Sensation MB-6A Re-do... - Page 12

**Yellowhand** · 02-21-2010, 01:16 AM

Boring a sprocket to fit the Sensation hub...

The plate for my lathe didn't have quite the slot distance I needed for the sprocket holes, so I elongated the slots with a carbide rotary file...

Tungsten carbide goes through cast iron like a hot knife through butter, so it took just a couple minutes to modify the plate...

**Yellowhand** · 02-21-2010, 01:23 AM

It takes only a minute to change from a chuck to a plate...

I needed to remove about .120" after centering the sprocket and tightening the bolts...

**Yellowhand** · 02-21-2010, 01:26 AM

I'll tack the sprocket on, spin it in a lathe to check and adjust for true, then TIG the sprocket directly to the hub...

**Yellowhand** · 02-25-2010, 12:19 AM

I made a new exhaust pipe for my Trail Horse...the bike is basically stock, so I think this new pipe looks more appropriate than the modified pocketbike muffler that was on it...

About halfway done making the intake for the taper-bore Mikuni...

**Yellowhand** · 02-25-2010, 07:48 PM

I have a cousin who is a professional welder/machinist, and he spends the majority of his working day running a TIG welder, so I stopped by to see him and asked if he could 'work his magic' on my wheel...

He welded the hub to the sprocket-side wheel half (Sensation Mfg welds only the other side) and then welded the sprocket to the hub..

Nice work, Z.C....thanks for doing it much better than I could have done it.

**Yellowhand** · 02-25-2010, 10:36 PM

I finished making the intake manifold to fit Mikuni 22mm thru 26mm taper bore carbs...

The mounting holes are differently sized and spaced when compared to a Mikuni VM22, so the manifolds won't interchange...

Fortunately, if you fab the manifolds from steel, it's only about $3 worth of materials and an hour of your time, so it's no big deal to make several different manifolds and try out different carbs to see what works and what doesn't...

**Yellowhand** · 02-25-2010, 10:54 PM

The yellow suede seat in the pics came off the chain bike...I dyed some new suede dark brown to make a new seat, so the yellow seat is homeless right now...and since it looks like Kenny is going to quit the seat-making business, I'll probably be buying more suede hides...

Yeah, they don't look as good as Kenny's seats, but I really enjoy making them...I make them for my little bikes and my big bikes...anything I can do to keep from sitting on the couch and watching the same crappy TV shows over and over again...

There's a piece coming up that might be interesting...those propane tanks are going to become gas tanks...round tanks go for stupid money on ebay...these are $3 each at Walmart, or $3.59 at ACE Hardware...plus some brass fittings...you might like them, and make one for yourself.

**bandit 40** · 02-26-2010, 12:51 AM

Quote:

Originally Posted by Yellowhand

I finished making the intake manifold to fit Mikuni 22mm thru 26mm taper bore carbs...

The mounting holes are differently sized and spaced when compared to a Mikuni VM22, so the manifolds won't interchange...

Fortunately, if you fab the manifolds from steel, it's only about $3 worth of materials and an hour of your time, so it's no big deal to make several different manifolds and try out different carbs to see what works and what doesn't...

Them look great Mark

Nice Job.....Im still interested in a couple of them ,if you get around to making any more

**Yellowhand** · 03-01-2010, 01:17 AM

There hasn't been a lot of progress lately...I took Injuntom's advice and shot the wheels with engine enamel...makes sense, since it's more durable and oil resistant...

I got sidetracked designing a tool...

I want to make some tubing that looks like linked spheres, or connected balls...think 'string of pearls' and you'll get the mental picture...

My first design was a set of dies for a press, but an uncle suggested I roll the design into the tubing instead of pressing it in...

So, I'm working on building a roller tool that uses a 1018 steel die I'm making on a lathe to form the contour into 1" OD hot steel tubing...

If the basic tool design works, I'll remake the die in heat-treated A2 tool steel so it lasts indefinitely...

As soon as I have something that works, I'll post some pics here...eventually the contoured tubing will be made into a minibike frameset, similar to the 'twisted' frame I'm in the middle of building...

**Yellowhand** · 03-03-2010, 02:39 AM

I needed to put new Carlisle sawtooth tires and tubes on the Sensation's one-piece steel wheels...

I put tires on one-piece wheels by hand, without any tools except shampoo...

With my luck, any tire iron or screwdriver I used would find the tube and cut it to shreds...

This set of tires was a bitch to get on, and I tore the skin on the heel of both hands from pushing the bead around the rim...

I have a set of 4-inchers I bought already mounted for another bike that were put on using a tire machine while someone wasn't paying attention to what they were doing...

They split the wire ring inside the bead, and when the tires heated up and softened, the bead stretched and one side of the tire blew off the rim...

Fortunately, the fork leg kept the tire fairly straight and the rubbing slowed the bike down without locking up the tire...

I pee'd a little, but wasn't injured...

I left the zerks in the Sensation wheels...I thought they look cool...you never see zerks on anything these days.