Had a nice constructive evening.
Took the bike apart, and rebuilt the forks and swinger onto my new frame.
It's a Malagutti frame, and conveniently, it's road legal too!
It's reg'd as a 50cc, but I will be sending the log book off to change that, to 125cc, so I can take this beast on the motorway if needed.
The swing arm goes in pretty well, bit of spacing required either side.
The forks, I still need to work out. I currently have the pit bike (44mm) taper cups, sitting in the cups from the frame, and then the pit bike bearings in them etc.
So it kind of all works, and due to both sets of cups being tapered, it's all centralized. Just not sure how 'safe' it is.
BUT, I need new yokes anyway, I need something wider set, as the legs are too close, and the wheel doesnt fit properly.
Gonna modify some sports-bike yokes I think.
Now, the frame. I'm quite happy with how it sits. At this stage, I made it a 305 / 310mm shock required:
I was about to call it a night, but then I decided not to. Clicked the kettle on again, and then grabbed the Rotax lump.
Slid the barrel back into place, to mock up the right size of engine etc, and decided to sit it into the frame, to see where I stand with mounts etc.
The RS engine, rear-mount sits on the swing-arm pivot bolt, and conveniently, so does the Malagutti.
And it's also quite convenient, that it lined right up:
The engine sat really high at the front though, leaving no room behind the barrel to get the manifold on, let alone the carb.
So you see, just further down from the mount, another mount.
I've made two cuts in the tube which runs across the frame, this lines up perfectly with the mount underneath. So I can drill the frame either side where the tube is welded on, and then run another long bolt down through it, to act as another rear engine mount.
It was at this point, where I was quite impressed, as I looked at the front of the engine, and the front lower mount, was about 1mm out from the mounts on the frame. With gentle persuasion (Dead-blow hammer), and wiggle, it went straight into place, and another bolt slid through, as a third mount.
This only leaves one more lower mount at the front to make up, which will be very easy. And then if I want to, I can do something about the upper (Cylinder head) X-member mount, which again, will be pretty easy.
Sprocket fits, side casings fit, there is room for rear-sets to bolt to the frame, and then run a linkage for the gears etc. Everything works very well. I'm chuffed!
Only slight glitch is this:
No room for carb again.
Luckily I can just chop this X-member off completely, weld two lengths of steel flat-bar, or maybe some tube from the two main frame rails, up at about a 45deg angle, and re-locate the shock mount further back, and a little higher. This will give room for the carb, and even an air-box if I am lucky.
Ben
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