denisesewa

For my brake lever I ended up having to use a steel one mounted to the inside of the frame , steel so I could cut, weld, heat and bend it into shape , is it possible to mount on the inside?

if I remember right my Beta Techno was 12 volt, I would think the Zero was 12 volt as well, nothing special about the Motoplat coil , one off a 90's era KTM should work , ( probably any 12 V coil would produce a spark for a test ) Keep up the progress

Thanks to all for the positive comments , Glynn, that is exactly the intention , so far the performance is just what I wanted.

So its been a while , winter kinda shut down the build then I went on a 3 month kiteboarding trip, then picked up a TL 125 and did a rebuild on the entire bike, so, last week I tore down the trials build, finished all welding , sandblasted/ grinded the chrome off and painted, went after all the little details on reassembly and couldnt be happier with the final result , just waiting on some paperwork to get it titled and my foot to heal so I can ride. Seat is installed so just one thumbscrew removes it in about 10 seconds , street electronics can be removed in about one minute.

Good job Glynn !! kinda cool getting something for a trials bike for cheap eh?

BTW, another example is the Magura Hydraulic clutch conversion kit for around $300 , I bought a chinese copy just to try it out for $50 shipped, works great, I am not advocating buying chinese stuff and try to buy from/support local shops, but I am on a limited budget and cant throw away $250 just to try something out. on the other hand I am sure this stuff wont last as long and the quality of the alloy is poor, but a seat for $22 verses $200 to $300?

Pitbike = China , and a saturated market

Plenty for sale on UK ebay http://www.ebay.co.uk/sch/i.html?_nkw=pitbike%20seat&ssPageName=GSTL

This is how things are going with my bike ( Same way I did the Techno) , I made a * mushroom* with a small spacer and plastic washer along with a longer screw for the mount on the front of the fender, then trimmed off all the protruding plastic from the seat base along with the rear mounting brackets, cut a * keyhole * in the appropriate location, I have to bend the seat base to get it to go on and the seat now snaps in place, it actually fits well enough that I probably dont need a mounting screw in the rear but I'll probably put one in anyway. So, one or two screws and it goes from trials to trail. Looks pretty good IMO and cost a total of $22 plus a couple screws.

That seal doctor does look like a nicer unit, gonna have to get one. you have a cool website, lots of familiar pictures , I'm just down stream in Canon City

So when I bought the 2006 TXT forks for my project bike I knew they had some nicks in the stanchions and the seals were leaking so I ordered a set of seals and with them came a " seal mate tool" ( figured it was a gimmick) , the seals on the forks were leaking bad enough that pumping them a couple times would leave oil film on the stanchions and after a trail ride there was oil down the leg and on the brake rotor. I used a " Lanski" knife sharpening kit which has small super fine stones and honed down the nicks and then just because I had it used the Seal mate tool to clean the seals, the amount of crud this tool removed is amazing and after following the info in this video I am shocked to find they no longer leak >> <<.I will change the seals and oil before assembling the bike for the final time but thought I'd share this in case anyone is interested , one thing for sure is I will use the tool occasionally to clean the seals on all my bikes.

on the Beta I made a "keyhole" in the plastic base for the front and installed a raised screw in place of the screw for the front of the fender , then one screw from under the rear part of the fender into the seat base, so only one extra hole in the fender was required , havnt figured out how I am going to mount it on the supermini yet.

You do have to do a bit of trimming of the plastic seat base and get creative on mounting it , I am presently working on doing the same for my Super mini build which will require relieving quite a bit more seat base than the Techno did, you will likely have to do the same on your TXT

Pitbike seats can be purchased cheap and have a shape that makes them ( relatively) easy to fit >>http://www.ebay.com/itm/381211921247?_trksid=p2060353.m1438.l2649&ssPageName=STRK%3AMEBIDX%3AIT. I put one on my Beta techno for mountain trail riding, its still pretty low compared to an MX bike or enduro but helped

Thanks!! You sending the old tank along sure made it easier to make a mold for the new one, Much appreciated !!

Looking a bit better with carbon parts finished, now to decide on frame color, Red maybe?

Hey Smokey125 , if you're reading this, I really like the look of that deep subdued semigloss shine on carbon , to get it on surfboards and hydrofoils I usually finish wetsand the final epoxy gloss coat down to 800/1000 and then use a slow machine buff with miracle-cut 1000 then wax , how do you go about it? do you topcoat with an auto finish as some surfboard builders do or just leave the carbon as it comes out of the mold? , I am now considering leaving alot of the carbon exposed and just do graphics with vinyl wrap rather than paint, any other options? Your advise is always appreciated. I really dislike this shine from the topcoat >> And prefer this subdued semigloss like these two boards I built >>

Just returned from a 2 hour trail ride, really liking this bike, its so much more fun and easy to ride than the clunky TTR was. Nothing rattled,clunked,cracked or fell off ( including the rider) , Jetting is on the rich side, by the time I climbed to 9000 ft from 5000 it was a little blubbery so I'll have to find middle ground on jetting , the side stand spring is rubbing the heel of my boot and is a nuisance just cause I know its there and the fork seals are weeping ( kinda expected that) . Overall its going to be just what I was looking for, less tiring and more fun to ride on rocky trails, playful enough to keep me entertained and will look good enough when done that I wont be embarrassed at a trials event plus I can call it my own.

Those bags look great , I have tried welding bags together to form complex shapes and have too many problems with leaks and end up with wrinkles anyway, these diatex bags seem to be the answer. Crazybond 700 said " I would suggest a larger front fender, sand in your eyes sucks! " This fender is the exact same shape and size as the one on my electric trials bike and has not been a problem , if it proves to be a nuisance I'll make a longer one. I swapped flywheels yesterday evening to the heavier one and now the bike will idle along in first gear without stalling, throttle response is still good, The hydro clutch conversion feels good but I may want to extend the clutch arm to lighten the lever pull even more, either that or I need some strength training for my finger, I also may go to a slower turn throttle but need to relearn trials riding before I make that change, its been 15 years and I feel like a newbe, although my balance isnt too bad my timing and technique is not even close and can barley get the rear wheel off the ground for a nose wheelie , new front brakes pads also need to get run in.

BTW, a quick check on a bathroom scale shows the bike to weigh 161 lbs ( 73 kg ) with oil but no fuel , weight bias is 76 lbs front and 85lbs rear ,with a tank of fuel ( 1 gallon) bias should be closer to 50 - 50 , anyone know what the weight bias percentage should be? Not really much I can do about it but I'd like to know anyway.

Well, I have the fiberglass molds I made initially so I'm covered if I break the fenders , the rest are pretty much repairable. Been working on adapting the TXT forks which turned in to more of a job than expected since I machined the frame's steering bearing pockets to accept larger OD bearings for the Beta forks, ended up having to press out the stems and swap the Beta stem into the TXT lower clamps, also had to start over with all the bushing and spacers for the front axle but what a difference these forks are over the Paoli USD forks , super rigid, Plush with no stiction and the length is perfect, besides the bike really looks better in my eye with these forks. Also made a new temporary fuel tank , might even come in handy for future trail rides as spare fuel. I had the swingarm axle slots extended forward 1 inch to bring the wheelbase to 51", changed the gearing to 11-60 which made a good difference and feels about right but after riding a bit today I think I'll put the heavier flywheel back on(18oz heavier than this lightened flywheel) . Made a carbon front fender mount and alum fork brace , kinda strange looking as it is 2 tiered but I think I like it and the added stiffness with the brace is substantial, laced up the aluminum front rim and mounted the trials tire , reworked the rear brake pedal to achieve a longer stroke with the kicker along with a bunch of other minor detail stuff. So its looking and riding like a trials bike now, ( at least to me) and I am close to the point of tearing it down, finish the welding and working on cosmetic stuff, sand blasting , sanding and painting as well as finish work on all the carbon parts, still havnt decided on a paint scheme, winter weather will determine when all that gets done. Pretty pleased so far

I think its strong enough but I'll give some thought to adding " wings" to the sides to stiffen it even more. the TTR 125 frame is prone to bending for that same reason ( Plastic skid plate and no cradle). On another note, I picked up a set of 40mm Zokes from a 2006 TXT, should be much better than the Paoli USD forks and lighter too , back to machining spacers , adapters etc., also laced up an aluminum rim to replace the steel rim for the front.

I have alot of various types of carbon cloth left over from building Kiteboard hydrofoils and did hand layup for these parts since vacuum bagging these shapes would be complicated ( RIM would be even more complicated and I've not studied the process). the Epoxy resin I use is from "US Composites" and has served me well, it is also alot cheaper than "Resin Research" which would be my preferred epoxy otherwise, the only down side to US comp's epoxy is that it does not have UV inhibitors in it so will require painting, thats OK with me since natural carbon would really heat the fuel in the sun. Once its Post cured it should be resistant to ethanol but I am going to use " Red Kote" tank liner to be on the safe side, I've had good luck with that product in the past and have some on hand. Yesterday I finished the airbox construction , have to add a couple mounting lugs then it will be ready for sanding and finish.

I've spent the past week or so working on fabricating the carbon fiber parts, the construction is finished ( except for the airbox and side plates which I'm still working on) , the final finish of all the parts will come after the rest of the bike is done , I also cut up and redesigned the exhaust and added a shortened FMF silencer from a KTM ( sounds great!, nice and quiet too ). Got the hydraulic clutch sorted out and it works awesome, easy one finger and predictable actuation . found a piece of really tough aluminum for the skid plate compliments of the scrap pile at a decommissioned military base, not sure what the alloy is but it was hell to bend it into shape , took 2 people, 2 trucks and a railroad tie to get it done. So today I strapped a lawn mower fuel tank to the handlebars ( going to wait till the carbon tank is completely cured) and fired it up for the first time, rode it around the yard a bit but since nothing is completely welded on the frame I just poked around slowly, the motor feels really good with the bigbore kit , I opted for a mikuni VM 24 for the carb and throttle response is excellent ( unlike the stock TTR) I think I'll need to gear it down some more, presently running 12-54 and can go to 12-60 but thats about the max unless I get a custom rear sprocket. geometry feels good , Still a hell of lot to work out and fabricate but I'm pretty stoked

These Vee-rubber tires ( same tires that come on the Gas Gas 80 ) actually seem decent, pretty soft unlike some of the "trials pattern" hard rubber tires you mention, I'm sure they are not as good as the Name brand trials tires but they will do for my purposes. Been working on shaping the rear fender from pink insulation foam , layed up the glass and now have a mold , I did cut up the subframe ( it was bent anyway) and shaped the fender for a bit more modern look.