1200 Hardtail build thread - Defensor II
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Joined: Jan 2011
Posts: 76
Likes: 1
Ok, we've been staying busy on Defensor 2. This is the time where we're making tons of little parts from scratch (the parts that nobody ever sees or notices).
Here's Justin doing the final touches to the wheels and tires. Tire lettering and wheel graphics:
The front end is all together and polished up:
Hard to see but had to make a custom bracket to anchor the caliper to the frame:
Custom cut axle spacers (note powdercoated sprocket). The chain is literally laser straight!
Our handmade tidy little battery box with foam insulation:
Powdercoated oil tank and seat bungs:
Handmade ignition key mount. Designed to locate in the center motor mount:
Another view:
Installed, almost looks OEM!
More to come as this build really starts to take shape. We still have to make a coil mount, headlight mount, taillight, lic. plate mount, paint, exhaust, wiring...etc. Make sure to check our FB page for more updates! http://www.facebook.com/pages/DP-Cus...17477074951026
Here's Justin doing the final touches to the wheels and tires. Tire lettering and wheel graphics:
The front end is all together and polished up:
Hard to see but had to make a custom bracket to anchor the caliper to the frame:
Custom cut axle spacers (note powdercoated sprocket). The chain is literally laser straight!
Our handmade tidy little battery box with foam insulation:
Powdercoated oil tank and seat bungs:
Handmade ignition key mount. Designed to locate in the center motor mount:
Another view:
Installed, almost looks OEM!
More to come as this build really starts to take shape. We still have to make a coil mount, headlight mount, taillight, lic. plate mount, paint, exhaust, wiring...etc. Make sure to check our FB page for more updates! http://www.facebook.com/pages/DP-Cus...17477074951026
Road Master
Joined: Jul 2011
Posts: 1,166
Likes: 7
From: NY
Some of us would notice the small details. Love all the little custom crafted parts. That thing is coming along nicely.
Question: What kind of paint are you using on the tires? Anything special or doesn't it matter?
Question: What kind of paint are you using on the tires? Anything special or doesn't it matter?
Road Warrior
Joined: Jul 2007
Posts: 1,898
Likes: 67
From: Saint Amant, Acadiana
More to come as this build really starts to take shape. We still have to make a coil mount, headlight mount, taillight, lic. plate mount, paint, exhaust, wiring...etc. Make sure to check our FB page for more updates! http://www.facebook.com/pages/DP-Cus...17477074951026
Advanced
Joined: Jun 2011
Posts: 67
Likes: 0
From: wisconsin
In case you are interested in looking, I do not have a facebook account and I can view their page. You just click close when the sign in screen pops up. At least that is what works for me.
Road Warrior
Joined: Jul 2007
Posts: 1,898
Likes: 67
From: Saint Amant, Acadiana
Won't get me too far, sooner or later a popup appears requesting login.
Edit: But that's OK, if it is not for me then I won't see it.
Edit: But that's OK, if it is not for me then I won't see it.
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Joined: Jan 2011
Posts: 76
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Thanks for the kind words guys. Today we closed early for Halloween but still managed to get a few things done!
Here's a custom coil mount in the works after some cutting, drilling & bending. It's a specific size to clear our tank just right.
After welding it up and painting it.... a perfect fit!
Our favorite part we made today! A chain tensioner made out of cold rolled steel and a sweet little skateboard wheel. We installed top of the line bearings, so it should do real well.
Still working on the headlight mount, which we're heating & bending here. It'll go on tomorrow. It has to be exact or the fairing wont sit right. This is one of those pain in the *** parts nobody will ever notice but it's a critical one.
Here's a custom coil mount in the works after some cutting, drilling & bending. It's a specific size to clear our tank just right.
After welding it up and painting it.... a perfect fit!
Our favorite part we made today! A chain tensioner made out of cold rolled steel and a sweet little skateboard wheel. We installed top of the line bearings, so it should do real well.
Still working on the headlight mount, which we're heating & bending here. It'll go on tomorrow. It has to be exact or the fairing wont sit right. This is one of those pain in the *** parts nobody will ever notice but it's a critical one.
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Joined: Jan 2011
Posts: 76
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Since we're talkin' about the little stuff that matters, here's another piece that has to be absolutely perfect for the speedo location. Made out of cold rolled, it's strong and stealthy!
Just got done welding, drilling and grinding it (mini electronic speedo in the background):
How she sits on the trees:
With the gauge:
And now with the fairing ... perfect fit and tucked in just right!
Just got done welding, drilling and grinding it (mini electronic speedo in the background):
How she sits on the trees:
With the gauge:
And now with the fairing ... perfect fit and tucked in just right!