During testing, I determined that the fuel pump was not running once the battery umbilical cord was disconnected. These pumps require clean 12VDC to run properly, but the output from my alternator is pulsed 12VDC. I had installed a large capacitor in the system to attempt to smooth out the pulses, but apparently this wasn't sufficient.
Unfortunately, the stock battery tray in a Sportster is inside the oil tank, so I could not install a factory replacement. There are not many mounting lugs in this section of the stock frame, so I designed a battery tray that clamps to a frame rail. I cut a pieces of 3/4" 6061 aluminum plate on my bandsaw, finished with a hand file, and machined a pocket with my mill.
Wednesday, June 15, 2016
Monday, June 13, 2016
Biodiesel Sportster Land Speed Racer - Part 16 - Rebuilding The Nose Cone
The final countdown to Ohio has begun, so I wanted to post the rest of the build pictures beforehand. This nose cone has spent nearly a decade hanging from a hook in my garage, and it is finally being used for its intended purpose.
This fiberglass nose cone was homemade by myself and my friend Ben for my first land speed attempt. This early bike was not well-made, and I ultimately saved a few of the better pieces and scrapped the rest.
This post is also a memorial of sorts. Through a cosmic twist, I am posting these pictures precisely five years to the day that Ben was fatally injured in a motorcycle accident. He was one of my closest friends, and I still think of him often. I am grateful that I have one of his expertly-fabricated pieces of bodywork, and that I can honor his memory by using it on this bike.
The donor was a heavily thrashed Suzuki dirtbike, and it was hilariously badly assembled by a high-school-age your truly, with zero build quality or safety features. Ultimately, the gas tank, foot pegs, nose cone, and some wiring were put into storage, and eventually recycled into the Biodiesel Sportster.
I made a large and heavy mold out of plywood, screen, and several gallons of Bondo that was then hand-sanded into the final shape. Ben was employed at a marine store at the time, and had become an expert at creating fiberglass parts, so he laid down the glass and made a strong and flexible cone. It was then cut and sanded into shape, given a thin coat of Bondo to smooth out the outer surface, and installed.
This fiberglass nose cone was homemade by myself and my friend Ben for my first land speed attempt. This early bike was not well-made, and I ultimately saved a few of the better pieces and scrapped the rest.
This post is also a memorial of sorts. Through a cosmic twist, I am posting these pictures precisely five years to the day that Ben was fatally injured in a motorcycle accident. He was one of my closest friends, and I still think of him often. I am grateful that I have one of his expertly-fabricated pieces of bodywork, and that I can honor his memory by using it on this bike.
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| RIP You Goofball |
The donor was a heavily thrashed Suzuki dirtbike, and it was hilariously badly assembled by a high-school-age your truly, with zero build quality or safety features. Ultimately, the gas tank, foot pegs, nose cone, and some wiring were put into storage, and eventually recycled into the Biodiesel Sportster.
I made a large and heavy mold out of plywood, screen, and several gallons of Bondo that was then hand-sanded into the final shape. Ben was employed at a marine store at the time, and had become an expert at creating fiberglass parts, so he laid down the glass and made a strong and flexible cone. It was then cut and sanded into shape, given a thin coat of Bondo to smooth out the outer surface, and installed.
The cone hung on my wall through college and various jobs and projects, before we decided to give it a second life on the Sportster. I sanded off the old peeling red paint, trimmed it down, repainted it Satin Black, and built a new mounting bracket to bolt it to the Sportster.
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Sunday, April 24, 2016
Biodiesel Sportster Land Speed Racer - Part 15 - Here Comes The Sun!
After a long Fall and Winter of wrenching, fabricating, and testing, Spring is finally here to stay! And to celebrate, I rolled the (mostly) complete Biodiesel Sportster into the sun for some proper photographs.
Sunday, February 28, 2016
Biodiesel Sportster Land Speed Racer - Part 14 - First Test Ride (Video Post)
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Saturday, February 27, 2016
Biodiesel Sportster Land Speed Racer - Part 13 - Odds and Ends
Here are all the various pieces that had to be fabricated. It's always those last details that drive you crazy and eat up your time!
K&N Round Filter Adapter
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| Made several grocery bags worth of chips.... |
CVT Cover
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| Hand-hammered from aluminum. |
Rear Struts
Frame-Stiffening Bracket
Secondary Shaft Keyways
Tuesday, February 2, 2016
Biodiesel Sportster Land Speed Racer - Part 12 - Rear Sprocket
To estimate sprocket sizes, I created a spreadsheet to calculate the approximate gear ratio for the final drive, and used trial-and-error to zero in. Ultimately, I decided to go with a 54 tooth rear and a 14 tooth front as the conservative testing ratio.
Theoretically, this combination should be good for a top speed of 74 mph at 3600 engine rpm. However, I cannot account for friction and wind resistance, so I will confirm that speed by real-world testing before I trust the math.
Theoretically, this combination should be good for a top speed of 74 mph at 3600 engine rpm. However, I cannot account for friction and wind resistance, so I will confirm that speed by real-world testing before I trust the math.
| Machining the spacer to fit the hub |
Thursday, January 21, 2016
Diesel Land Speed Racer Mk2 - Part 11 - Exhaust Fabrication
This is my first attempt at building an entire exhaust system by myself, so the welds are snotty, the whole thing was made from leftover scrap pipe, and ultimately I covered the whole thing in fiberglass heat wrap to hide my shame. Here is the whole process in its gory, splattery detail!
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| My homemade pipe-cutting rig |
| Working out the rough shape of the pipe joint |
| No turning back now! |
| Please don't judge my skills based on these welds.... |
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| Taking shape |
| Adding the downpipe |
| Definitely not trying to hide those welds...... |
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