... ... ... ...

Nov

22

I wanna make BMX bikes for pit bikes.

By Rafter

How tight would it be to be all BMX’d out at Polini races. We could make jumps and stuff and there would be more danger for the drunks to get into.

Dont lecture me about whats cool in BMX stuff I have no clue or care. This bike was 20 bux and wrecked. Got it from a toothless dude who does our sandblasting.

Dont lecture me about whats cool in BMX stuff I have no clue or care. This bike was 20 bux and wrecked. Got it from a toothless dude who does our sandblasting.

Someone remind me to order stickers

Someone remind me to order stickers

Nov

22

Jimmy Visits from a land of Treats Bearing Treats

By Rafter

black

Tony's Derbi Revolution

Jimmy came to the shop today and worked 12 hours on race bikes for next April’s Polini Cup. Serious dude. Tony and Jimmy worked all day on almost matching Derbis for themselves in an effort to keep up with/or pass Jeff Johnson of Choke Motorcycle shop next race season. Heres some pictures for you to lurk on for a spell.

black2

Getting mocked up

jimmy1

Happy happy Jimbo

jimmy-wprking-it

Grind

pipe2

Prep for weld

red-derbi

Tommys original 25lb hobbit seat

start

Tony's Start DS50 Derbi moped. Working pedals on a scooter body rad.

fin

Jimmy with the elusive Nathan Kiehn. Over looking newly added cross bars inspired by our favorite Jeff Johnson

mill-case

If you dont like the crank your supposed to use get your ass to work so you can use what you want.

mill1

Mill skill

fork

Those forks dont fit Derbi........... Uh,,,,,,, they do now!

Nov

20

Motomatic bout to solve all your intake issues.

By Rafter

intake

Except maybe you poor Tomos bastards. We’ll get to you later.

Nov

18

Tony Simoni’s Grande Hobbit Derbi Mix Race project

By Rafter

Words by Tony Simoni

The idea

Nate came to me in late December of 2008 and let me know of this awesome race moped idea he wants me to build. He had been waiting months for the parts for various parts to come in so he could determine what our best options. Here was Nate’s “Grande” idea:
Use a sturdy frame, light-weight motor, a variator/clutch parts that can handle power, and make a sturdy sub frame. Keep in mind I am a large guy with more weight than the average rider so large size and sturdiness was a key factor.

Major Components

Vespa Grande: Frame & integrated Gas Tank
Honda Hobbit: Cases & Rear Wheel
Derbi Variant (Flat Reed): Crank, Clutch, Variator (TJT), Metrakit cylinder kit
Motomatic Exhaust: Destroyer
Motomatic Sub frame: Built by Nate out of thin walled 4130 steel tubing made to match a typical moped wheelbase of 44”.
Rear Shocks: Honda XR 75
Front Forks: Pit bike forks (last race used EBR race forks)
Front Wheel: 17” rim with a Motobecane hub with a pit bike disc affixed.
Rear Wheel: 16” rim with Honda Hobbit hub and GSXR 750 disc brake affixed.
Motomatic Powder Coating: Thank you Mike Rafter
Carburetor: OKO 21mm (changed to a 24mm)
Ignition: HP1 Puch ignition

The assembly:
In addition to the assembly of these key parts much effort was put into how to get these parts to work together.
• The sub frame had to be offset to ensure the drive belt was aligned
• A special reed cage manifold was made to squeeze the largest reed cage (Gilardoni) within the stock mounting stud pattern and yet still have the reed pedal close as possible to the crank case and also direct flow directly into the transfer ports.
• The rear Honda Hobbit torque driver was modified so it can match the variation (movement) of the Derbi Variant Variator.
• The HPI ignition needed the taper re-machined for a good fit, the hobbit cases needed to be machined to fit the seals and Puch stator plate, and a stator plate base needed to be machined. 10 hours spent here.
• A custom seat had to be supported and fabricated. (Thanks to Nate)
• The 70cc Metrakit kit needed slight modification of the stud holes and small amount of epoxy was used on the cases to match the stock Metrakit base gasket shape. Also, a 1mm base gasket was used to keep 1mm clearance between the piston and head.

Tuning the Machine

Race #1 & 2 – Initial Motor Development:
Out of the box with no porting just minor case matching the 1st time we rode the machine it did 64 MPH with very little jetting. It later dyno’d at 10.5 HP at 9,500 RPM.

Race #3 – cooling issues:
The porting inside the kit became extensive and the head was re-profiled to raise the compression. The engine ran head temperatures exceeding up to 475 F, so an air duct was fabricated to direct air across the head. A wheelie was achieved and the moped became very fun to ride. 58 MPH was achieved at the end of the Atwater straight-away. The moped dyno’d close to 13 HP at 11,500 RPM, but the clutch was having issues engaging which yielded inconsistent dyno readings.

Race #4 – starter clutch removed:
the starter clutch was removed to avoid rough inconsistent take-offs. The moped became a real competitor. However, after the 2nd lap head temperatures began to rise above 400 F and the end of the Atwater straight-away speeds dropped to 52 MPH.

Race #5 – the power is all there:
The cylinder was raised 1mm, an experimental pipe was used, and the resulting engine speed was ramped up to 13,500 RPM. A water-cooled head was fabricated to cure the cooling issues. 60 MPH was achieved at the end of the Atwater straight-away. The moped dyno’d at a consistent and strong 12 HP.

Road speed test with stock rear gears 69 MPH
Road speed test with Malossi rear gears 73.8 MPH

Red line is before race three, Blue line is last race configuation. Smoother power overall.

Red line is super peaky power configuration as run during Polini Cup race Three. Blue line is smoother power overall as configured for the last race of the season.

OG moped hubs modified to accept disk breaks

OG moped hubs modified to accept disk breaks

03

Some color for good looks

02

Powdercoated spokes

GSXR Disk Super close tolerances

GSXR Disk Super close tolerances

Mock up

Mock up

Mocked up and stood up

Mocked up and stood up

First pipe getting fitted

First pipe getting fitted

Sub frame

Sub frame

Sub frame

Sub frame

Yellowed up

Yellowed up

Yellowed up

Yellowed up

Everyones favorite cases

Everyones favorite cases

Can't buy this reedblock at your local corner store.

Can't buy this reedblock at your local corner store.

Gila reeds fitted in

Gila reeds fitted in

Ready to bolt on

Ready to bolt on

Snug fit

Snug fit

Two large pedals flow better than 4

Two large pedals flow better than 4

Look just below the reedblock. Tony reduced crankcase volume by adding a block of Alu and improved flow.

Look just below the reedblock. Tony reduced crankcase volume by adding a block of Alu and improved flow.

Add a wing to the reed block to keep things flowing

Add a wing to the reed block to keep things flowing

HPI

HPI

Late nights

Late nights

Big gun

Big gun

Built in some adjustment

Built in some adjustment

Does it even fit in the oven?

Does it even fit in the oven?

First time loaded up to hit the farm roads for testing

First time loaded up to hit the farm roads for testing

Stock vs modded rear variators

Stock vs modded rear variators

This steel can take a lot of time to hack at. Shit is tough.

This steel can take a lot of time to hack at. Shit is tough.

Springs are also a pain

Springs are also a pain

More working out variation

More working out variation

Pretty

Pretty

Clutch bell and TJT lathed down for less rotating mass

Clutch bell and TJT lathed down for less rotating mass

Powdercoat it for good measure

Powdercoat it for good measure

Water pump parts made from scratch

Water pump parts made from scratch

Good dyno results make Tony's thumb go up.

Good dyno results make Tony's thumb go up.

Belt riding high for happiness

Belt riding high for happiness

Aircooled pipe testing

Aircooled pipe testing

Pinning the throttle and maxing RPMs

Pinning the throttle and maxing RPMs

17 inch rim swapped for 16 inch rim for a better tire. Pirelli 2.75

17 inch rim swapped for 16 inch rim for a better tire. Pirelli 2.75

Spring mounted pipes make for quick changes while Dyno testing

Spring mounted pipes make for quick changes while Dyno testing

DR. Pully sliders. TJT wieghts self destuct quickly and get all flatspotted.

DR. Pully sliders. TJT wieghts self destuct quickly and get all flatspotted.

TJT plus DR. Pulley

TJT plus DR. Pulley

So many pipes so many powerbands

So many pipes so many powerbands

Red Rocket pipe is funny fun and fast

Red Rocket pipe is funny fun and fast

Hella bells and whistles. Custom water cooled head Tony made from a block of Alu

Hella bells and whistles. Custom water cooled head Tony made from a block of Alu

13415 RPM !!!! I'd say thats on the high side.

13415 RPM !!!! I'd say thats on the high side 11.1 horse power 68.3 mph on the dyno.

Tony gassing up the bike for road speed test with Terry Dean Cain as driver.

Tony gassing up the bike for road speed test with Terry Dean Cain as driver.

No overheating and great speed results

No overheating and great speed results

Duck Down

Duck Down