Superdream Build thread

[alexanderfoti]

****Update, all updates will be posted on here and on fotifixes.com

Click http://fotifixes.com/ for latest updates


Hi all

I recently bought a superdream with a diesel conversion from Tim on here.

I am now upgrading the ending to a 400cc and adding a 500cc amr supercharger.

The first step I have had is to pull out all the old fuel tank etc etc. This build will be a twin tank build with two "side bag" tanks that sit on the rear, these were chosen from scooters as they have a fuel level gauge ( a pet hate not having one!)

I have removed the old engine and will be cleaning everything up and offering up the 400 to see where work needs doing. Pics:

[henneberg]

Hi,

Looking forward to follow your progress on the project. Which type of gearbox are you using ?

rdgs, Erik

[alexanderfoti]

Many thanks.

At the moment im using a Villiers 4 speed gearbox. As long as I can mate it to the bigger engine using the same primary drive cover, I should be fine

[alexanderfoti]

Update! And I am stuck.

I was planning on using the old primary drive case/mount and clutch/gearbox but im not sure its going to fit , as per this image:



Firstly the engine needs to move across to align with the rear chain and the bearbox input shaft/clutch.

Secondly it needs to seperate out slightly towards the front of the bike so that access can be gained to the throttle control and fuel stop screws.

I think I have 3 options:

• Run the chain/clutch open with no constant lubrication and with a longer chain

• Convert to belt drive (giving more slack in adjustment and more space

• Go to a CVT

Now im not a fan of the CVT transmissions (no offence to anybody that is), I just think it detracts from the driving experience so I think im going to go down the open chain (With a gaurd) route unless there is any reason why not,

Other pictures:





What are your thoughts.

[alexanderfoti]

Update:

AFter a bit of shifting, I think I have line of sight for an open chain.

Only issue is that there is quite a bit of offset.






Is this too much to be running?

If yes, would I need to employ a jackshaft arrangement, not sure if there is enough space for that...

Thanks for the assistance!

[Sphere]

I have my engine bulging out the right side, and I don't have much issues with it. Maybe shifting would be a bit easier if the shifter wouldn't have to be bent, but you get used to it. My biggest gripe with the Enfield gearbox is the gap between 3rd and 4th, which makes downshifting a horrible experience. I need an Enfield with an ER-5 gearbox or something

[alexanderfoti]

Yeah,I have this same issue, but I find it rideable. Do you think running the chain in the open is going to cause any issues?

[alexanderfoti]

I hear is a modification kit available to decrease the gaps

[Sphere]

Yeah,I have this same issue, but I find it rideable. Do you think running the chain in the open is going to cause any issues?

Are you talking about the primary drive chain? I would not prefer it that way, but I suppose you could.

[alexanderfoti]

Yeah,I have this same issue, but I find it rideable. Do you think running the chain in the open is going to cause any issues?

Are you talking about the primary drive chain? I would not prefer it that way, but I suppose you could.

I think it should be okay, like a rear drive chain, just need to keep an eye on the lubrication, or possibly build an auto oiler for it, cant see any issues though?

[Sphere]

Maybe a tensioner as well, and whatever you do make sure you dress it properly so it won't eat into your left leg.

[alexanderfoti]

Yeah, I'm going to fabricate a shield out of stiff chicken wire type thing. I wonder how I would go about tensioning in a dry environment, maybe an idler wheel made of rubber?

[nanno]

... maybe an idler wheel made of rubber?

Get an old skateboard from the scrapbin and cut an axle in half, the wheels are some really tough plastic and have a bearing in the center. (Which is some std. thingy and can be replace cheaply with a proper double sealed one!) If you have a lathe you could turn a slight groove into it, so it centers itself on the chain.

Cheers,
Greg

[alexanderfoti]

Yeah, I was thinking along those lines last night when browsing ebay:

http://www.ebay.co.uk/itm/280785831943? ... 1423.l2649

[alexanderfoti]

I wonder if I can get away with attaching the engine at the front(Downtube) + back(gearbox, mount), or should I use a supporting plate underneath the engine

[XLerate]

I wonder if I can get away with attaching the engine at the front(Downtube) + back(gearbox, mount), or should I use a supporting plate underneath the engine

That would probably depend on whether the engine is a stressed member or simply installed into place. With a monocoque design the engine case would have to be able to take stress loads as a frame member. If it's just to install the engine, with it giving some extra support to frame, I think you're fine. Pics tell me there should be no problem on your chassis with that strong backbone.

[alexanderfoti]

I wonder if I can get away with attaching the engine at the front(Downtube) + back(gearbox, mount), or should I use a supporting plate underneath the engine

That would probably depend on whether the engine is a stressed member or simply installed into place. With a monocoque design the engine case would have to be able to take stress loads as a frame member. If it's just to install the engine, with it giving some extra support to frame, I think you're fine. Pics tell me there should be no problem on your chassis with that strong backbone.

Thanks. I think im going to install some box frame on either side, just to take some of the stress away from the engine (you never know with the chinese castings)

[XLerate]

Thanks. I think im going to install some box frame on either side, just to take some of the stress away from the engine (you never know with the chinese castings)

Indeed, agreed! They seem to do okay on machining in many instances, but metallurgy isn't their specialty....

[alexanderfoti]

****Update, all updates will be posted on here and on fotifixes.com****

Click http://fotifixes.com/ for latest updates

[alexanderfoti]

Right, the engine mounting is all sorted now! (finnaly!) I have also attached and figured out a throttle method so fingers crossed this will work well, due to not having an exhaust or a proper fuel tank, I haven't been able to test it properly

I will update this thread with pictures etc, but until then, have a look at my site for how I have figured it out! Many thanks.

[alexanderfoti]

I now have an idling engine!

and all the mounting in place (ready to be re bolted up when I have finished fine tuning the throttle arrangement )

Now that the engine is in place, all that's left is:

• Primary drive chain/belt (havent decided yet, depends on alignment)
• Electrics
• fuel tanks + filter + piping
• Pollak switching valve
• battery bracket
• fix the brakes

So quite a bit

Have a look at http://fotifixes.com for pictures.

[alexanderfoti]

wEhay!

I have connected the primary drive up, and first time it was spot on alignment!

I have also attached my chain tensioning device and refitted the clutch! I have packed the bearings in the clutch with bearing grease. I will need to remove the clutch again to reattach the rear drive chain (and I need to remove the gearbox to attach the gasket! (doh!) , so I will inspect the bearings then to see if there is any obvious wear on those.

I will also need to re-route the clutch and throttle cables, as at the moment when you turn the handlebars it revs the engine

Also I will need to pull apart the wiring which I think is going to be harder than I initially thought

Pictures below:

[XLerate]

Looks mighty fine, Alexander! Some excellent and clever workmanship. I think you have a real winner there!

[alexanderfoti]

Many thanks! Its getting there, I have a deadline of April to get it out of the garden so I'm going to be working late into the night!

[alexanderfoti]

I have posted an update on fotifixes, here is the content:

The next stage in the the diesel bike saga is to cover the primary drive. I would love to run it open but this poses two problems:

1. The primary drive could easily consume my leg
2. The gearbox isn’t particularly oil tight, so I would end up with a oil all over the front brakes, fuel tank etc.


So, I have purchased some thick wire fencing and have used the bolt holes on the side of the engine to mount it, using some metal plating to give it strength, so far, I am around halfway done. Once the frame and mesh is in place, I will cover the whole thing with 10mm seat foam to keep most of the oil in and to quiet the whole thing down slightly.

Additionally, all the existing wiring has been removed, the old fuel tank has been re-mounted and a Mitsubishi Pajero diesel filter has been added (primarily for the water sensor!)

[Sphere]

Without any detailed knowledge of your contraption, it looks like an accident waiting to happen. Be safe.

[alexanderfoti]

Without any detailed knowledge of your contraption, it looks like an accident waiting to happen. Be safe.

What makes you say that?

Its a pretty common build combination , l100 + Enfield 4 speed. The only thing missing is the primary drive cover (Which many bikes do not have). The temporary cover I have installed (until I can elongate the existing one I have) will protect me from oil spray from the chain and placing my leg into the chain.

I have had help from Tim (thanks!) with regards to engine loading and forging and how we are to mount the engine etc, so I see no major issues.

[Sphere]

I am talking about the wiremesh, when that gets moving at any respectable rate it will tear through soft tissue like a hot knife through butter.

[alexanderfoti]

I am talking about the wiremesh, when that gets moving at any respectable rate it will tear through soft tissue like a hot knife through butter.

Ah I see what you mean, it has since been covered with foam, (And all sharp edges rounded off and bent inwards). Its not the best solution, but seeing as I have a time limit to get the bike out of the garden, its the best situation at the moment

[alexanderfoti]

Thank you for your concern though

Next highest priority is aluminium plate to be fashioned around the primary drive.