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I could use any switch I want for the ignition so long as it's rated for the current I'm running through it. The point of a relay is to broaden the selection of switches I can use to control the main power. It also means I can run a much smaller gauge wire to and from the switches I'm using to...

#1C# indicates the Relay number, and the contact number of that relay. LTS = Left Turn Signal RTS = Right Turn Signal BLS = Brake Light Switch BL = Brake Light HL = Headlight R1 = Main Relay R2 = Horn Relay H-BTN = Horn Switch S1 = Starter Solenoid SMTR = Starter Motor The only portions that...

Cost Availability of leftover/surplus parts at work Less bulky Easier to work with I have pretty limited space to work with and I'm more familiar with the DIN mount industrial parts. Automotive relays are made for higher inrush currents than I need and would have taken up way more room. They...

Crappy cellphone picture update. I wasn't having electrical system issues. The motormount as built with the battery installed in it was allowing the engine heat to boil the electrolyte in the battery. It took killing 3 batteries before I realized this and I have since made a new battery tray...

The diode in my charging circuit has apparently gone bad and has been allowing the charging coil to suck the battery dry. https://vimeo.com/97540532 https://vimeo.com/97540722

Very small update on Vlad. Went through two dead batteries I had ordered online. Both were crap when "new". Ended up finding out that I can get the same battery at Home Depot for a bit more money, but also much easier to return and less likely to be crap. Used the down time to snip every-other...

Finally done dicking around with the electrical enclosure. Had some issues getting it to fit yesterday, and decided it was way too shiny. Tomorrow I can start wiring. I'm not sure where I would take it around here for jumps. But I will get a video recorded soonish. The only one I have is 2...

That's going to be true no matter how long you've been doing it. I have difficulty just reminding myself of the basics (prep work prep work prep work and plan ahead for warping) when I haven't welded in a while. Wait until you start welding other materials in ever more awkward locations and...

Main jet is drilled out to #79 (1/32"). I have not yet run the engine with the new air box, but it isn't significantly different from the previous setup aside from location.

Mostly finished with the new electrical enclosure. Made out of stainless plate, treadplate for the box sides, and t-slotted aluminum for the corners. I just need to drill some holes for wire pass-through and once my relays show up I can get the wiring finished.

Air box cover made out of more treadplate scraps. Formed on the pan-and-brake, cut to fit, then drilled. 1-1/4 tubing cut on the band saw using the miter guide. More parts to weld together. The heavy welds on the lower motor mount distorted it a bit so I had to clamp it down and mill the...

Since the new motor mount is slightly wider, the old cover won't fit. So I'll have to make a new one. Traced the carburetor gasket onto a post-it note, then used an engraver to transfer that onto aluminum. Used a manual knee mill to rough out the inside and channels, then finished the...

Made a good deal of progress today. Did a complete teardown of the bike. Here's the two cracked welds in the old motor mount. I made changes to the CAD files I still have of the original motormount, printed templates out on the plotter, then taped, scribed, and center punched. I cut them to...

Two of the welds on the lower motor mount are cracked pretty badly. I'm going to be dropping the engine out of the frame sometime in the next week so I can start the process of making a new one from scratch. The original mount included a lot of room for adjustment because I made it early in the...

This is what I ended up doing with my dirt bike frame. http://www.captainslug.com/temp/vlad_029.jpg http://www.diygokarts.com/vb/showthread.php?t=23823

Took it out of storage with no issues. Battery is fine, no bad gas, started up easily. Runs a bit lean with the new exhaust so I probably need to drill out the main jet a little. http://www.captainslug.com/temp/vlad_049.jpg http://www.captainslug.com/temp/vlad_050.jpg 05/02/14 Edit: Drilled...

New header is finished. I bought an 11-inch clearance mini bike header from OMB Warehouse, cut it short, welded a 3/4 NPT half coupler onto it, then made and welded on a tab so I can secure it to the frame. http://www.captainslug.com/temp/vlad_046.jpg...

Just finished removing the governor and subsequently an oil change. Probably would have been much easier if I just dropped the engine out of the frame. But not doing so helped me confirm that I have the minimum amount of space needed around the engine to get the valve cover off. I did discover...

Finally got around to taking some pictures of the electrical enclosure. In hindsight it's not a good idea to put your electrical system underneath the engine since any oil leaks as well as road grime will get in there. To work on anything in there I'm laying on my back staring up at everything...