Baja Doodlebug mod/rebuild

[Oxymoron]

I'm still stuck on your first photo. How did you get that tiny kid to balance on top of the bike like that?

Thank you. I laughed out loud on that one

 

[mckutzy]

I ride when I can, couple of months I've been in transition to moving to another house, so all my stuff is in storage. It sucks, I bought the new DBR1 clutch and can't ride it yet.

 

[Oxymoron]

I ride when I can, couple of months I've been in transition to moving to another house, so all my stuff is in storage. It sucks, I bought the new DBR1 clutch and can't ride it yet.

That does suck man... that thing is too cool to be locked up. I was initially going to get that clutch, but decided not to use it on the mini bike because I share it with my boy (don't think he's ready for the added distraction of trying to operate the throttle and clutch without stalling or ending up on his back). I'm definitely getting one of the next iterations for a kart project.

 

[OzFab]

I should be slightly ashamed... I'm an electrician

At least your outlets work No tradesmans syndrome" there...

I'm still stuck on your first photo. How did you get that tiny kid to balance on top of the bike like that?

At first glance, I thought the same thing; the trip up is the handlebar in front of his legs...

 

[Oxymoron]

At least your outlets work No tradesmans syndrome" there..

Haha, yes... I make sure everything works. I just try not to do many electrical projects around the house. I loathe residential work. I do controls and automation for a living, which is fun, as opposed to residential, which is like.... work

Okay, small update...

I was going to wait until the weekend to install the torque converter, but needed something to occupy my mind after having to put down my 18yr old cat yesterday. It was cold and dark outside, so I threw some paper towels on the floor and started into it.
http://i1243.photobucket.com/albums/gg545/quinsdad/Doodlebug/IMG_2026.jpg

It became clear that I'll need to do some hacking on it to resolve some clearance issues. The brackets for the factory chain guard and factory chain tensioner are in the way of the driven pulley. It's raining here today, but if it tapers off this evening it should give me enough time to wheel it outside long enough to cut those old brackets off of the frame.
http://i1243.photobucket.com/albums/gg545/quinsdad/Doodlebug/IMG_2029.jpg
http://i1243.photobucket.com/albums/gg545/quinsdad/Doodlebug/IMG_2028.jpg

 

[Oxymoron]

----------------
Torque converter
----------------

So, I cut the old brackets from the frame, and installed the GTC Torque Converter.

Goodness. It's freaking awesome. Wheelies are even easier than before, and putting around at low speed is an ease, without fear of burning up the clutch.

It takes a bit longer to get to top speed, but I'm okay with that.... the top speed is a bit higher. :thumbup:

Anyway... I'm looking forward to the next upgrade/ride/rinse/repeat
http://i1243.photobucket.com/albums/gg545/quinsdad/Doodlebug/IMG_2031.jpg
http://i1243.photobucket.com/albums/gg545/quinsdad/Doodlebug/IMG_2030.jpg

 

[landuse]

Awesome!!

 

[Oxymoron]

Thanks Bud! This stuff is really fun. I mean, the build process alone is fun... but watching my boy ride with that big grin on his face makes it even better.

Riding something you built yourself is such a satisfying feeling too. It's a feeling that is familiar to many of you, but it's new to me (for the most part). I can't wait to start building the next thing! Maybe I'll finish this one first though

Well, I also made some temporary foot pegs. I got a little crazy going over some dirt jumps in the woods and broke the right peg on the landing. It had gotten bent a couple months ago, and I used a torch to bend it back, but that weakened it. I took some 1" SHS and used transfer punches to line the holes up. I made both, since only one on the right with the original one on the left looked pretty stupid. I also made them longer, since that big engine and TC are so wide. They look a little weird but hey, it keeps us riding in the meantime until I come up with something a little better. This was just a 5 minute fix to get us back on the trail

No pics of those yet... but here's my youngest on his electric mini bike... waiting for daddy to hurry up and ride, and stop taking pictures
http://i1243.photobucket.com/albums/gg545/quinsdad/IMG_2032.jpg

 

[landuse]

Yup, there is definately no better feeling than riding something you made. You always say to yourself...I made that? and it actually goes??

It seems like the bug has definately bitten you

 

[Oxymoron]

Yup, there is definately no better feeling than riding something you made. You always say to yourself...I made that? and it actually goes??

It seems like the bug has definately bitten you

Yep, been bitten for sure. I love being able to tell people "I built it" when they ask where I bought it Then I let them ride it. Good times!

 

[OzFab]

Sweeet Great to see you got it all sorted

You always say to yourself...I made that? and it actually goes??

Again, I find myself saying speak for yourself

 

[landuse]

Sweeet Great to see you got it all sorted



Again, I find myself saying speak for yourself

Hey....when you are as mechanically challenged as I am, you will be surprised whan anything you make works

 

[OzFab]

Fortunately, one thing I'm not is mechanically challenged...

 

[Oxymoron]

LOL at you two

I've still got quite a bit to do, but I did replace the brake caliper yesterday. Still need to replace all of the bearings (which I'll do when I break it down for paint), make spacers to go between the triple tree and head tube, weld brackets to the frame to attach the new seat, and probably change to a 70T sprocket for the rear wheel. Gearing is a bit high right now with the 65T (12T at jackshaft).

I'll still remove the governor, get a billet flywheel and conrod, and heavier valve springs. I ordered this yesterday, so as soon as I get that I'll rejet the carb.

I'm sure there's more I want to do that I'm forgetting, since I'm not looking at it right now... but I'll update the thread when I do.

Thanks again for the support and interest everyone! :thumbup:

 

[OzFab]

LOL at you two

Get used to that, we carry on like that all the time

I'll still remove the governor, get a billet flywheel and conrod, and heavier valve springs.

FYI: You can safely remove the governor now; the stock valve springs will cause valve bounce or flutter at around 5000rpm, protecting the conrod & flywheel. You only need to worry about them when you use the heavy valve springs...

I ordered this yesterday, so as soon as I get that I'll rejet the carb.

I can't see the images but, be aware, you'll probably need an adaptor...

A hi flow exhaust is the other part of that equation; tha old addage "the better an engine can breathe, the better it will perform" only works if the engine can breathe in & out...

Be careful with the jetting, let the engine tell you what it needs first...

 

[Oxymoron]

Get used to that, we carry on like that all the time

It's funny to watch... you're always busting his b@lls... and landuse is always ready to relish in the moment if he can call you on something :sly: Funny!

FYI: You can safely remove the governor now; the stock valve springs will cause valve bounce or flutter at around 5000rpm, protecting the conrod & flywheel. You only need to worry about them when you use the heavy valve springs...

I read that somewhere... probably here, and it was probably you That's just my list of "to do's" for the engine. Removing the governor internals will be first, if for nothing other than to simplify the throttle linkage and tidy that up. I'll do the flywheel, conrod, and valve springs all at the same time.

I can't see the images but, be aware, you'll probably need an adaptor...

A hi flow exhaust is the other part of that equation; tha old addage "the better an engine can breathe, the better it will perform" only works if the engine can breathe in & out...

It's a kit. Comes with the adaptor (angled), one longer stud for the carb, the pre-filter and filter, and some bracket I don't think I need. Poo... just remembered that I forgot to get the oil. There's a few motorcycle shops near me, I'll just get some next time I'm near one.

I already took the muffler off, and replaced it with a contoured pipe and little screw on muffler. The tiny muffler will come off when I put the high flow intake on. I might just flare the pipe at the end also... I mean weld a flare to the end of it. Not sure yet.

Be careful with the jetting, let the engine tell you what it needs first...

I have a set of needle drills and pin vise. I'll go incrementally, and take test runs between. Fortunately they're cheap, if I go too far. That may wait until spring though since it's starting to be pretty consistently cold here (calling for snow tomorrow). Test runs aren't going to be convenient, nor does that represent the average temperature we'll be riding in, so I'd likely have to tune again in the spring.

Actually, the whole rebuild/modify process is going to slow considerably for the same reason... in addition to not really having permission to use some of the equipment I use at work. All my buddies in the shop watch my back when I do... I just don't like risking it if I don't have to

I'll definitely take care of as many of the little things that I'm able to in my house, without pi$$ing off my girlfriend :beer:

 

[Oxymoron]

Got some goodies today. Hope to install this weekend. Working Saturday, having a water heater replaced, and throwing a mini party too. Hmm... maybe Sunday... if I feel okay

Have a good weekend everyone!

EDIT: Decided not post my builds on this site any longer. Take it easy.

Chris

 

[johnnyboyy]

looks good

 

[johnnyboyy]

very cool lil bike

 

[Oxymoron]

Thanks johnnyboyy. I've done quite a bit more to it since my last post. Built a few other things too.

Take care.