position of them as they were a bit too high and too pointy and thin. so that got remedied by hammer forming some new ones and welding them in a lower position. 12 Quote Link to comment Share on other sites More sharing options...
gazguy Posted January 7, 2022 Author Share Posted January 7, 2022 Just before New Years I sent the frame, swingarm and wheels away to get blasted. I was charged a bit more than my usual guy but he wasnt open over the holidays. After a bunch of primering and sanding the frame and other parts were ready for paint. doing body work really sucks! I dont know how anyone can do it for a job. I can pretty much say I've spent most of my time off waiting for paint to dry. Once the paint had a chance to cure, which was all of 3 hours I started bolting parts on cos I'm really impatient haha. The engine is a manual Lifan 125 which was in my CT90. Following numerous trips to MBike more and more parts were acquired. Over the weekend I'll try and get the wiring and fuel lines sorted out. 4 Quote Link to comment Share on other sites More sharing options...
Popular Post gazguy Posted January 7, 2022 Author Popular Post Share Posted January 7, 2022 19 Quote Link to comment Share on other sites More sharing options...
Popular Post gazguy Posted January 14, 2022 Author Popular Post Share Posted January 14, 2022 A few more jobs ticked off on the chaly over the past few days. A big hurdle was the wiring as I'm pretty shit at it but getting better, with the help of my dad we got there. I had to cut down the side stand considerably, the footpegs will be changed for Anderson style pegs I had to put an adjuster on the clutch lever as I've routed the cable through the frame and can't access the inline adjuster. New chain, rear sprocket and chain adjusters mounted too. @dvsdev.chaly on Instagram 3d printed me a fuel tap handle which is awesome 15 Quote Link to comment Share on other sites More sharing options...
gazguy Posted January 25, 2022 Author Share Posted January 25, 2022 I really wasnt feeling the tiny side stand and it was pretty pointless to be honest. So I opted for the centre stand. With it being lowered quite a bit it lifted the rear wheel so far off the ground it became unstable. I cut off 25mm from the bottom and made new pads from some 25mm shs. I purchased a chaly big bore exhaust from mbike, its for a standard chaly so the rear mount doesnt meet up due to the bigger engine. Other than that it looks pretty sweet. To stop the centre stand from hitting the swing arm and the chain i whipped up a small stainless bracket with a rubber stop and bolted it to where the passenger pegs would go. I tried the kickstarter from my C50 to see what the fitment would be and it was touching just by millimeters. I didnt want it scratching my new exhaust everytime I kicked it over so I managed to get an old c50 kickstarter from my mate Jeremy, pie cut it and bent it forward and tig welded it up with stainless rod. Plenty of clearance now! 8 Quote Link to comment Share on other sites More sharing options...
gazguy Posted February 3, 2022 Author Share Posted February 3, 2022 On my lunchbreak at work I knocked up a rear brake adjuster on the lathe, its an old 3 phase colchester and runs like a champ. I made up a battery box that also held the voltage regulator and the flasher unit. I'll get around to powdercoating it at some point 4 Quote Link to comment Share on other sites More sharing options...
flyingbrick Posted February 5, 2022 Share Posted February 5, 2022 Hope 2022 is going better for you man. How did you hammer form those headlight ears so perfectly? I can't seven see hammer marks?! Quote Link to comment Share on other sites More sharing options...
gazguy Posted February 13, 2022 Author Share Posted February 13, 2022 As the weathers been pretty shit here in CHCH over the weekend I got stuck into the chaly. Another trip to mBike and a good few dollars lighter I walked away with a tinted windshield and some widend rims. the front is 3.5 inch and the rear 4 inch. 7 1 Quote Link to comment Share on other sites More sharing options...
gazguy Posted February 15, 2022 Author Share Posted February 15, 2022 The battery box has been powdercoated at work and installed, I used those cable tidy velcro straps from Bunnings to hold the top down. Also a sneak peak at my kicker pedal I made, its getting pinstriped tomorrow to finish it off. 5 Quote Link to comment Share on other sites More sharing options...
gazguy Posted February 19, 2022 Author Share Posted February 19, 2022 This thing is nearly complete now. I just need to make a bracket for the horn which I'll do tomorrow. I put some feelers out for an air filter cover, to no avail. So my way of thinking is cant find it, make it! So thats what i did. I used a combination of pressing and hammer forming. I used 2 75mm OD 6mm thick discs and 1 2mm 75mm OD disc cut to the profile I need. It just needs some minor massaging then prep it for paint. The last major piece of the puzzle was the seat which I got this morning thanks to Andy and Wei at mBike. Bolted it on and couldnt be happier then took it for a hoon down the street 8 1 Quote Link to comment Share on other sites More sharing options...
gazguy Posted March 2, 2022 Author Share Posted March 2, 2022 Its normally the smaller jobs that take the longest, but im gradually ticking them off the list. 1st up is the painting of the air filter cover 2nd is the air filter cover. I found some old mag wheel centre caps at work, drilled some holes and put a 6mm rivnut in the air filter. 3rd is the kicker pedal I fabricated out of some flatbar, plate and an old vans phone case i had hidden in a drawer. Lastly I bought some side boxes at the winchester swapmeet last year when swapmeets were actually a thing and you could go to them. Just toying about with the idea of them but Im pretty keen to make some brackets, colour code them and have them fitted ready for syds run this year to store some tools, spares and a few BRB Hazy Pale Ales 5 3 Quote Link to comment Share on other sites More sharing options...
gazguy Posted April 8, 2022 Author Share Posted April 8, 2022 I got the chaly registered and road legal and took it out for its first shakedown run a few weeks back around the hills and through Lytellton to Wunderbar. Those side boxes I got from the swapmeet last year were on the back of my mind so I pulled the pin and started making some brackets for them The boxes themselves are pretty rough and have a few cracks and pieces missing, so I'll address them, paint them and maybe add some gas struts. 6 1 Quote Link to comment Share on other sites More sharing options...
Popular Post gazguy Posted April 8, 2022 Author Popular Post Share Posted April 8, 2022 14 2 Quote Link to comment Share on other sites More sharing options...
gazguy Posted June 27, 2022 Author Share Posted June 27, 2022 Whilst the blue panniers were a great addition theyre just too brittle and small parts kept breaking off after every ride. So I bit the bullet and decided to start making some from steel. To start with I made some channel out of 18g with a slight radius, not a breaked edge. Then I had to modify my shrinker stretcher stand as once I got to certain point it would hit the stretcher stand upright. so I moved them apart . Using the shrinker I incrementally started shrinking the sides. Shrinking one side then the other so they'd both be the same. One end is 90 and the other is just under. Next is to make the sides and get them welded in 6 Quote Link to comment Share on other sites More sharing options...
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