Blast Project
 
         
 
  • Week 1
  • Week 2
  • Week 3
  • Week 4
  • Week 4.5
  • Week 5
  • Week 6
  • Week 7
  • Week 8
  • Week 9
  • Week 10
  • Week 11
  • Week 12
  • Week 13

Day 1 (each day represents an actual day of labor)
9-27-08

No work has begun yet, but the unboxing has occurred.

Blast06 Redneck Frame Prep
My '06 Blast
Redneck Itsabast Frame
Size comparison

 

Day/Week 2

I gave myself an hour to see how far I could get with the tear apart. I got the seat off with pure muscle, the battery came out without even a hickup, the gas tank shield came off after 10 different widgets had to be moved, then the tank itself stalled me.

The manual told me to remove a hose clamp and then remove the hose. I ended up sawing it off with a knife. Then it tells me to remove two bolts that have star patterns. Stall, I don't happen to have one. So I skip to the exhaust system. Easy I think. The bolts are on the outside, but the screws are on the inside. I have no idea how to get them loose. So I stopped there for today.

 

Day 3
10-5-08

I was able to remove the gas tank with a minimum of effort. Two star screws, a couple of bolts and off it went. The next was the muffler. I don't know what torturer put this together, but I had to lay on my belly, hold a hex wrench in place while ratcheted off the bolt. The other was even worse as I had to use an extended screw driver with a hex bit, stand over the bike and hold it while I ratcheted away on the other side. Thankfully its a small frame! It's definitely looking more sleek with less.

I finally figured out what that cross shaped item was. It bolts in the back of the motor and provides mounting for the controls and brake reservior. Only I wanted front controls! Off goes an email to Frede.

 

Day 4
10-11-08

Today's progress was extremely slow. I misread the manual - thinking that I was one step away from dropping the motor. Wrong. I went as far as getting a floor jack to lower the motor down...

I removed the horn. It's in the way of one of the main bolts on the isolator mount in the front. I tried to turn that nut and it wasn't going anywhere. I was sitting on the floor with one foot on the bike and both hands on the wrench. No go. So I decide to give that a break and remove the air box and carb. I've begun to find that the manual is either poorly written or designed for a mechanic with ADD. Ever couple of lines it says lower the motor. What?

I got most of the bolts off aroud the air box and couldn't get the screws off the mouth of the carb. I called my buddy Cheryl to lend some brains. She's brings some break free and we get to work on the motor bolts. We get those lose, but burn about a half hour working on the airbox. In frustration I read ahead in the manual and find that I just have to release the hose clamps between the carb and manifold. Dang.

We get that off with some struggle with the throttle cables. So the next part is to lower the motor. Wrong. Even Cheryl is giving that the stink eye. She notices that everything is still connected. So we go further into the manual and end up taking of the right side foot pegs and belt cover. After than we swing the bike under a beam in preparation for the frame removal - if the manual isn't steering me wrong.

Day 5
10-12-08

I wanted to give myself an hour today to finish up a couple of things from yesterday. I was finally able to get the last bolt hold on the left side foot pegs off. Yeah! I undid the rear shock after suspending the back half from the rafters. I decided to skip a step which may bite me in the butt later, but I chose not to remove the drive belt. Loosening doesn't seem to be important so we shall see.

The next portion is to remove the vents and oil lines. I made the smart choice and drained the oil before detaching the hoses. That would have been a serious mess. The manual says detach the hoses, but there is no indecation at to what end I might do this or how to detach the hoses. They have a locking clamp that I've never seen before. Another question for Frede at Redneck.

The motor is now firmly supported by my wood stack. I think I'm going to have to make another one before I swivel off the frame just to be sure.

 

Week 5 (10-25-08)

Finally! The frame is seperated from themotor and the swingarm. I threw my back out moving the frame off, trying to keep everything from falling over.  
Hoses and wires.  
Frame and front forks  
This is what's next...  

What's next:
- I've got to get a longer 1/4" hex to take off the frame bracket off the motor.
- I've got to pull the handle bars and controls before I can pull the forks.
- Then it's the wiring hareness...

Week 6 11-1-08

Massive progress by my standards. I was able to remove the final frame bracket off the motor/swingarm. I placed the new frame on the motor to get a feel of what things would look like. I disassembled the controls to the point I could remove the front forks. And then took of the triple trees and most of the wire harness. It's a good day!

What the future may hold Front forks pulled Ready for install in new frame

Notes:

- What to do next? I think partially assemble the new frame with triple trees and forks (do I use the old bearings? Because I'll have to take it apart again at least once).
- Contine to remove the wire harness and consider transplant.
- Get exhaust pipe started... (how?)

Week 7 11-9

Just a quick hour today to finish the tear down. I pulled the entire wiring harness without problem.

The Harness and handlebars with controls. Or as I told Cid - the nervous system. Getting ready to put the forks on the new frame. I took the tank off for fitting. The old frame completely bare. 8 or 9 hours worth of work!

Notes
- put the new bearing cups in with old bearing sets.
- how do I get the old bearing off the triple trees?
- put the old folks on.

Week 8
1-17-09

After taking off a rather long time due to finals and Xmas vacation I was able to get back into the swing of things. Mark and I had to spend some quality time working on the rear shock mount which is now ready to accept the shock, but I have to find a bolt that will work out for me. A mystery!

together1 togther2
As you can see I finally have the front forks assembled and the new rake is very cool looking. I had to take them apart right after the photo because I have to get the bearing seats into the frame. I imagine that it's going to take a blowtorch to manage that. In this view you can see the license plate holder coming off the rear axle. Nice design touch from RE.

So, I also received the front crontrol mounts, but I can't see anyway in which to mount them. Another phone call to RE in case I'm missing something, but I also sent them pictures in hopes something makes sense to someone.

I had a long discussion with Ray about finishes. It looks like powder coat might not be the best bet in the end. I have to find out about the most durable inexpensive plain finish I can find.

I also have to find out about the battery. Mine will fit inside the compartment in the oil tank, but in hangs out almost halfway. Do I need a different model?

Week 9 - Jan 31, 2006

Progress has been the normal slow pace, but this week we were able to get the front controls put into place and try to figure out what equipment will be required to fit everything tightly. Finding the bolts was probably the longest part of the journey.

control view 1 Control view 2
control with forks 1 control with fork 2

Next - press in the fork bearing cups a bit deeper; move the engine to Marks for custom cutting of washers and such.

Week 10
2-28-09

You can see how things are starting to come together finally. A more forward view. You can see how much we had to add to get the mounts clear of the case.

 

Week 11
3-7-09

The voltage regulator bar is now in place! Only 8 hour on the lathe. The only thing left to do is to get the bolts trimmed and make sure everything is tight.

To do list:
-trim existing bolts to length and mount forward controls
-work on exhaust
-create connector from new controls to old

 

Content 13
     
     
     

Week 13
July 2009

Exhuast is finally starting to take shape.