Stuff you have fixed today

[qwakers]

axle tube measured and cut. just got to manufacture the hub carriers and put it together...

axle manufacturing time....

i came across the unusual issue of not having the right tool. well that's not quite true.
the issue is my mig is only 180amp, and to compound that it only has 0.6mm wire in it, so it's not up to the job of welding 15mm plate. i DO have a tig that will also stick weld, and it absolutely does have the balls to weld that heavy gauge, but this is a seriously mission critical weld, and i havent stick welded for a very long time... so i went off to dads workshop to use his 220 amp mig and as i was there it would have been rude not to utilise his plasma cutter and other nice toys whilst i'm at it.


after cutting the bit of 15mm plate to size i used a 82mm tct hole saw to cut the center hole. the chips from this are seriously evil. microscopic. sand like even. and seriously sharp. they get everywhere and hurt a lot. wear gloves.

his plasma is only 50amp so no its not going to manage neat cuts of this thickness, but it severed a 50mm square hole well enough. most of the issues and lack of neatness are because this is my first go with a plasma.

then all welded up.

the 15mm plate was welded together in 2 passes, a root and cap if you may. this is my first ever experience of that technique, so its not as neat as id like, but it'll be strong enough.

 

[Keithmac]

Bit of an odd one this week.

Have a BMW R1150RT in, customer bought it cheap as it only idled with Fast Idle lever cable tied fully up, last owner ran it like that for years..

I assumed it was just the normal throttle bodies out of balance and poorly set up (they were!), but more to it than that.

Got it running great on the bench and thought nothing more of it until roadtest time.

Bike began to run pig rich and not happy at idle, old plugs were sooted up when they came out earlier in the repair but presumed that was down to dirty air filter (I fitted a new one) and short runs.

Turns out when the ECU gets warmed up by the engine it thinks the battery voltage is miles off actual voltage (8v at 14.5v at worst!).

Got it bad enough where it was still at fault when I took tank off, stripped connector and verified voltage was correct on Pin1 (Power Supply pin) while ECU connected, popped ECU in freezer for 10 minutes and retested and all back to normal..

Seems the dead time correction at 8v is enough to massive overfuel the bike (should be 2.6ms when normal, was 3.6ms when playing up).

I've go a replacement ECU on the way but nice to be able to see live data and verify it is faulty rather than firing the parts cannon.

 

[DAPPH]

So pleased I've been retired 38 years from playing with that crap.

 

[leadpig]

Another gate was only going to fix the scroll that kept popping out of frame, till I found the rust worm.
Put a bit of 4mm plate on each side and padded beads on top with tig, nice to use tig again

 

[sardine]

Another "one in every skip" Henry vacuum on my bench yesterday, cable was cut off and that usually means it's done for, so i immediately took it apart and started testing the motor, switches ect, there was nothing wrong with it , so why cut the cable off ? What value is a few feet of 1 sqmm cable ?

 

[ajlelectronics]

Bit of an odd one this week.

Have a BMW R1150RT in, customer bought it cheap as it only idled with Fast Idle lever cable tied fully up, last owner ran it like that for years..

I assumed it was just the normal throttle bodies out of balance and poorly set up (they were!), but more to it than that.

Got it running great on the bench and thought nothing more of it until roadtest time.

Bike began to run pig rich and not happy at idle, old plugs were sooted up when they came out earlier in the repair but presumed that was down to dirty air filter (I fitted a new one) and short runs.

Turns out when the ECU gets warmed up by the engine it thinks the battery voltage is miles off actual voltage (8v at 14.5v at worst!).

Got it bad enough where it was still at fault when I took tank off, stripped connector and verified voltage was correct on Pin1 (Power Supply pin) while ECU connected, popped ECU in freezer for 10 minutes and retested and all back to normal..

Seems the dead time correction at 8v is enough to massive overfuel the bike (should be 2.6ms when normal, was 3.6ms when playing up).

I've go a replacement ECU on the way but nice to be able to see live data and verify it is faulty rather than firing the parts cannon.

View attachment 470267
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View attachment 470263

Is that a CANBus 'bike?

 

[qwakers]

axle manufacturing time....

i came across the unusual issue of not having the right tool. well that's not quite true.
the issue is my mig is only 180amp, and to compound that it only has 0.6mm wire in it, so it's not up to the job of welding 15mm plate. i DO have a tig that will also stick weld, and it absolutely does have the balls to weld that heavy gauge, but this is a seriously mission critical weld, and i havent stick welded for a very long time... so i went off to dads workshop to use his 220 amp mig and as i was there it would have been rude not to utilise his plasma cutter and other nice toys whilst i'm at it.


after cutting the bit of 15mm plate to size i used a 82mm tct hole saw to cut the center hole. the chips from this are seriously evil. microscopic. sand like even. and seriously sharp. they get everywhere and hurt a lot. wear gloves.

his plasma is only 50amp so no its not going to manage neat cuts of this thickness, but it severed a 50mm square hole well enough. most of the issues and lack of neatness are because this is my first go with a plasma.

then all welded up.

the 15mm plate was welded together in 2 passes, a root and cap if you may. this is my first ever experience of that technique, so its not as neat as id like, but it'll be strong enough.

the wheels are back from the machineists and will work fine (literally charged me beer money. £20 to change the center bore in his massive mill as his lathe wasn't big enough) slapped tyres back on (the finest 8 year old joyroads..) axle is mocked up. swapped the final new borg and beck hub onto the astra so i now have 2 used hubs for the trailer. ready to fit it and paint it.

 

[Farside]

Another "one in every skip" Henry vacuum on my bench yesterday, cable was cut off and that usually means it's done for, so i immediately took it apart and started testing the motor, switches ect, there was nothing wrong with it , so why cut the cable off ? What value is a few feet of 1 sqmm cable ?


View attachment 470344

Some overly-cautious householder clearing out stuff cuts the cord off because of (imagined) legal ramifications if somebody should take away a fully-corded appliance which might have a fault and electrocute themselves.

 

[Keithmac]

Is that a CANBus 'bike?

No, it's pre CanBus.

I had a BMW S1000XR in a while back for RHS rear indicator not working, that was CanBus and required a new Chassis Control Module, £400 or more iirc just for the module.

Customer asked if I could just change the "flasher relay", unfortunately not as it hasn't got one!.

 

[DAPPH]

Another "one in every skip" Henry vacuum on my bench yesterday, cable was cut off and that usually means it's done for, so i immediately took it apart and started testing the motor, switches ect, there was nothing wrong with it , so why cut the cable off ? What value is a few feet of 1 sqmm cable ?


View attachment 470344

Likely they cut or burnt the cable & decided a new bigger shop vac was the order of the day .

 

[awemawson]

I cut the plugs off two built in generic ovens that I replaced in our holiday cottages lest week, not for safety but because I wanted them for the replacement ovens. Ovens were fine but getting a bit tatty. I’d intended to take them to the tip but in the end gave them away on marketplace.

 

[qwakers]

axle manufacturing time....

i came across the unusual issue of not having the right tool. well that's not quite true.
the issue is my mig is only 180amp, and to compound that it only has 0.6mm wire in it, so it's not up to the job of welding 15mm plate. i DO have a tig that will also stick weld, and it absolutely does have the balls to weld that heavy gauge, but this is a seriously mission critical weld, and i havent stick welded for a very long time... so i went off to dads workshop to use his 220 amp mig and as i was there it would have been rude not to utilise his plasma cutter and other nice toys whilst i'm at it.


after cutting the bit of 15mm plate to size i used a 82mm tct hole saw to cut the center hole. the chips from this are seriously evil. microscopic. sand like even. and seriously sharp. they get everywhere and hurt a lot. wear gloves.

his plasma is only 50amp so no its not going to manage neat cuts of this thickness, but it severed a 50mm square hole well enough. most of the issues and lack of neatness are because this is my first go with a plasma.

then all welded up.

the 15mm plate was welded together in 2 passes, a root and cap if you may. this is my first ever experience of that technique, so its not as neat as id like, but it'll be strong enough.

axle mocked up and wheel fitted to check clearance. plenty.

and all welded up... 180amp mig, 0.6mm wire, set to full power and wirespeed nearly flat out. really needed 0.8mm wire for this.

just gotta paint it.

 

[ajlelectronics]

No, it's pre CanBus.

I had a BMW S1000XR in a while back for RHS rear indicator not working, that was CanBus and required a new Chassis Control Module, £400 or more iirc just for the module.

Customer asked if I could just change the "flasher relay", unfortunately not as it hasn't got one!.

Thought so. I was intrigued by your equipment as I thought that my GS-911 was the dog's, but apparently not! I have my own Ibus scanner that I use for the radio conversion module development.

 

[addjunkie]

axle mocked up and wheel fitted to check clearance. plenty.

and all welded up... 180amp mig, 0.6mm wire, set to full power and wirespeed nearly flat out. really needed 0.8mm wire for this.

just gotta paint it.

That axle will be good for 5 ton or so, not sure about the rest of it!

 

[qwakers]

Overkill is my favourite type of kill

 

[Bobupndown]

Another "one in every skip" Henry vacuum on my bench yesterday, cable was cut off and that usually means it's done for, so i immediately took it apart and started testing the motor, switches ect, there was nothing wrong with it , so why cut the cable off ? What value is a few feet of 1 sqmm cable ?


View attachment 470344

Never managed to find a cheap, or better still free one yet. Loads on Facebook near me around the £60 mark, which seems steep for a used vacuum managed to get a perfect washing machine for half that last week!

 

[bourbon]

Not finished yet. But a work in (very slow) progress. The doll that this is the leg off, is around 2 foot high and the leg is 9 1/2 inches long. Found most of the bits, but I'm having to fill the lost bits.

 

[qwakers]

axle mocked up and wheel fitted to check clearance. plenty.

and all welded up... 180amp mig, 0.6mm wire, set to full power and wirespeed nearly flat out. really needed 0.8mm wire for this.

just gotta paint it.

smack the wheels on, pair of mudguards and job jobbed.

did it with roller and brush as i couldnt be arsed moving the car outside. worked ok, but would not recommend.

 

[Keithmac]

Thought so. I was intrigued by your equipment as I thought that my GS-911 was the dog's, but apparently not! I have my own Ibus scanner that I use for the radio conversion module development.

We are on Texa Diagnostics.

Some manufacturers give a few Parameters to look at, others (Piaggio Group / Ducati especially) give pages worth of real time data.

Very handy tool but not cheap, you can't even turn a service light off on the new bikes without one though.

I'd be lost without it really, this bike did not store any DTC's so it would have been guess work without the full diagnostics.

 

[galooph]

Finally got round to replacing the pneumatic wheels (that never seemed to hold air for long) on my trolley with a pair of yellow puncture proof ones that I think @8ob linked to a while back