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Archive | March, 2012

Final weigh-in before the event

7 Mar

If you’ve been reading this you’ve seen that I’m keeping track of weight gains and losses on the bike. With all the extra parts for protection and lugging, I would like to net out at a zero weight gain to the bike by replacing parts with lighter versions (e.g., exhaust pipe) and just tossing unneeded parts, like passenger pegs. The big things I could weigh individually, but the little stuff just got thrown into a bag to weigh later, like today. So here’s the bag ‘o junk – old turn signals, bar-end weights, passenger pegs, upper chain roller, piece off the clutch lever, etc. – and the weight savings, 5 pounds. As of the February 23 post the bike had gained 1 pound. Not bad considering the tail rack, surf racks, skid plate, luggage rack, etc. But with this savings we were at a 4 pound loss, but.

The DBz Flat Top Duffle tail bag came in today; that’s another 2 pounds. (The DBz stuff is really light.) And I finally weighed the magnetic (heavy) tank bag I already had (and had never used because my Ducatis have either plastic or aluminum tanks); 5 pounds! So the 4 pound loss has turned into a 3 pound gain, and there’s not much more I can do without spending a lot of money, as in hundreds per pound. Better to lose some weight myself!

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Test Run

6 Mar

I loaded up a 6’8″ in a canvas Julie Bag for a test ride. I cruised on up the the newly opened Deus Ex Machina on Venice and Lincoln to show the crew there what they had helped inspire. (There was an article on Deus in The Surfers Journal that showed one of their surf rack modified bikes.) I was surprised at the reaction. The moment I pulled up they all piled out to check it out. I showed them around the bike, making lame excuses for my prototype PVC mount for the front, but they seemed pretty stoked. They took some photos. Much better than this one of the DR back in my little garage, board in rack. How did it work. Excellent-ly. 😉

Yes, bad photo. But this isn't the right board bag, so the good shots will come later. You can see the PVC poking out under the nose. That's been painted black. The bungie up front attached to a tie wrap that goes through a small but convenient hole in the frame behind the triple clamp.

Board Support Up Front

6 Mar

A big concern has been how to support the front of the board and to keep it from hitting the front wheel or fender when turning, and to make sure it doesn’t get caught on the front brake cable. Since the racks are on the rear, they are only holding the back third of the surfboard, so wind and bumps will cause the front of the board to move around. Probably a lot. The DR650es has an oil cooler with a frame extension for protection. It’s a perfect place to mount some sort of stabilizer. For now, and maybe forever, I cobbled together a support piece out of PVC. Here’s the piece for mounting to the frame.

What's difficult to see here is how I cut the PVC to mount onto the frame tube.

Yes, working at night. I ended up putting a piece of neoprene between the PVC and the frame tube to keep the PVC from cracking and to give some shock absorption. Hose clamps are used to secure.

 

Surf Racks Mounted

6 Mar

Mounting the Carver surf rack to the Manracks tail rack was almost straightforward. As you can see in this pic, one bolt looks different from the other. The Carver rack mounting bolts are LONG, and would drill into the fender, so I replaced the left side bolt with a shorter one, about 3″. Not seen here is that I put a third bolt in the center. That one is even shorter. It’s a solid mount.

You can see that the Carver surf racks clear the DBz luggage racks nicely. That was a relief.

Carver Surf Racks

6 Mar

OK, down to the good stuff: Surf racks on a motorcycle. I checked Deus Ex Machina rack, but you can’t buy it without buying the motorcycle attached to it, and at this point they’re only doing street bikes. I also checked out the Surfer Peg rack, but again, it’s street oriented, and needs to attach to the frame. That’s not inherently bad, but it would require fabrication that I’m not quite interested in. Primarily, though, it’s the street focus that steered me away. I settled on the Carver Racks, even though they’re not for motorcycles – bicycles and scooters, but not motorcycles. What I liked, though, is that it could be bolted to the rear rack.

When putting the racks together I encountered a small problem: The rubber tubes were too long, so the pieces wouldn’t fit together without a bit of cutting. I called the guys at Carver in Hawaii. They were a bit surprised, but were good with the mod.

Moose Hand Guards

5 Mar

Another delicate area is the handlebars, especially the clutch and front brake levers. Even a parking lot tip-over can break a lever, so a fall in rocks out in the Baja boonies would be worse. So hand guards are in order. Tons of online research yielded nothing but concern about finding myself having to do a bunch of handlebar cutting, buying new levers, and all sorts of make-it-fit stuff, because everywhere I looked I read about problems with the installation. I found the fewest problems with the Moose guards, so I went with those. Actually, the problems were few. Just the usual make-it-fit stuff. The one real problem was the clutch lever not fitting inside the guard. (The brake lever would have had the same problem, but the previous owner bent it in his fall. Convenient for me.) That was solved with a hacksaw. And I saved an ounce or so!

Not an elegant fix, but it works, and I can clean it up later.

Case Savers

5 Mar

A slow-speed fall could spell disaster if the brake pedal or shifter gets driven into the engine case. And it happens all the time. So adding case savers is a must. I checked out the case guards at Procycle. They’re $80 and made of stainless steel. Then I found the aluminum (translation: lighter) guards at Motorcycleproducts for $60. Lighter on the bike and wallet too.

Easiest things in the world to install, once you find the right adhesive. The instructions ask for “RTF” adhesive. Went to the local hardware store, OSH, but they never heard of it. Went to Home Depot, same deal. But after scouring the aisle I found this (below). As it turns out, it’s basic silicon seal.

After finding the right stuff it’s easy. Clean the guards with 409 to remove all dirt or finger oils, and spread the silicon seal.

Press the guards to the cases and tape to hold in place.

After letting the silicon seal set for a day I added a bead around the edges to keep dirt from getting inside.

UPDATE: The installation went well, and after riding over 2,500 miles in Baja, most of that in desert temperatures well over 100, I’ve seen no problems. The news is that ProCycle now has installation instructions on their site. Not much different than these, but they like the red silicon. Check it out here.