JON1482 Pilot bike replica project

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JON1482
Posts: 724
Joined: Wed Jan 20, 2010 7:22 am
Location: WALES, U.K.

JON1482 Pilot bike replica project

Post by JON1482 » Sun Aug 15, 2010 2:24 pm

Hi all , I've been squirelling away collecting bits from all over the place. Anyhow here are some pics of what I've done so far. The bike is a 1984 XL (600cc) but the WOW item for me was finding a pair of PM 13' rotors, I got them from Greece of all places from a nice guy named George!
I've also got bits and bobs from e-bay to make up the displays and buttons. The next BIG thing is starting on the body, but before I do that I need to take the front wheel to a local engineering firm to have it adjusted so the rotors will fit safely.
Im trying a back brake from a Honda XR 400 so I can have a matching pedal back brake as is fitted. I am looking for a better rear disc to fit both the wheel and the XR brake. So fingers crossed that the PM rotors will be fitted and then I can get on with the transformation.
More to come.....
Attachments
orig bike edit.jpg
orig bike edit.jpg (79.5 KiB) Viewed 12755 times
bike.jpg
bike.jpg (132.14 KiB) Viewed 13197 times
Last edited by JON1482 on Tue Nov 16, 2010 12:30 pm, edited 8 times in total.

JON1482
Posts: 724
Joined: Wed Jan 20, 2010 7:22 am
Location: WALES, U.K.

Re: JON1482 Pilot bike replica project

Post by JON1482 » Sun Aug 15, 2010 2:28 pm

One last thing is the replacement fuel tank, It fits in nicely under the rear section. I plan to make the 'back pad?' of the seat easily removable for fill ups.
Attachments
bike tank.jpg
bike tank.jpg (145.14 KiB) Viewed 13199 times

spyhunter2k
Posts: 622
Joined: Sun Jan 21, 2007 9:53 pm

Re: JON1482 Pilot bike replica project

Post by spyhunter2k » Thu Aug 19, 2010 2:59 pm

Nice start. The PM rotors are the hardest things to find, so you have that behind you. Bike looks good. I'm not sure if you'll be able to keep the tank in the back there. The last time I lined up the side panel blanks on my bike it looks like the rear of the frame (under where that metal loop is in the back) will need to be removed or bent downwards. The seat on the pilot bike is low and goes straight back.

JON1482
Posts: 724
Joined: Wed Jan 20, 2010 7:22 am
Location: WALES, U.K.

Re: JON1482 Pilot bike replica project

Post by JON1482 » Fri Aug 20, 2010 4:01 am

Thanks for the heads up Seth. I hope we can swap ideas / snag solutions along the way. I plan to go and see the series bike in Cumbria to get some close up pics of the brake brackets, ( I may have to use a covert camera in my shoe :lol: ).
I'd like to thank you for inspiring me to start my own replica, I dont think I would have thought it possible until I saw your work.

jesse1
Posts: 110
Joined: Fri Aug 06, 2010 5:03 pm

Re: JON1482 Pilot bike replica project

Post by jesse1 » Fri Aug 20, 2010 4:47 pm

Does anyone know if the rear disc on the bike was 10", 11'', 11.5" or 11.8" I don't remember?

Mark

JON1482
Posts: 724
Joined: Wed Jan 20, 2010 7:22 am
Location: WALES, U.K.

Re: JON1482 Pilot bike replica project

Post by JON1482 » Wed Aug 25, 2010 4:02 pm

Today I ran a start up test using the fuel tank, it started with the first kick, how impressed am I :D. I'll have to refine the fitting of the tank as it's close to the exhaust so for safety I'll need to sheild it and as Seth pointed out the frame may need moding at the back to allow for the custom seat pieces. I Also started painting the frame black. I'll post some pics when that and the engine / gearbox is done. I've just found out that my wife's best freind's Dad is a retired metal worker with a shed full of tools ......custom brake brackets please! ;)

jesse1
Posts: 110
Joined: Fri Aug 06, 2010 5:03 pm

Re: JON1482 Pilot bike replica project

Post by jesse1 » Thu Aug 26, 2010 4:22 pm

Hi Jon,

Is that 13 inch rotor flat or offset? what size rotor are you going to use for the rear?

Mark

JON1482
Posts: 724
Joined: Wed Jan 20, 2010 7:22 am
Location: WALES, U.K.

Re: JON1482 Pilot bike replica project

Post by JON1482 » Fri Aug 27, 2010 10:45 am

Hi Mark they are flat, but I have a feeling that the should be off set, in some photos you can see the light reflecting off the disc, but I'm more than happy with how they look. I really dont know about the rear disc, from the pics it looks as if its around 11', but to be honest I will fit what I can as long as it's close enough.

JON1482
Posts: 724
Joined: Wed Jan 20, 2010 7:22 am
Location: WALES, U.K.

Re: JON1482 Pilot bike replica project

Post by JON1482 » Wed Sep 01, 2010 3:52 pm

Hi all, just a quick update. Bike and engine block has been painted. Push buttons are done. Now for the hard bit!
Attachments
hand control edit.jpg
hand control edit.jpg (32.12 KiB) Viewed 12980 times
power up down edit.jpg
power up down edit.jpg (40.42 KiB) Viewed 12986 times
bike black.jpg
bike black.jpg (133.91 KiB) Viewed 12994 times

spyhunter2k
Posts: 622
Joined: Sun Jan 21, 2007 9:53 pm

Re: JON1482 Pilot bike replica project

Post by spyhunter2k » Wed Sep 01, 2010 4:08 pm

Looking good. What brand of buttons are those?

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