Milk's 03 Bullet dual sport build

[noisymilk]

Hello folks,

I figured rather than clog up the Iron Barrel forum with this post, I would do it down here. I hope to make this a continuing thread about my building of my Enfield into a functional dual sport machine.

I had spent some time earlier (thanks to those who chimed in....I always like smarter peoples opinions) considering making my enfield a hack. I even did some serious pricing on the matter. But, truth be told, I think I would be better in the long run going this route. I intend to do the bottom end in the future (obviously), but not the full fireball. I don't want to go high compression, as there will be places in the world where I can't get reasonable fuel, and I would like it to still run.

Proposed upgrades (I will try to maintain this list and update as finished):

-alloy barrel and piston - Done! Ace lightened 535 piston and alloy barrel are purchased.... and installed now!

-carbeurator - not done!! Sourced a PWK30 from a forum brother. But am not equal to the task of dialing it in. Strongly considering CVK30 or 32. Sticking with perfectly functioning stock Mikcarb for now.

-airbox mod - done (Ace aircan installed)

-head improvement - done (stage 1 head with kibblewhites) (and also send for some fancy coatings and a valve reseat after I tried to fry it AGAIN in the AZ heat)

-bash plate

-screw on oil filter - Done!  plumbing is done (currently an oil cooler which will go away), just need to buy product. purchased and installed and functioning very well.

-improve luggage situation - ok....current thought (subject to change at any moment) is Wolfman Summit saddle bags, and purchase the Inder trailer for 2 up travel.

-improved rear shocks - Hagon 2810's (about 3/4 of the way down the page). Slimline progressive springs. 320-340mm in length....a good inch longer than stock so I can hopefully have some more rear wheel travel:
http://www.hagonshocksusa.com/HagShocks.htm

-sealed bearing kit for trans - done...running on gear oil only now

-breather mod kit - done installed easy peasy, and seems to be doing what it should. Awesome.

-currently planning on maintaining 19" rims. Several good tires are in the running as my dual sports. Kenda K761's, TKC 80's, Mefo Explorers. We'll see as purchase time approaches.

-full re-wire of the bike. Because I like my wiring better than anyone elses. Will be adding the improved rotor/stator, some flood lights, going all LED and possibly adding some running lights. Also adding wiring for GPS/phone charging/future heated gear.

-Speedo - damn....Nfield Gear can't get the Radon anymore. Am looking at other vendors for it, or perhaps an Acewell 2853 or similar. Have located a person on fleabay who has several Radon speedo's for sale....likely go this route.

-get current header coated. Go see the people at Jet Hot:  http://www.jet-hot.com/

-new muffler - done a forum brother has hooked me up with an exact replacement for my shorty sausage muffler.

-progressive springs for the front, if I can source them.

-trials bars - done (Protaper SE CR High's. Probably wind up with risers of some variety.) photos on page 2.

-new turn indicators all the way around. These up front:
http://stores.intuitwebsites.com/hstrial-QualiRegResou/-strse-24/LED-Turn-signal-fdsh--LED/Detail.bok

These in back, with blinkers for brake lights:
http://www.superbrightleds.com/cgi-bin/store/index.cgi?action=DispPage&category=TRUCK&Page2Disp=%2Fspecs%2Ftlsr14a9_specs.htm

-add tool tube - this one: http://www.agrisupply.com/operator-manual-canister/p/67670/

-larger tank - thinking 25 or 30 liter

-a horn - done! I went with a Screaming Banshee horn. It really works quite well.


The end result of all of this is to have a machine that will go to Anchorage in the next few years, and eventually to Tierra del Fuego. And that will pull me and my wife and a trailer for stateside trips. I realize this is a bit of a long shot for an enfield, but I think I can get it done. I'm not a freeway flyer, and this bike has been doing this type of stuff for years overseas. We'll see. Wish me luck....

Be safe, all.

[noisymilk]

So, I have spent several days with my recently re attached panniers. Shite! I forgot how much they rattle.

So, soon it will be off with the panniers for work! I am thinking they are going to become 20 MM ammo cans. Looks like I can easily cut down the current racks, do a little of this and that....get a pannier puck system from Happy Trails, and mount the ammo cans complete with quick release function. Looks like I can come up with at least 3 good mounting points, and create a better support system across the back with pieces that I cut off. That single bar in the original system isn't going to be enough.

A little more truck bed liner, and should be good to go. Also...not stupid expensive.

Be safe, all.

[boggy]

I am thinking they are going to become 20 MM ammo cans.

Like that idea.

[noisymilk]

Thanks boggy,

some photos for inspiration:

I am taking my inspiration for the mounting assembly from here - http://krian.jimdo.com/motorcycles/royal-enfield/panniers/. Although I am also thinking of cutting the rear fender almost all the way to the back of the seat, relocating an LED brake light up there and on the back of the saddle cans, and building a subframe of sorts, so the rear tire could just be pulled and rolled straight out the back without unmounting anything in the case of a flat.

More photo's I've found:




Weight is a real consideration. Figure the 2 cans plus mounting are gonna be 45 lbs.

However, since I've been on my new lifestyle (no soda since Nov 1, half portions all day, and making my own fruit/veggie juices), I'm down 20 pounds. So I figure maybe I'll be alright....plus upgraded shocks I mentioned above.

Be safe all.

[jartist]

Those ammo cans are way heavy and huge on a little royal enfield. I'm sure you could make it work but I'd be tempted to spend some dough on aluminum cans from happy-trail. Pelican cases have been used too but I had a hard time finding the right size for the enfield when I was planning my bike. Good luck on the project, I'm looking forward to seeing your results!

[The Garbone]

Maybe if you could cut the fender and put a hinge on it like old school Harleys and such.  Might have to change out the tail lamps and plate assemble for clearance but it could work.

[noisymilk]

Br Jartist: yeah I hear you on the weight. And its all out past the rear shocks and practically behind the rear tire. That's a consideration. I'm hoping improved shocks and the subframe work i'm trying to do will help there. As far as just buying off the shelf aluminum panniers....well happy trails and touratech REALLY like their products. That's the kind of money i'm going to be spending on the crank anyways....would rather save it for engine work. And yeah, looked at plastic cans of many varieties. There's even a top loading pelican....1440 I think....that's still in the running. Its expensive though as well. We'll see. Gonna build the rack first, then figure what to hang on it.

Br Garbone: thanks for the encouragement. Never saw the hinged rear fender before, but that's a solid idea. I'll have to look into it. And yeah, turn signals and taillight and license plate are all already planned to be relocated and replaced with all LED options. Along with new wiring, all DC system and somesort of headlamp improvement. Perhap just and HID in current casquette. Perhaps a trials casquette and some sort of sexy head lamp from the aftermarket adventure sites. Trailtech or baja designs or something. Budget withstanding of course.

Thanks guys. Working on pannier frame now. Will post pics of progress when there is something to show.

[cyrusb]

You can get those 20mm ammo cans in FRP. Very sturdy and light. A pal of mine has them on his "Adventure" bike.

[barenekd]

Maybe if you could cut the fender and put a hinge on it like old school Harleys and such.

That bike has a hinged fender, doesn't it?
Bare

[The Garbone]

Bare ,  I think the way the panniers are attached and the dual seat prevent the stock setup from lifting.  On my bikes it flips up.   
 



I was thinking of something like this..

http://www.jpcycles.com/product/7110090

[baird4444]

Milk-  I've got an offer for you if you think you'd go this direction. I've got a set
of bags, not throw overs, that could be used in racks. They look more like
cases to me....  looks like but NOT leather; have a core-plast lining inside
to keep ridgid; handles for carrying.
   14.5"W X 5.75" D X 12" H   
  Yours for the price of shipping from zip 61920.
      I got'em on fleabay for the brackets to install another set  - Mike

        If Milk refuses- 1st PM to me will get....

[noisymilk]

Br Baird444 - That's a very generous offer. I myself will be passing, as I want a hard lockable pannier for adventure touring. However, maybe one of the other forum folks will take you up on it.

Br Barenekd and Garbone - You are correct, the stock bench seat prevents the hinging up function that is available (apparently) with solo saddles. And I don't want to have to get crazy unbolting stuff to change a flat on the side of the road in the middle of nowhere. Pulling the castle nut, pulling the axle, popping the tire off and rolling it out the back is the objective. If I can cut the fender up enough to make this easy (or at the very least possible while up on a 2x4 on the center stand) that works for me.

So, been researching pannier options again, based on previous conversations about weight of ammo cans. However, the only pelican case I was interested in (http://pelican.com/cases_detail.php?Case=1440) turns out to weigh 14.5 lbs empty. And at $125 a case, and not much weight savings over ammo cans, I think I am still leaning that way.

Hey...if you need a tool tube on your bike, you can't hardly beat these: http://www.agrisupply.com/operator-manual-canister/p/67670/.  I will likely have one or two of these in the end. Tools and camping fuel I believe. Gonna add this to my original list up top.

Also, picked up a new set of handlebars. These : http://www.protaper.com/products/handlebars/se in the "CR HIgh" shape. $30 on the local craigslist. Not bad. Came with a tank bag as well : http://www.joerocket.com/catalog/index.cfm/251/381/Luggage/Manta_Tank_Bag. Looks good for carrying some bottled water and some chargers and stuff. Not a big ass one for carrying a map, but a good starter to figure out what I need. Plus, the intention is to use GPS as map (although I do like lo-tech frequently in the "I'm effing lost!" category).

They don't rise much in comparison to the stock bars I have, but are stronger build with reinforcement bar. Think I will purchase a set of these as bar risers : http://www.roxspeedfx.com/cgi-bin/cart/showitems.cgi?subcat_id=268. They will fit right onto our bike, and have a significant adjustability. I am thinking 2" rise is the way to go. Going to install the Protapers first a ride a bit to see what I think I need.

I'd be interested in people thoughts about 19" dual sports vs. doing the 18"/21" change. I'm not going to be doing single track or anything. But given the places I want to go, do I need to do the change?

[jartist]

There's very few choices for dual sport tires on the 19" rims.  The only reason I'd change wheel sizes would be for the wider range of choices available with 18"/21" wheels.  K70 tires on 19" rims are quite capable if you're staying out of thick mud.  There used to be vintage style trials type tires available for the 19" rims but everyone who carries them are out of stock so I'm wondering if they're a thing of the past.

[Eamon]

There used to be vintage style trials type tires available for the 19" rims but everyone who carries them are out of stock so I'm wondering if they're a thing of the past.

Shinko makes a DOT Trials auniversal type tire - the SR241.  They make a 3.50x19 version that ought to work.  I've thought about them for forest roads etc.
http://www.tiresunlimited.com/ALL%20TIRES/Shinko/shinko_sr241_trials.htm



I think plenty of places carry them and I imagine most any shop can get them.

Eamon

[jartist]

Those are the ones.  Everyone was out of the 3.50X19 size when I was shopping before but they seem to be in stock around the net now.