nklr...aluminum welding

[nhjim10]

Its not so much that I *need* the extra capacity, but I *want* it. For one thing, with this bike I've fought mileage issues ever since new. If I'm doing mild commuter riding and am very careful, I can barely squeak 220 miles out of a tank. On the highway, it drops to 160-170. That 220 miles was riding like Grandpa with speeds between 40-50. Highway mileage is whether minimal or loaded, and a 16t sprocket. I've adjusted the carb, and the plug has always looked great (original plug at 18k miles), no changes. I did the t-mod, drill & needle shim at around 12k miles, still no changes (not that those things would really affect mileage). All mileages are counted from full until I have to switch to reserve. I'm hoping the poor ring sealing and oil consumption had a little to do with it, and I may see a bit better with the 685 kit. But the extra capacity is so I don't have to stop for fuel every 160 miles on the highway. Ideally I would love to at least double that distance, using a combination of improved mileage (crossing fingers) and extra capacity. When I'm trying to rack up the miles on the highway every fuel stop consumes time. While a fuel stop should take 5 minutes, in reality when combined with human nature, it can easily turn into 10-15 minutes. Factor in slowing down for the exit, hitting a stoplight or two each direction, removing the helmet, fueling up, taking time to grab a snack or drink *while I'm there anyway*, hitting a couple stoplights on the way back onto the highway, and getting back up to speed. For a 1000 mile day at 160 miles a tank, I'm looking at a minimum of 6 fuel stops. At 10 minutes each I'm at an extra hour. If I can cut those stops in half I can save an easy 30 minutes throughout the day. That doesn't matter when I'm just doing a relaxing day ride around New England, but on the long trips it adds up. In fact, when I attempted my first Iron Butt saddlesore ride I missed doing it by minutes. I was at 987 miles at the 24 hour mark. Other factors affected it, such as having to work a full 8 hour shift before I left right from work, and having a chain grenade in Virginia, forcing a couple hours of downtime while I made repairs and located a chain. I think I've decided to limit added fuel capacity to what I can easily do, such as a rear tank and/or IMS tank. As soon as hours pick up at work and I get rid of a payment I'm currently stuck with (done in July) I'm most likely going to pick up either a V-Strom 1000 or ST1300 for the long rides. I like the minimal bike of the Vee, but I like the shaft drive of the ST (I'm an ex ST1100 owner). Then I can add fuel capacity to either of those and really stretch out my stops. Jim

--- In DSN_KLR650@yahoogroups.com, "fasteddiecopeman" wrote: > > I can generally go around 500 kms (300 miles) to empty, and I 'modded' my fuel petcock so that I have about 160 kms (100 miles) once I go on reserve. The longest run I've done between gas station AVAILABILITY is the Dempster Highway, where gas is available at the start, mid-point, and end, so you need a range of about 360 to 375 kms. I believe I went onto reserve prior to the stations, but NOT for many kms! > Do you REALLY need MORE gas...? > Cheers, > Ed >

[salinej1@juno.com]

On Sun, 20 Feb 2011 23:31:25 -0000 "nhjim10" writes:

> Its not so much that I *need* the extra capacity, but I *want* it. > For one thing, with this bike I've fought mileage issues ever since > new. If I'm doing mild commuter riding and am very careful, I can > barely squeak 220 miles out of a tank. On the highway, it drops to > 160-170. That 220 miles was riding like Grandpa with speeds between > 40-50. Highway mileage is whether minimal or loaded, and a 16t > sprocket. I've adjusted the carb, and the plug has always looked > great (original plug at 18k miles), no changes. I did the t-mod, > drill & needle shim at around 12k miles, still no changes (not that > those things would really affect mileage). All mileages are counted > from full until I have to switch to reserve.

SNIP

> Jim

<><><><><><><> <><><><><><><> Jim, I'll suggest the slide drilling and needle shim will affect fuel usage. You don't mention valve checks or checking cam timing. I'm gonna bet you have a cam out of time one tooth. Yup, right from the factory, it can happen. That can affect engine performance. I would be really disappointed with my KLR if it got less than 47 mpg. Good luck with your project and rides. Best, Jeff Saline ABC # 4412 South Dakota Airmarshal Airheads Beemer Club www.airheads.org The Beautiful Black Hills of South Dakota 75 R90/6, 03 KLR650, 79 R100RT . . ____________________________________________________________ $39 Auto Insurance? Special Online Rates As Low As $39 a month From Top Firms. Free Quotes http://thirdpartyoffers.juno.com/TGL3141/4d61b7012b6f139eecdst06vuc

[ron criswell]

I think you need to slow down, relax, sniff the gas pumps at each refuel, enjoy the scenery. I usually stop every 100 to 150 miles because my butt hurts. I did 989 miles on my Concours once coming back from Florida but wouldn't want to do it a lot. I have rode my KLR from Chama New MX to DFW a number of times in one day not trying to be an Iron Butt guy but once you get out of the NexMX mountains, there isn't any good reason to stop until DFW. Criswell Sent from my iPad

On Feb 20, 2011, at 5:31 PM, "nhjim10" wrote: > Its not so much that I *need* the extra capacity, but I *want* it. For one thing, with this bike I've fought mileage issues ever since new. If I'm doing mild commuter riding and am very careful, I can barely squeak 220 miles out of a tank. On the highway, it drops to 160-170. That 220 miles was riding like Grandpa with speeds between 40-50. Highway mileage is whether minimal or loaded, and a 16t sprocket. I've adjusted the carb, and the plug has always looked great (original plug at 18k miles), no changes. I did the t-mod, drill & needle shim at around 12k miles, still no changes (not that those things would really affect mileage). All mileages are counted from full until I have to switch to reserve. > > I'm hoping the poor ring sealing and oil consumption had a little to do with it, and I may see a bit better with the 685 kit. But the extra capacity is so I don't have to stop for fuel every 160 miles on the highway. Ideally I would love to at least double that distance, using a combination of improved mileage (crossing fingers) and extra capacity. When I'm trying to rack up the miles on the highway every fuel stop consumes time. While a fuel stop should take 5 minutes, in reality when combined with human nature, it can easily turn into 10-15 minutes. Factor in slowing down for the exit, hitting a stoplight or two each direction, removing the helmet, fueling up, taking time to grab a snack or drink *while I'm there anyway*, hitting a couple stoplights on the way back onto the highway, and getting back up to speed. For a 1000 mile day at 160 miles a tank, I'm looking at a minimum of 6 fuel stops. At 10 minutes each I'm at an extra hour. If I can cut those stops in half I can save an easy 30 minutes throughout the day. > > That doesn't matter when I'm just doing a relaxing day ride around New England, but on the long trips it adds up. In fact, when I attempted my first Iron Butt saddlesore ride I missed doing it by minutes. I was at 987 miles at the 24 hour mark. Other factors affected it, such as having to work a full 8 hour shift before I left right from work, and having a chain grenade in Virginia, forcing a couple hours of downtime while I made repairs and located a chain. > > I think I've decided to limit added fuel capacity to what I can easily do, such as a rear tank and/or IMS tank. As soon as hours pick up at work and I get rid of a payment I'm currently stuck with (done in July) I'm most likely going to pick up either a V-Strom 1000 or ST1300 for the long rides. I like the minimal bike of the Vee, but I like the shaft drive of the ST (I'm an ex ST1100 owner). Then I can add fuel capacity to either of those and really stretch out my stops. > > Jim > > --- In DSN_KLR650@yahoogroups.com, "fasteddiecopeman" wrote: > > > > I can generally go around 500 kms (300 miles) to empty, and I 'modded' my fuel petcock so that I have about 160 kms (100 miles) once I go on reserve. The longest run I've done between gas station AVAILABILITY is the Dempster Highway, where gas is available at the start, mid-point, and end, so you need a range of about 360 to 375 kms. I believe I went onto reserve prior to the stations, but NOT for many kms! > > Do you REALLY need MORE gas...? > > Cheers, > > Ed > > > > [Non-text portions of this message have been removed]

[nhjim10]

Its not so much that I purposely plan for those rides, they just seem to happen. My longest trip was when I went to Kentucky for a weekend of camping, trails, and telling lies around the campfire. I didn't have much time I could take off, but I wanted to be there, so I left on a Wednesday after work and arrived Thursday evening. Thats the trip I had chain problems on. We hit the trails Fri and Saturday, then I left Sunday for the trip home. I took the scenic route on the ride home and did stay in a motel Sunday night. I was back at work Tuesday. My first somewhat long ride was on a boring Saturday. I woke up and decided I had nothing to do, so I jumped on the bike and did a loop around Lake Champlain and got home around 1am. That was a 440 mile day. Another Saturday started off similar, with a somewhat late start. I just chose a general direction and rode, and ended up deciding to visit my wife's cousin in Ft. Fairfield, ME. I had dinner there then came home. That was close to 700 miles that day. Lots of rides to the coast and downstate which average 300-400 miles for the day. I'm hoping if my bike comes out well that I'll be able to do the Trans Labrador Highway this season. If the bike goes back together and runs well I'll start planning for it. Jim --- In DSN_KLR650@yahoogroups.com, Ron Criswell wrote:

> > I think you need to slow down, relax, sniff the gas pumps at each refuel, enjoy the scenery. I usually stop every 100 to 150 miles because my butt hurts. I did 989 miles on my Concours once coming back from Florida but wouldn't want to do it a lot. I have rode my KLR from Chama New MX to DFW a number of times in one day not trying to be an Iron Butt guy but once you get out of the NexMX mountains, there isn't any good reason to stop until DFW. > > Criswell > > Sent from my iPad >

[revmaaatin]

--- In DSN_KLR650@yahoogroups.com, "nhjim10" wrote:

> > Its not so much that I *need* the extra capacity, but I *want* it.

Watching some chopppper shows ie OCC, when they want a larger tank, they build one; or super-mod one that is factory by cutting out a chunk and welding in a section to suit them. A used tank, with bulges added in the front and side walls would do every thing you describe; perhaps adding at least 2 and if real creative, up to 4 gallons. Think what adding two 1-gallon milk cartons to the leading edge of your tank and the area just below the filler add 1/2 gallon cartons there. Fab it up in paper and plastic milk jugs. It is not necessary to be pretty ah la Mad Max. Beyond my shop and present welding skill level but not beyond my imagination level; its a simple drill of cut and weld by someone with the ability and means to do so. BMW had a funky tank on the R69S (may have been a 'factory-after market') that held 9+ gallons using the concept I described. It left a place for your legs but in front of it, and above it were (cough)tastefully added bulges that gave the bike incredible range. revmaaatin.

[Jud]

--- In DSN_KLR650@yahoogroups.com, "revmaaatin" wrote:

> > > > --- In DSN_KLR650@yahoogroups.com, "nhjim10" wrote: > > > > Its not so much that I *need* the extra capacity, but I *want* it. > > Watching some chopppper shows ie OCC, when they want a larger tank, they build one; or super-mod one that is factory by cutting out a chunk and welding in a section to suit them. > > A used tank, with bulges added in the front and side walls would do every thing you describe; perhaps adding at least 2 and if real creative, up to 4 gallons. Think what adding two 1-gallon milk cartons to the leading edge of your tank and the area just below the filler add 1/2 gallon cartons there. Fab it up in paper and plastic milk jugs. It is not necessary to be pretty ah la Mad Max. Beyond my shop and present welding skill level but not beyond my imagination level; its a simple drill of cut and weld by someone with the ability and means to do so. > > BMW had a funky tank on the R69S (may have been a 'factory-after market') that held 9+ gallons using the concept I described. It left a place for your legs but in front of it, and above it were (cough)tastefully added bulges that gave the bike incredible range. > > > revmaaatin. >

Two of the more common /2 aftermarket tanks were by Heinrich and Hoske. I'm sure there were others. Sitting in a barn about 8 miles from me, I have about half of a handmade aluminum /2 tank. I traded a Sears 106 Gilera for it back in the days when my appetite and ambition for motorcycle projects knew no bounds. My /2 project suffered some setbacks, so the tank project got shoved way down on the priority list. There is always a fascination with more fuel capacity, but I think that unless you have to do an ironbutt event where time is of the essence, you can't really need more than an IMS tank can offer. Nominally 6.6 gallons, mine took 7.2 the first time I have filled it. It may have stretched since then, as on a couple of occasions, I have put in 7.1 without going on reserve. Of course my main petcock pipe may have come adrift, too. Anyway, at an average 45 mpg, my KLR will go over 300 miles between fills. Even allowing for the odd stretch of 75 into a headwind, I am pretty safe at 240 between fills. If I had one of those mythical KLRs that routinely turns in 55 mpg I could go 390 miles between gas stops. But would I?

[Horton Oliphant]

https://www.tinmantech.com/index.php The above website covers welding, brazing and soldering aluminum. They sell supplies and have some nice videos, on Youtube, of some of the processes. Here is a nice video of gas welding aluminum sheet. http://www.youtube.com/watch?v=aF1Srs_e1Aw

On 2/15/2011 7:08 PM, Greg wrote: > I read about a product like this in a British bike mag and turned up this product when I Googled. Looks way too easy. I've welded aluminum with both stick and mig before and I definitely had much more effort expended then this before I was done. The product is called Dura Fix, has anyone ever heard of it or tried it....See the link below.....Have a great evening .....Greg > > http://durafix.com/index.html#order > > >