The TRX900 Project kicks off

[coxylaad]

ok, not done a lot, but I will post up progress anyways.

I have sourced some steel bar that is an interference fit with the tubing of the TRX frame. I am currently in the process of crafting a set of lugs to weld onto the frame for the bolt on subframe.

pics:


that's a piece cut to length, with this:



As you can see from the first pic I have started cutting out the hatched area. all will become apparent when I get finished. I am being hindered by my 15 month old son, I cant get in the garage when he's awake as he just wants to play all the time, and I cant operate my chop saw when he's in bed because I will wake him up!! the little bugger

anyways this is where its going to go:



imagine the bit sticking out chopped in half down the middle with a threaded hole through it. Dog was bored by this point.



Also fitted the R6 shock. if it performs as good as it looks I will be well chuffed!



Should have the engine back in over the weekend.

[trixynut]

Good to see some progress mate, well done (even if you Lab isnt that interested!)

[coxylaad]

it will be done this summer! Some rapid progress coming up soon!

[Quan-Time]

Good work mate, keep it rolling.

[alextrx850]

Gidday Coxy..im wondering on the welding to fit the link rods..possibly plug welds on opposite sides and a full tube end 360 degree weld...would you pre heat the insert as its gonna take a lot of heat to promote penetration and not to distort the tube end too much.

[alextrx850]

Me again..sorry to be a pain, but i am interested...to make the link..would you be making another [plug link] for the joining frame tube...but only welded 180 degrees opposite..to the engine frame..?
What type of replaceable rear section would you go for..R1...R6...Vespa..
And a lot of the replaceable rear section frames might be made of alloy...?..alloy/steel...??
TITALATED

[coxylaad]

Well, its such a tight fit I could quite easily drill through the frame into the plug and tap a bolt in there and it would never move. However I am not sure how good that will look, and given that these welds are on show I will be getting my welder mate to run a 360 degree weld round the edge, then I can have the lot powder coated.

The subframe will be my own concoction, made from steel.

[devlin]

Just silver braze it. Plenty strong enough for the application and much lower temp than welding.

Looking like some decent progress and looks good.

[coxylaad]

Do you think that will be strong enough? or look good enough?

I could double that up with a drill and tapped bolt on the inside of the frame out of site....or I could just have it welded....

[alextrx850]

Just silver braze it. Plenty strong enough for the application and much lower temp than welding.

Looking like some decent progress and looks good.

Like Devlin is suggesting..the load will be mostly push or pull along the length of the bar, while lateral frame flex [probably not much that far back]..wouldnt be over the custom links ability...a silver or bronze[brass] braze into there with the two pieces to be brazed a dull red hot...the silver would be a slightly higher quality media to the brass, but the brass wouldnt need to be as hot to avoid tempering the tube material and haveing crack problems down the track..
you would want someone who knows their welding equipment and the properties ....of the which way you are to go with this....id think that you will enjoy others coments on your mod...pretty neat idea, so you would want it to LOOK the goods as well...eh ?
Ive seen the rear section of some sports bikes with the alloy frames and note that the rear seat assemblys are not that massively engineered...in fact snap off easilly in a prang....id use a harley for any large framed pillions anyway..

[cal]

Mate I dont want to piss on your chips, but...I dont think you have enough material going into the frame.... there i said it...if it were mine, I would have at least 40mm going into the frame tube, that would give support from the frame its-self and the welds would become far less stressed, it would also allow you to drill a small hole in the frame only top and bottom (less visable) and weld around this holes inside to the steel plug/adaptor.
If the extra weight is an issue you could always drill out the centers of the inserted parts?

I only say this cause if those joints were to fail and you got hurt I would kick myself for not saying, Whats the verdict from the others? more metal?

[coxylaad]

nah, if its welded properly then its welded. making it longer is pointless in my opinion and will just add weight.

[coxylaad]

long time no update.

Finally after getting married and being away sunning it for 3 weeks I am back and now sorted and looking at the TRX again.

so, I fitted the painted oil tank to the engine, and fitted the engine in the frame.

Fitted the throttle bodies to the engine, then decided to mock up the rest of the bike just to charge my interest up:


I have to say I am not particularly convinced its going to look good anymore


probably something to do with dribbling over this in the local dealers for the past week


thankfully its way too much money for me so its not something I would consider, but it does make me think about how I want the trx to look.

I think the R6 tail section is just too wide. I would prefer something a bit narrower and a bit shorter - suggestions on a post card please.

next job I have to think about is how I am going to get that fuel pump/sender unit into the bottom of the TRX fuel tank. again not really sure how I am going to do this either. I have the flange to fix it to the TDM tank, just need to cut a hole in the bottom and see whats needed.

[coxylaad]

sorry double post

[Gix]

I'm running the same R6 tail (5sl) and found the 5SL subframe didn't require that much work to bolt straight on. Also means I have the strength to carry pillions if I wish.
It looks good on the bike too... the RC8 is a much narrower bike with very angular lines so suits that rear end..not so sure how that would look on a TRX