Been doing plenty lately, but only just taken any pics.
Rolled up an alloy oiltank:
Used the filler neck off the old Weslake one. Ends are domed - I had 2 pieces of domed ally from a pair of polished belt drive covers; one small, one large. So I beat out a matching pair. The smaller ones will go on the intake plenum:
Cant finish the ends until the inlet is done. You can see the dump valve underneath; its a Forge dump-to-atmosphere one off a Subaru Impreza. Had to machine up ally carb flanges to take the mk2 Amals.
From the aborted Buell XB9 project came a set of stainless headers which were perfect for making the head-to-turbo exhaust. Flak-Monkey sorted out all the stainless flanges.
Now sorting out the intercooler. Deciding where it should go. Initially, thought it would go here:
But its a bit vulnerable, so I'm now thinking of putting it acrossways up top. Its a cut down one from a Range-Rover that was kicking about.
Yesterday I made the end tanks for the intercooler. Took all afternoon; would have been easier to make them with flat sides, butI wanted them rounded off and shaped to help flow. Spouts not done as waiting for beaded tubes.
Waiting on other stuff too so made a start on the tank as David needs to know about fuel pump position and whether we can get it in the tank.
I want the bike to looks a bit BSA-ish, so a conventional tank is needed. Mounted way low, it wont affect the riders ability to hunker down too much.
Its an old BSA one bought for £20 a few months back. Obviously it wont fit this frame!:
First welded up the filler hole:
Then cut it in half:
Cut a filler strip out of 22g, 1.75" wide at the back, 0.75" at the front. Tacked it in place. Edge fit must be perfect as possible.
Tig'ed it together carefully, doing short runs here & there, mostly without using a filler rod. A few blow-thrus:
It distorted a fair bit; was I bothered? Naaah!
Carefully dressed the high spots off with a soft disc and set about hammer & dollying. One of the best tools I ever bought was a set of stake-dollys & stand off an emigrating friend. Got about 20 dollys. This one was right for this job:
After some bashing & fettling:
It'll still need a small skim of filler, but not much. Getting it perfect would take a lot longer and theres danger of overworking the metal, especially on a tank where leaks are a possibility.
A quick go-around with the snips, and its in place. Plenty to do yet.