Damn it! (part 2)

Well, look what I got in the mail today... Yes, I went for the radial one. And yes, it is a little bit on the large side. But as "Road Warriors" pointed out: the rest of the running gear is really modern, so I decided continue my theme of juxtapositioning old school elements like the tank and seat with bang up to date engine and brake components. I think it's this mix of 1975 and 2010 that makes my bike stand out somewhat among other trackers.

I won't mount them until this weekend after the final MOT on friday. Will post some pictures of the finished bike then, including some other minor touches I've been busy with. Then it's on to the next one. I'm working on a Photoshop composite of a café racer at the moment. I hope you'll like it!

Damn it!

I promised myself that I would keep my old Brembo brake pump and clutch lever, but I just can't resist ISR's stuff. It's just so... bl**dy gorgeous in a Mies van der Rohe "I didn't intend for this Skyscraper to look this good, I just paid a lot of attention to the proportions" kind of way.

So... I called Acke Rising (owner of ISR) to hear what I should buy. He suggested the old style brake pump (he knows I'm building a tracker), but I had my heart set on a radial one. What do you think: radial or old school?

Free distort.

I like italic racing numbers on bikes. They look like they are forced into leaning backwards as the bike accelerates. At least if you view the bike from the left side. The problem is that if you put italic numbers on the right side of the bike – then they lean the wrong way! Not nice. Thankfully there is a workaround. You will need Adobe Illustrator (or another vector graphics application) and a little patience. But it will be worth it.

Step 1 is choosing a font that you like. I very much like a font called "City" that was designed in the 1930s for the Berthold type foundry in Berlin. So I chose that.

Step 2 is firing up Adobe Illustrator. Make a new document and write your desired numbers two times. “Create outlines” of the numbers (It's under "Type" in the top menu). This will turn your numbers into easily manipulated vector objects.

Step 3: select the effect called “Free distort” (Effects/Distort & transform/Free distort). You can now distort the numbers into pretty much any shape you like. In order for mine to fit in with the lines of my tail piece I made my numbers a little bit lower towards the end of the bike, which will emphasize the "leaning" effect. I added a black outline to my numbers for that "Nascar" look.

Step 4 is saving your document as an Illustrator eps-document and then emailing it to your local digital printer who will print them on vinyl and cut them out for you. There really isn't more to it!

polymimetic alloy.

No, the part in the picture is not manufactured by Skynet in some sort of potential alternate future. It's actually made in good old Sweden by a firm called ISR.

As I'm waiting for the beuraucratic paper mill to return my paperwork, I've been busy making some decals and surfing the web for a replacement for the crude looking Tochico brake caliper I've been using so far. And beeing Swedish, there just is no way around the fact that ISR makes som pretty impressive and affordable stuff. At least if you compare to other calipers of the same quality (I won't post the price here since I suspect my wife checks this blog now and then, but it was about a third of the cost of a comparable Brembo caliper.). ISR makes six piston calipers as well, but I went with four pistons since I think it looks better. And besides: who has ever seen a race bike with six piston brakes?

It needs new spacers, but the very friendly proprietor of ISR, Acke Rising, has promised to turn some for me. I'll post a pic of it mounted when the spacers arrive. Now I just have to resist the temptation to buy new master cylinders from ISR as well...

Thrilla in Svedala.

Put on the kettle and get comfortable, cause this post is going to be long. In my last post I wrote that I had booked an appointment to get the final SFRO-approval for my frame. What I hadn't expected was that this final inspection would turn into such a palaver.

But before we proceed I thought I’d just take a minute to explain the process of getting what is to all intents and purposes a scratch built framer through the Swedish M.O.T/approval procedure. The Swedish government has outsourced the responsibility for inspecting “amateur built” bikes and cars to an organisation called SFRO. SFRO consists of a small number of Swedish car and bike enthusiasts who, by being fiercely thorough make sure that no dangerous or badly built contraptions reach the streets. And by making sure of that, they protect the hobby from bureaucrats who would like nothing better than to put a stop to our beloved hobby. I just wanted to make that clear from the outset to make sure you don’t get the impression that I in any way have a beef with SFRO. You can see where this is leading now can’t you…?

In order to get a bike like mine approved you first have to get your frame/bike SFRO-inspected in an unpainted state. At this point the welds must be left untouched (i.e. not ground or sanded). This to show that the craftsmanship is up to scratch and that the overall geometry of the frame is sound. I passed that one with flying colours. Next step is to paint and assemble the bike and have the bike noise tested. And as you know, I somehow managed to pass that one too. The third step is where the SFRO inspector actually rides your bike and makes sure that it handles and that the brakes work and so on. If it does, you can then book an appointment to have the bike M.O.T’d and get your official papers and your registration plate.

So, with that in mind, let’s rewind the tape a month or so. I loaded my bike on my rental trailer and drove the 75 clicks to Svedala where I was meeting up with the SFRO guy. I unloaded and the guy complemented my on the looks of the bike, the components and the overall craftsmanship. After taking some measurements he mounted a G-meter on the tank and drove off. He came back after 15 minutes or so and I got compliments on the brake performance. Not surprisingly really since the brakes are a bit oversized, to put it mildly. He then checked the paperwork once more and was just about to put his stamp of approval on the bike when he decided to have one last look on the receipt I got from the place where we bought the frame tubes…

As I may have mentioned, SFRO doesn’t like Cro-Mo tubing, so we decided to opt for regular steel tubes to make sure the bike passed with as little fuss as possible (the bike is so light anyway that it makes little difference on the street). Now, SFRO publishes a book every other year where all construction rules, permitted measurement etc are listed together with a list of all the different kinds of tubing that SFRO prefers. What we didn’t know at the time when we ordered the tubes, was that SFRO, in their latest book (that we didn’t have), had inserted a paragraph where it stated that cold drawn steel tubes should be avoided due to possible problems with brittleness resulting from bending the tubes.

The SFRO-guy looked up from his papers and said in a sombre voice “we have a problem”. He explained the issue and my heart sank. Suddenly my frame was unusable anywhere outside of a racetrack. I loaded the bike up again and thoughts of torching the bike and trailer and leaving it by the roadside to burn went through my head. My wife told me later that I looked completely gutted when I walked through the door.

After a few days of almost clinical depression I got a text from the SFRO-guy where he stated that there was one possibility we could try: a Brinell-test to see if the tubes we had used perhaps would fall within the permitted tolerances after all. He would start looking for the test equipment that was supposed to be somewhere in Sweden. The weeks came and passed. And with them the best part of the Swedish summer. Until finally this week when I got the call: “Can you come to Svedala on Saturday? We have a bit of a SFRO-conference and I have been able to locate the Brinell-test equipment”.

I felt a bit like I was presenting my bike to the Spanish Inquisition as I rolled my framer into the large garage where the SFRO-guys were having their meeting. I was told to leave and come back in two hours. I drove to a press centre and picked up the new PB while I waited for the minutes to tick down.

I hour, 59 minutes and 50 seconds later I pulled into the court yard and was met by “my” SFRO-guy who, not unlike the emperor in “Gladiator” slowly raised his hand in front of him, stuck his thumb out and gave me a slow-motion thumbs up… It passed.

In the image above, you can see where they scratched off the paint in order to test the steel. I guess I will have to repaint the frame, but I’d much rather do that than start all over from scratch!

I know I've said this before: but this time it really is close to finished...

The sound of silence.

If you've ever heard a big bore Husky at full chat you know it's loud. Proper loud. Little children screaming, car alarms going off at 50 yards - loud. Then imagine that you have an 84-decibel limit to adhere to. That's exactly what I was up against today when I did the mandatory noise test for my street tracker.
I always thought that passing the noise test would be the hardest part of the whole M.O.T-process and I knew from the start that there was no way in h**l that I could get my bike under 84 dB at full throttle – not unless the test was done in deep space. So first on my list was finding a way of making it impossible to give the bike the full beans. After some head scratching I found a nice little hole on the underside of the plastic carburettor lid. I put a 50 mm long screw in there, which made it impossible to lift the throttle more than about 40 % of the way. That went some way towards getting the noise down. Next up was filling the SuperTrapp silencer with sound deadening fibre glass "wool" and taking out 11 of the 12 discs at the end of the silencer.

At this point I was kind of happy with the results but the induction sound from the carb was still too loud to my ears (I was guessing at this point since I didn't have a dB-meter). So yesterday night I started panicking a bit and began botching together a sort of external air box over the exposed KN filter. And when I say botch, I really mean botch. Or how does cutting out plastic pieces from IKEA boxes, filling it with cell foam and gaffer taping it all up sound? Botch Engineering Ltd.

After a few hours sleep I brought the bike up from the garage to do a test start before I was to load it and go to Malmö (some 65 clicks away). It absolutely refused to start! No matter how many times I kicked the thing – nothing. Obviously it didn't get enough air and I had to modify my "air box" one more time, with one hour to go to the test. I finally got it started and it sure was quiet:-) I also ran like Chitti Chitti Bang Bang with a bad cold. Ah, to hell with it I thought and loaded up.

After waiting in line for an hour or so, watching all sorts of machinery go through the sound trap, I handed my bike over to the guy who was going to do the test ride past a dB-meter and watched him "speed off" with the engine coughing and farting on "full gas" (40% throttle). On his return pass I could see the frown on his face and he gave me the bike back stating that it "just wasn't working". I felt the panic rise since I knew that there wasn't going to be a new test for some weeks. I told him I was going to do some mods and could he please give it one more go? At this point the other bikes and cars had passed their tests and it had started raining. So I started tearing frantically at my "air box" to try to give the bike some more air. Guess what? The bike refused to start. I kicked and kicked. I checked the plug, the fuel and everything else I could come up with. Nothing. After some 15 minutes of this I was drenched in sweat. Seconds from giving up, the last remaining biker told me to throw away that stupid air box since "I was screwed anyway". I did and the bike fired up and I handed it over to the tester, expecting disaster.

But do you know what? IT PASSED! I was actually one dB under the limit even without the stupid airbox. I haven't felt so relieved in years. On Monday I'm going back to get the final clearance on the frame and then the final M.O.T will be a mere formality. Wish me luck!

It's a wrap. Or is it?

I spent a few good hours yesterday wrapping my exhaust. A pretty fiddly job, even with the coolers off. The headers turn and twist and the clearance is marginal at best. Now, I know that exhaust wrap isn't strictly in keeping with the flat tracker-style, but the Husky exhaust isn't the prettiest in the world and I like the way a wrapped exhaust looks. So sue me.

It looks like a piece of cake, but it is actually pretty difficult to get the wrap to fit perfectly. After having finished with the light coloured wrap (picture #1) I took a step back to admire my handiwork. And quickly realised that it looked too retro. And that the light wrap clashed with the colour theme of the rest of the bike. Damn!

30 minutes later I had purchased a new wrap (another 50 Euros) and started over again. This time, with the darker wrap (picture #2), I think I got the look I was after.

A word to the wise: use a long sleeved sweater and maybe even latex gloves when you wrap your own exhaust. Those little fibre glass strands itch like a son of a *****. I washed my arms three times and still couldn't stop the itching. In the end I had to resort to using my wife's body lotion. Yuk.

BTW: the new Öhlins spring is now in place (after having been powder coated black). It's 60 Nm instead of the 110 Nm standard spring. Hopefully this will smoothen out the super stiff ride.