Weldangrind's New Lifan GY5 - Page 3

Weldangrind · 07-08-2013, 10:52 AM

Made a little more progress on the weekend. I wanted a free-flowing muffler that the USFS guys would approve of, and I wanted a cleanable spark arrestor. I found a 2001 XR250R muffler for a fair price on eBay, so I bent some tube and welded it together. The muffler came with a quiet core insert, but I also have a wide open insert on my '96 XR250R, so we'll see which one sounds better.

I also cut the heat shield mounting bungs off of the head pipe and re-welded them to accept a different heat shield that I had laying around. The original heat shield is really large, and I wanted something smaller. If I get motivated enough, I might build a custom shield out of stainless.

After I was satisfied with the fit, I painted the exhaust system with semi-gloss black heat paint. I also made some progress in fabricating a headlight mount. No pics for that yet.

SpudRider · 07-08-2013, 12:36 PM

I love your custom muffler work!

nyvdub89 · 07-08-2013, 08:04 PM

Quote:

Originally Posted by SpudRider

I love your custom muffler work!

X2

Weldangrind · 07-08-2013, 09:32 PM

Thanks, guys.

Weldangrind · 07-11-2013, 01:28 AM

I made some more progress. The paint had cured enough that I could mock up the exhaust system. When I fabricated the midpipe, I failed to make a mid-point mounting bracket, so that's next. I really like the Duplicolor high heat semi-gloss black.

I bent up some aluminum recently to mount the headlight that I bought on Taobao, and I think it worked out well. My buddy offered to reinforce it for me with his TIG welder, so I expect that we'll find time for that next week. I secured the mount with stainless T-bolt clamps, and then I drilled the mounts for some neat little signal lights I found on eBay.

This shot shows the bracket, but it also shows the Roketa speedo and indicator lights, along with the Roketa steering lock ignition. It all seems to work well together. There's plenty of room below the indicator lights for future considerations, like controls for heated grips, etc.

SpudRider · 07-11-2013, 01:33 AM

Nice job!

Trailbikeryder · 07-11-2013, 04:48 AM

Nice Progress

zingshoen · 07-11-2013, 06:47 AM

nice simple instrument setup. are you going with the honda silver red colour scheme?

Weldangrind · 07-11-2013, 10:38 AM

Quote:

Originally Posted by zingshoen

nice simple instrument setup. are you going with the honda silver red colour scheme?

Not on purpose. The frame is a sort of silver / grey, and the plastics will be black and red with a black seat and black tank. I've changed the bike quite a bit, but the registration says red, so I don't want to stray too far.

I like the instrumentation as well. I have no need for a tach that lies to me, and I like the Roketa speedo.

Weldangrind · 07-27-2013, 01:42 AM

Forum member Atomic Wedgie welded my aluminum headlight frame for me, since cracks developed on the corners from bending. He also added some extra pieces for strength.

This is an action shot of TIG welding in progress.

And this is the frame mounted to the forks with stainless T-bolt clamps.

satelliteone · 07-31-2013, 05:57 PM

looking very awesome

Weldangrind · 08-01-2013, 12:17 AM

Quote:

Originally Posted by satelliteone

looking very awesome

Thanks! I hope to complete it this weekend and go for a victory ride.

FastDoc · 08-01-2013, 12:12 PM

Wonderful work.

I love the action shot.

The exhaust is looking great.

The XR exhaust is durable and quiet. You will love it.

Weldangrind · 08-01-2013, 07:19 PM

Quote:

Originally Posted by FastDoc

Wonderful work.

I love the action shot.

The exhaust is looking great.

The XR exhaust is durable and quiet. You will love it.

Thank you.

The XR pipe sound volume will depend upon which insert I use with it. The 2002 version is a quiet core, but my '96 is nearly wide open. We'll see which one sounds better and is less obnoxious.

Weldangrind · 08-07-2013, 01:54 AM

I made a bunch of progress over the weekend. I completed the wiring over the weekend, and I discovered that the audible turn signal box is quite necessary, since there's no quick way to incorporate a flasher. There is a nice by-product of the box, and that is that the turn signals flash rapidly nine times when you apply the brake. Since Son of Weldangrind will be the primary pilot, I'm happy to know that the Lifan has this safety feature.

I discovered an oddity. I had unplugged the alarm, without knowing how it interacted with the electrical system. The bike started up fine without the alarm, but I couldn't switch it off! Neither the kill switch nor the key switch had any effect on the engine, yet the key switch could shut off all electrical accessories.

The solution was to simply plug the alarm back in, minus the loudspeaker. The kill switch and key switch now work properly.

I hope to get some time on the bike tomorrow evening, at which time I'll install the front brake (and flush it). After a little tuning, it should be ready for a maiden voyage. I'll post pics when it's done.

07-08-2013, 10:52 AM	#31
Weldangrind Join Date: Mar 2009 Location: Sardis, BC, Canada Posts: 25,977	Made a little more progress on the weekend. I wanted a free-flowing muffler that the USFS guys would approve of, and I wanted a cleanable spark arrestor. I found a 2001 XR250R muffler for a fair price on eBay, so I bent some tube and welded it together. The muffler came with a quiet core insert, but I also have a wide open insert on my '96 XR250R, so we'll see which one sounds better. I also cut the heat shield mounting bungs off of the head pipe and re-welded them to accept a different heat shield that I had laying around. The original heat shield is really large, and I wanted something smaller. If I get motivated enough, I might build a custom shield out of stainless. After I was satisfied with the fit, I painted the exhaust system with semi-gloss black heat paint. I also made some progress in fabricating a headlight mount. No pics for that yet. __________________ Weldangrind "I figure I'm well-prepared for coping with a bike that comes from the factory with unresolved issues and that rewards the self-reliant owner." - Buccaneer
	0

07-08-2013, 12:36 PM	#32
SpudRider Join Date: Jul 2008 Location: Idaho Posts: 25,054	I love your custom muffler work! __________________ Spud "Never argue with an idiot. He will drag you down to his level, and beat you with experience." Mark Twain 2015 Zongshen ZS250GY-3 (RX3) 2006 Zongshen ZS200GY-2 (Sierra 200) 2005 Honda XR650L 2004 Honda CRF250X 1998 Kawasaki KDX220 Mods made to my Zongshen ZS200GY-2: http://www.chinariders.net/showthread.php?t=6894
	0

07-08-2013, 09:32 PM	#34
Weldangrind Join Date: Mar 2009 Location: Sardis, BC, Canada Posts: 25,977	Thanks, guys. __________________ Weldangrind "I figure I'm well-prepared for coping with a bike that comes from the factory with unresolved issues and that rewards the self-reliant owner." - Buccaneer
	0

07-11-2013, 01:28 AM	#35
Weldangrind Join Date: Mar 2009 Location: Sardis, BC, Canada Posts: 25,977	I made some more progress. The paint had cured enough that I could mock up the exhaust system. When I fabricated the midpipe, I failed to make a mid-point mounting bracket, so that's next. I really like the Duplicolor high heat semi-gloss black. I bent up some aluminum recently to mount the headlight that I bought on Taobao, and I think it worked out well. My buddy offered to reinforce it for me with his TIG welder, so I expect that we'll find time for that next week. I secured the mount with stainless T-bolt clamps, and then I drilled the mounts for some neat little signal lights I found on eBay. This shot shows the bracket, but it also shows the Roketa speedo and indicator lights, along with the Roketa steering lock ignition. It all seems to work well together. There's plenty of room below the indicator lights for future considerations, like controls for heated grips, etc. __________________ Weldangrind "I figure I'm well-prepared for coping with a bike that comes from the factory with unresolved issues and that rewards the self-reliant owner." - Buccaneer
	0

07-11-2013, 01:33 AM	#36
SpudRider Join Date: Jul 2008 Location: Idaho Posts: 25,054	Nice job! __________________ Spud "Never argue with an idiot. He will drag you down to his level, and beat you with experience." Mark Twain 2015 Zongshen ZS250GY-3 (RX3) 2006 Zongshen ZS200GY-2 (Sierra 200) 2005 Honda XR650L 2004 Honda CRF250X 1998 Kawasaki KDX220 Mods made to my Zongshen ZS200GY-2: http://www.chinariders.net/showthread.php?t=6894
	0

07-11-2013, 04:48 AM	#37
Trailbikeryder Join Date: Jan 2013 Location: Germany Posts: 231	Nice Progress __________________ My CB : http://www.youtube.com/watch?v=ZbZ8q-grmOQ 2012 Skyteam V-Raptor 250 2011 Yamaha Tenere XT 660Z abs 1996 Kawasaki Vulcan 800 Classic 1989 Kawasaki GPZ 500
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07-11-2013, 06:47 AM	#38
zingshoen Join Date: Jun 2009 Location: Brisbane, Queensland, Australia Posts: 648	nice simple instrument setup. are you going with the honda silver red colour scheme? __________________ 1971 Garelli Gulp 50cc with open ports and 16 mm Bing Carbie + 1980 Honda XL 223 ZS + 2007 Zongshen LZX200G + DR400SM
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07-27-2013, 01:42 AM	#40
Weldangrind Join Date: Mar 2009 Location: Sardis, BC, Canada Posts: 25,977	Forum member Atomic Wedgie welded my aluminum headlight frame for me, since cracks developed on the corners from bending. He also added some extra pieces for strength. This is an action shot of TIG welding in progress. And this is the frame mounted to the forks with stainless T-bolt clamps. __________________ Weldangrind "I figure I'm well-prepared for coping with a bike that comes from the factory with unresolved issues and that rewards the self-reliant owner." - Buccaneer
	0

07-31-2013, 05:57 PM	#41
satelliteone Join Date: Sep 2010 Posts: 36	looking very awesome
	0

08-01-2013, 12:12 PM	#43
FastDoc Join Date: Mar 2009 Location: Southeastern Washington desert Posts: 14,761	Wonderful work. I love the action shot. The exhaust is looking great. The XR exhaust is durable and quiet. You will love it. __________________ Happy to serve.
	0

08-07-2013, 01:54 AM	#45
Weldangrind Join Date: Mar 2009 Location: Sardis, BC, Canada Posts: 25,977	I made a bunch of progress over the weekend. I completed the wiring over the weekend, and I discovered that the audible turn signal box is quite necessary, since there's no quick way to incorporate a flasher. There is a nice by-product of the box, and that is that the turn signals flash rapidly nine times when you apply the brake. Since Son of Weldangrind will be the primary pilot, I'm happy to know that the Lifan has this safety feature. I discovered an oddity. I had unplugged the alarm, without knowing how it interacted with the electrical system. The bike started up fine without the alarm, but I couldn't switch it off! Neither the kill switch nor the key switch had any effect on the engine, yet the key switch could shut off all electrical accessories. The solution was to simply plug the alarm back in, minus the loudspeaker. The kill switch and key switch now work properly. I hope to get some time on the bike tomorrow evening, at which time I'll install the front brake (and flush it). After a little tuning, it should be ready for a maiden voyage. I'll post pics when it's done. __________________ Weldangrind "I figure I'm well-prepared for coping with a bike that comes from the factory with unresolved issues and that rewards the self-reliant owner." - Buccaneer
	0