111 risposte a questa discussione

[Jeram]

Hey guys I'm new on here, just thought Id share my project with you. I picked up a 2003 Cagiva Mito evoII 125 for $2500 last last year and took it for my first trackday. I managed to run only 4 seconds slower than my oldman on his R1, I figured I could crack the 2minute mark pretty easily with just a new set of tires (I was running old bald touring tyres that only passed scrutineering because the bloke was nice)




Then It occurred to me that If I could get the Mito to brake much harder, turn fast, accelerate more rapidly and hit a higher top speed that I could run with the big-boys in the fast group even with my novice skills So I had the motivation, all I needed was an excuse;



30minutes later while running a hot lap, I went around the outside of an 1198S at turn two, lent her over too far, dug the foot peg into the track and top a trip into the gravel at 150. ouch



Sounds to me like an excuse for a project. It had to be a 2T, The powerband is like a drug. So I decided to build a 2T supermono.

The aim of the bike was to build a bike for less than a 5 year old 600cc bike ($7000)



The bike needs to be able to round up a stock 600 on a big track like phillip island and I wanted to give a 1000cc bike a run for its money on a tighter track like Broadford. 2 weeks later when I could walk without looking like Id crapped my pants I started making phone calls and found a bloke in Newcastle who knew his 2Ts, he was referred to me by Steve from Two Stroke Shop.



So far during my daily ebay searches Iv found the following bits, at very cheap prices to keep the bike within budget.



KTM380 motor with an Electronic Power Valve (EPV) similar to that used on a late model 2Ts<BR>Motor has a Wiseco Piston,



custom shaped head,



cleaned up ports,



39mm PWM eliptical slide, shortened carb' with solendoid controlled power jets



Custom Two Stroke Institute Pipes,



and reworked exhaust ducts to mimic the last generation Aprilia 250 GP bikes





Ignitech ignition



Aprilia RS250 adjustable Showa Forks





Honda RS125 Maxton TT shock


Aprilia yspoke wheels



Aftermarket gasket and seals



525 pista race glass from Netherlands





Race discs from EBC
Talon Custom Sprokets



Custom Subframe (front and rear



RGV vj22 race tail





Dunlop KR slicks,

125/55 or 120/70 front,

155/60 rear Pirelli dragon



Also picked up an r6 radiator and goodridge clutch lines this week.



Here are some pics of the motor in the frame

http://i70.photobucket.com/albums/i92/Sabo...reet/jeram2.jpg





Expected final outcome







MORE COMMING IN 5 MINS

[Jeram]

the monster expansion chamber! Mocked up in cardboard from printed out CAD drawings, its ready to go to the lazer cutters now






Nose Cone on the bike


Pipe in fairing... JUST FITS!!



Forks wheels brakes

RS FORKS, Pegaso Wheels, Mito Yokes, EBS ducati/cagiva discs, 999R callipers












callipers need some spacer brackets made at the lazer cutters,
IV SILENCED THE CRITICS, YOU CAN RUN A TWIN DISC APRILIA WHEEL WITH RS250 FORKS USING STANDARD MITO YOKES AND AXLE
Its a much better alternative to the heavily sprung ducati forks
all thats needed is .5mm copper sheet for the bottom yoke holes, 2x 5mm axle spacers, 2 calliper brackets
EASY!

MY New ebay bargain front brake setup

[Jeram]

got a great ebay bargain billet gas cap...
I love that now everything is CNC'd that cheap chineese isnt nessisarily a bad thing...
very impressed with the quality!!



Got a Two Stroke Shop bipass thermostat to keep the bike right on temp!!


My fathers friend owns the Austrlian Factory Honda superbike team, so he sold me these trick warmers for a very cheap price!!



Talon billet clutch
Very impressive for 150bucks




New ports, ducts and pipe should yeild a little more power now!





carbon front fender



Tyga Seat, this and the fender were ordered and arrived at my door within days!!
very impressed.. thumbs up TYGA!!




purchased a micro EGT and sensor.

Features:
• Exposed Tip Sensing Junction, ungrounded (Fastest Response Time)
• Includes 316 SS adjustable compression fitting
• Made in the USA
Specifications:
• Type K Thermocouple
• -148°F to 2372°F range (-100°C to 1300°C)
• Special Limits of Error accuracy (+/- 0.4% of reading)
• Probe diameter 1/8 inch (0.125 inch) (3.175 mm)
• Inconel 600 sheathing for longevity at high temperatures
• Stainless steel over-braid with Teflon™ insulated conductors, 6 feet
• Response time (200 milliseconds)


Next post, comming in 5mins...
the latest trip to newcastle to finish the bike off!

[Jeram]

This weekend I made the much anticipated 1000km journey to Newcastle to pay Lozza a visit a Two Stroke Institute (TSI).





took off from Melbourne airport at 10pm on the Thursday nite after being stranded on the runway for 2hrs. But as soon as I stepped of the plane into the nice warm weather I knew I was going to have a great weekend.

I spent the first night unpacking the boxes apon boxes of Ebay goodies I had dumped in Lozza’s PO box over the last 6 months, It was reminiscent of Christmas morning. I then took some time to learn about the latest and greatest it two stroke technologies; dual exhaust cylinders and reduced turbulence via tapered transfer ports.

But the best part of the nite was getting to fire up my new CRM250AR that I had stored at Lozzas place






I dragged myself out of bed first thing on Friday morning where we began to finish of the new TSI workshop by building benches installing machinery with a crane and carrying boxes of parts up onto the second floor where the parts inventory is being established.



This process took until Saturday morning to complete and then the fun stuff began!
On Saturday morning I began work on the fairings which involved drilling and fastening with dzus fasteners aswell as fitting the screen and mocking-up the seat unit.














Saturday-day we installed the lathe and then proceeded to make some front wheel spacers for a final front wheel fitting. But firstly we had to hoist the bike of the ground because the bike lifts were already occupied.






Saturday nite we went out for an Irish pub meal and drinks before returning to the shed until the early hours to produce some brake calliper mounting brackets.

We started with some masonite with a pencil, verniers and a digital protractor. On the second try we got is spot on. We then transferred the template onto 14mm think Aluminium plate.



To get to this stage we required the ban saw, milling machine, center punches, callipers, and the old faithful die grinder
These are now all but finished, they fit and hold the calliper as designed but need cleaning up on the mill to look “professional”




We then began to work on the rear wheel where a spacer and a calliper mount modification was found to be required, but sadly we did not get time to
finish this


Next on the to-do list was the chain alignment which was sorted rathe quickly with a laser alignment tool.
Sunday morning we got out of bed pretty early and went straight out to the shed, had a pretty nastly nights sleep on an airbed covered in fibreglass shards so I couldn’t wait to get out of bed.
We started by machining up the “top hats” out of phosphor bronze for the rear engine mounts.
While I designed and tested a DIY soda blaster for cleaning parts, after several attemps where I returned to the shed covered in white powered with a still dirty part I finally got it to work with great results.



In some sections where the bicarbonate soda was really flowing it almost produced a finish not to far from polished Ally.
Anyhow, back to the engine mounts...
before





AFTER







These made the engine fit absolutely perfectly...






We then moved onto the front engine mounts,
The concept for these is as follows.
14mm billet Alluminium engine mount arms mount to the engines with a 12mm shaft and spacers, the engine mount is mounted to the frame with a single Hi-tensile bolt that acts as a pivot point, a second rubber mounted bolt acts as a dampener for limiting pivoting movements in the engine mounts.
This should reduce vibration greatly.






These mounts are still in the template stage and need to be finished in a similar fashion to the calliper mounts.
It was then time to down a beer and race to the airport to catch my Sunday night flight back home to Melbourne.
How 3 days went by so quickly I will never know.
Hopefully now that Lozzas shed is complete, we can progress even further over the new year and with a bit of luck get her fired up on the next visit

[Jeram]

More updates comming in the next month!

enjoy!

spread the word!

Messaggio modificato da Jeram il 24 January 2011 - 04:19

[{mRk}]

Congratulations, well done.

[skiddolo]

fantastic

[_JayD_]

congratulation!!!!!!!!!
wonderful job

[spina]

old.
non ci ho capito una sega ma quoto!

[Loki]

Good job first of all!!!
there are all the promises for a beautyfull special
very great engine but personally the fairing does not, absolutely not, convince me
...100kg? mmm.. are you sure? you can't reach this goal with the parts you have listed and that i've seen in pictures

we all wait for your updates

[andrewsp]

spina, il Jan 24 2011, 12:39 PM, ha scritto:

old.
non ci ho capito una sega ma quoto!

ri quoto XD

[Jeram]

Apogies for not writting in italian, there was too much text and photos, it would have taken me hours to do it in italian aswell
The bike will be 100kg's because the Ktm engine is much much lighter and smaller than the mito engine!
we put the bike and all the parts on the scales and it wieghed 105kgs, close enough to 100kgs
just wait untill I have enough money for a set of BST wheels! one day!


Apogies per non scrittura in italiano, c'era troppo testo e foto, mi avrebbe preso ore di tempo per farlo in italiano come pure
La moto verrà 100kg, perché il motore KTM è molto molto più leggero e più piccolo del motore mito!
abbiamo messo la moto e tutte le parti sulla bilancia e si wieghed 105kgs, abbastanza vicino a 100kgs: D
aspetta solo che hanno abbastanza soldi per un set di cerchi BST! un giorno!

[Nrg69]

Jeram, nice works... compliments to you and Lawrence
Say hello to him for me!
Cheers
Stefano

[brio]

You're a fucking mad and I envy your madness so much

[Jeram]

Nrg69, il Jan 25 2011, 09:57 AM, ha scritto:

Jeram, nice works... compliments to you and Lawrence
Say hello to him for me!
Cheers
Stefano

Ill be sure to say hello for you!

I think he mentioned you a while ago before we went nuts with the KTM engine,
Back when it was just a hotted up mito motor he was going to get some trick bits from italy for me.. I think that was you???
you must be his "italian contact" haha

[*mito_ev_93*]

spina, il Jan 24 2011, 12:39 PM, ha scritto:

old.
non ci ho capito una sega ma quoto!

quoto

[Jeram]

Airfairs booked for the 10th of march

Should get alot of the little bits and peices done

build the bottom end of engine, build some new engine mounts, subframes, mount the fairings, and do the spacers and brackets for the rear wheel and brake, and some other little bits and peices

Then all we need to do to finish the bike is modify the top end of the motor, electrics, paint, dyno tune

[Jeram]

Had some trouble trying to get through airport security with a few kilos of CRM250 cylinder in my carry on baggage, but after putting it through the scanner a few times and giving me funny looks, they finally let me through!





had some dramas with getting the old roller bearing out of the cases. tried the 3 bearing pullers that we had and bought a new one then modified it on the lathe and still couldnt get it out. local ktm dealer was too busy to help us out on the day so we had to potpone the engine rebuild.
we ended up loosing a half days worth of work on this, and it also meant that we couldnt complete a few other major jobs that we had planned.

new engine porting and pipe has been developed based on jan thiels rsa250 research and development. this should increase the power output the 85hp+ at the engine at 8500 rpm. Started porting the ktm cylinder. its looking great but is very different to you'd think was a 'fast' cylinder. its very odd. but It works

still needs some more work, but its not far off


cant show any more pics of this bit

built a front subframe from aluminium sheet, welded it together and mounted the fairing up to the bike.










we finished off the brake calliper brackets only to find that they covers just three quaters of the disc so i quickly whipped up some nw ones which place the calliper in a better spot for braking power, feel, and disc wear.






Put the new clip ons on the bike and removed the original bar mounting tabs






painting the engine covers, but dont like the look of them, so Im masking up the text and am going to paint the rest satin black.
So it will be black with orange text eventually







I built some ram air ducts from cardboard, these will eventually be mocked up in carbon.
and made some templates so that the fairings can be done in carbon , that took alot longer than I thought.





I found that the R6 radiator didnt fit inside my fairing so I dusted off the mito Radiator and put it back on



Got a new LED bar tacho instead of an analogue.
I chose this because its simple, effective... and with 75-80ftlbs of torque Im not going to need to precisely shift the gears to make rapid progress.




I inspected the gearbox I got off ebay US, it is as close to new as you can get! so Im wrapped about that!


Cant say NO to BLING like this



looking good with the fairing fully mounted (Im missing the back-left gold mito fairing/frame mount if anyone has one?????)





Overall we didnt get nearly as much done as we would have like to, but what can you do... sh*t happens (fukin bearings)
but instead we managed to get some of the 1,000,000 small jobs out of the way which are the real time consumer at the end of a project



Got the cases and crank back from KTM today, the old ones are removed and the new bearings are in.
also ordered my REDBULL decal/sticker kit

I did originally post up pics of the cylinder, but out of respect for Jan thiel and Lozza I removed the pictures of the cylinder which promises to make 80hp at the rear wheel now It is a very odd looking cylinder, you wouldnt imagine that it'd be fast by looking at it.

[skiddolo]

good job but platforms are not too backward? seems like a position for accelleration race

[Jeram]

platforms?

do you mean the foot pegs?

Those are not finished, just roughly in place so that we can build the pipe around the foot pegs