Tommy's Sonauto replica

[Tommy10bikes]

I cant remember if i have posted about this before , but my next project is going to be a tester.
The intention is to do a Sonauto XT500 Paris Dakar replica , I have a stirpped down XT500 with YZ wheels
and YZ 465G forks, the rack is made am i have found a contact to make a special tank in 2mm ali.
Before i send him the frame i have had to make the bar riser which i think should be 30 to 35mm
higher.



The next problem that has cropped up was the length of the damper clamp bolt thats 35mm short now,
i think i have read somewhere on this forum that there are some yamaha models that have longer bolt.
Any of you guys know of any models that will have a longer shaft bolt. Only other option would be to
drill the head of the bolt out and make a longer bolt and insert it back into the inside of the clamp.





This one i wrecked just to see how it was attached.



TTB

[marcm]

Think if you want to keep it period looking you may have to drill head off and use a longer bolt,there are modern bar clamps that bolts come out of,I've possibly got some gas gas ones kicking around which are for a standard diameter bar,not oversized.i think if they were painted or powdercoated black they wouldn't look out of place as they are rounded shape not big chunky square things like the rental ones?

[Mezo]

Ive been so looking forward to this project, popcorn bucket filled & you have my full attention.



Mezo.

[55W1985]

Ohhhhhh this is going to be a hot one!
Remember there are nice videos from that time on youtube as reference!
Keep posting

[Tommy10bikes]

Thanks for the support and interest, ,I think its my olny option to dill the head out, maybe i may be able to drill small holes in the ali and force the head bolt thats left keeping the hex profile in the clamp.
Mezo , i am also been looking forward to this one, hardest bit is getting the tank done. the rest will be a breeze.

Well maybe.

TTB

[Eric66]

Looks like you will have to find a drunk ,blind upholster to make a replica seat cover that crap looking Or maybe there is someone in England that already makes ill fitting covers
Regards Eric

[Fred333]

Hi Tommy,
I think that was me:


I wantedd the risers from the XTZ 660 on my TT.
The boltlenght is the same but the diameter is diffrent.
XTZ 8 mm
TT 10 mm
I ended up putting the XTZ-risers on my Tenere.(which is nice)
Olli

[marcm]

Can we have a vot on if it's gonna be blue or white?
.

[Tommy10bikes]

Olli thanks for the info , thats the post that i had seen before .
However somehow i have sorted the problem without too much of an issue, simple enough to do as well with the use
of a lathe. All i did was to drill out from the inside of the clamp ( handlebar side ) a large enough hole and tapped the
main bolt through, this left a segmented hole with flats formed inside.



Next job was to get some cap head screw long enough to pass through and enough left to cut the correct thread, the head of the cap
screw had to be turned down and 2 flats ground enough to insert into the bar clamp.
Last job is to cut to length and cut a final small thread at the base of the bolt,this bit i have to do but overall the hardest part ended up
being a very simple solution.







.

Ah well the seat, i have to admit it looks like its been done by a blind man, mine will have a brown suede top base with a leather
dark near black brown side section rather than the shit PVC sides.

TTB

[Tommy10bikes]

Srted and very pleased with these and they havnt cost me a dime , only my own time.





TTB :D