Day One - New Project

[hodakamax]

Hey Greg, yes I have some packing to install. I doubt it will help much but it might be acceptable for my use. I have a Circle F pipe on my 94A that performs great but is just too darn loud. It requires ear plugs even on a trail ride. There are lots of screens and baffles in the old 94A pipe that I'm using on this project and hopefully this silencer combination will at least make it rideable. We'll see (or hear). If this works out I may try to extend the unit to include a spark arrester.

Max

[hodakamax]

Wow, it's darned hot and muggy in Kansas today and I'm stuck in the indoors Hodaka shop. I may never need a spark arrester but while I have time on my hands I decided to at least make provisions for one before the new silencer turns 2-stroke black. The plan is (should I need one) to make a fine mesh screen cylinder that could be flared to go under this washer that is now bolted to the silencer. The screen cylinder would be about 3- 5" long and terminated on one end and flared on the other.

Just fiddling,

Max

[Bruce Young]

Max does the end of the spark arrester you built have the US forestry approved spark arrestor info on it. They have to read that info from the outside without sticking a probe into the unit. In the old days people would not believe what we put inside to stop the probe. That is the reason they went to the stamped info on the unit. Make that provision if you have not as well, it has to have that to make it pass some riding areas, throughout the US. Great work as I have said before you are an artiste. Bruce Young

[hodakamax]

Hey Bruce, there is a USF approval rating stamped on the pipe but the silencer has been fabricated from scratch. I'll probably never need one but I would like for it to be legal.

Thanks for the info!

Max

[Bruce Young]

I knew that something like that would never slip by a master builder. DETAILS,,DETAILS !!!! Thanks Bruce

[---]

Do you want it to be legal, or look as if it is legal. They aren't the same thing. Personally, I don't care about the legality. Nor do USFS enforcement types know what a true spark arrestor looks like, which in fact is why the stamping is on the outside of the unit. The wording doesn't make it legal. The wording implies that at the time of manufacture, it was made according to an approved design, of which there are several. Once modified in any way, it is no longer legal regardless of what goodies are inside. But who is going to know just by looking? The USFS and DOJ would have to resurrect design permits for a forty year old bike to prove that what you have didn't come on the bike. I don't see that happening. If the Feds can't catch a terrorist after several interviews, how are they going to catch you?

[hodakamax]

Yikes, I'm starting to panic. The Day One Project is nearly finished and I'm running out of ideas for modifications. The kinky exhaust seems vulnerable to damage and maybe I can build something to prevent disaster from happening. This skid plate/exhaust protector thing has been on my mind for awhile and maybe it's time to figure this thing out. At least I've started on it. This is what's happening so far. More to follow.
Max

[hodakamax]

Here it is mounted. The guard is 1/4" aluminum and even though it is very strong and stiff appears to need some bracing to keep it from contacting the pipe during front impact. A brace and some cosmetic work will be the next step to prolong the project.

Max

[hodakamax]

Cheez, this new guard project is about to wear me down. What seemed pretty straightforward fabrication turned into a 7 hour marathon today. Big fun of course but I am tired. This bracing was complicated in that there was a lot of trial and error plus lots of measuring not even counting actual fabrication. Not much room in there. All that's left is the detailing, fasteners and final assembly (I hope). I must say that it's rock solid now! Maybe tomorrow.

Maxie

[hodakamax]

I was talking to Ed the other day and he mentioned a "jeweling" process for the new guard. It was done on the engine cowl of The Spirit of Saint Louis. I gave it a try and I'm undecided if it's too flashy for the project. Most of it won't be visible, maybe I should look at it installed. Jeweling or brushed? Opinions considered. I must say that really goes fast, like 10 minutes for both sides. Check it out!

Max

[Bullfrog]

Dang you are FAST! That would have taken me days! I like it! It just screams "Custom!" -- like the rest of the bike.
Ed

[Bruce Young]

I to vote for the Jeweled look, Bruce

[taber hodaka]

I like it . Clarence in Minn.

[hodakamax]

Can't go wrong with three expert opinions, jeweling it is!

Maxie

[hodakamax]

OK, I think it's finished. This is an expensive piece figuring X- number of hours at minimum wage. A bit of overkill for sure. It's hard to give up the project after over a year of dabbling. What a fun experience. The seat guy will be here tomorrow to get the final info for the seat.

A bit more info on the guard. The basic 1/4" aluminum piece was purchased from a local fab/metal shop for $19 including a plasma computer cut out. It weighed in at 2.5 lbs and I removed 1/4 lb by drilling holes. Material purchased for the brackets was $4.75. The bends on the plate cost me lunch for my metal fab/machinist guy, $10 including tip. I splurged on fasteners at Ace Hardware for about $8. Bracket bends were vice and hammer. A drill press, hole saws, hammers, files and such were the tools available. How could you have that much fun for less than $40?

Max

[hodakamax]

A quick report on the "jeweling" process. It has limited applications of course but it was amazingly simple. After Ed's comment that I should try it on the new aluminum guard, I rummaged around and found this roughly 1" wire brush and mounted it in the drill press. I tested the process on the underside of the guard and was startled by the emerging visual effect. I had no layout and just overlapped and free handed the rows. I seemed that you could make no mistakes. The entire piece was covered in less than 10 minutes. Amazing!

Max

[hodakamax]

After mounting the guard my fears of too much glitz went away. It seems that just enough is showing to be interesting. Probably a good idea thanks to Ed. I must say that it doesn't just bolt on. The front brace pieces have to be fed in one at a time for assembly. Not only do you need another hand but you also need smaller fingers than I have. Not much room in there. A little frustrating but I guess I won't be removing it that often. Anyway this part is finished and the seat guy just picked up the new seat pan and made many measurements. Getting close to the end of this part of the adventure!

Max

[hodakamax]

Well I'm pushed off to page 2 again. Time to act on a new idea for the project. This has always been a weak spot on these old brake pedals and things are a little slow while waiting on the seat to be finished. I've bent some 1/4" rod to brace the pedal both lengthways and crossways. I think my expert welder has probably taken the weekend off and I'll have to wait until next week for the final on the pedal. Hmm, my new boots are always slipping off the brake pedal. It might be time for some alligator teeth also.

Later,

Maxie

[hodakamax]

I never tried to make alligator teeth before and it took a couple of tries to get the spacing and bit size figured out but I think this will work. 1/4" bit on 3/8" centers worked out not perfect but OK. I also narrowed the width of the petal outside and rounded the corners for a better wrap of the teeth. A fun afternoon, I wish I knew how to weld.

Max

[hodakamax]

This morning I took my brake project to Rod Blackburn's locally famous Exhaust and Hot Rod building shop for final welding. I remember now why I gave up welding. Again, he was enthused and dropped everything to knock it out. Another nice job again. Check it out!

Maxie

[viclioce]

Nice!

[hodakamax]

Hey thanks Victor. Just got it remounted, looks factory! A while back I bought some new Alpinestar boots for the ISDTRR in Oklahoma. They fit great but they're so rigid and heavy duty I couldn't feel the brake pedal and they occasionally slipped off the pedal. Hopefully this will help!

Max

[Dale]

That does look very nice. Just like it came that way...

[bchappy]

Should have come from the factory that way. Good job.

[dirty_rat]

Funny that you mentioned that you lost some feel of the brake pedal with new boots. I found the exact same thing. I was so used to my old (30 some years old) Hi-Point boots, that when I got a new pair of AlpineStars I couldn't feel the brake or the shifter lever. I ended up getting a pair of O'Neal boots because I could feel the brake and shifter with them (but I'm sure they don't give as good of protection as the AlpineStars do.)