The Second build.

"Super Cub Trials "Mini-Otter".

(Frame nearly Done.)

 

 

"Two Classics and a Dog".

 

Story of frame build further down the page.

 

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As this second Super-Cub Trials  build, has be on hold for a time while I decided what to do with the project. Now Back On and being built.

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Ed March C90 Adventures.

I Remembered this video I had watched while looking for a engine supplier, and there was a link to it, and I liked it

well here it is.

 

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I must say that looking at all of Ed's video diaries I know I was right and the Super-Cub trials project is worth salvaging.

This next Video is to try and get you to help out Ed complete his video diaries for the rest of this trip.

 

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More later, I have mailed Ed ,but he is probably in the middle of the second leg of his adventure but I am sure he will reply when he gets the mail? fingers crossed.

 

Episode Seven Newfoundland.

 

 

And Episode Eight.

And Ed needs a New computor if you have one you dont want?

 

 

More Episodes as Ed Makes them.

 

Episode 9,

C 90 adventures. the trail across  America.

 

 

More C90 Adventures when Ed makes them.

 

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10 go mad in Vietnam.

 

 

The two Lads from Banbury Oxon UK, are about to start a around the globe adventure on nothing more than an Honda scooter with an adventure sidecar fitted.

 Good luck lads we hope your dream comes true. but it wont be easy.

 

We will now document your preparation and journey here on this page.

 

Here is the Honda Scooter the lads Reece and Giles are hoping to use.

 

 

 

More on this story later.

 

 

Lee's Adventures. On a Transalp.

 

Transalp. Photo.

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Here is the Honda Transalp as purchased from a guy in Wigginton Buckinghamshire for £1500

on the 12 may 2006.

We built two Alloy flight-case type panniers and fitted a  new front disc and pads, and taller screen  the bike was serviced at the Leamington Honda agents, and that was it, before setting of on the "Around the edge of Britain"trip.

Lee's Adventures on this bike will be further down the page.

 

Eldest son Lee did two solo trips on a Honda Transalp a few years back the first was named "Edge Of Britain" started a couple of days after getting his bike licence. both for charity.

 

And the second "Edge of Iceland" a couple of years later when the Transalp had just been sat in the corner of a dusty workshop for the two years and only dusted of and serviced before setting off on the trip.

I will get these tales from Lee and the magnificent photos he took in Iceland.

 

The Story is further done the page.

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Back To the Super-Cubs.

 

20/03/2017.

 

Here is ex Purple Helmet Colin Farghers C90 trials.

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Colin now lives in France and not the Isle-Of-Man.

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Colin as just ordered a YX140 engine for the bike,

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 And I am going to give him the information of what we did to our first bike to get it to run how a trials bike should.

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 There will be a Page on Colin's bike later. and he may even build another frame?

$$$$$$$

Photo Later Glitch

Photo Courtesy Colin Fargher.

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YX 140 engine now fitted and tryed today 26/03/2017.

 

Story Later.

 

 

Jon Bliss built Cotswold C90 super-cub.

 

Jon Bliss built Original Super-cub C90 trials. Easy-rider.

 

Photo Courtesy Offroad Archive and Jack Knoops.

 

Here Young Ben Wilmore riding his Jon Bliss built Cotswold C90 Super-Cub trials.

 

 

Ben's Bike. Jon Bliss Built, Cotswold C90 Super-Cub.

 

Here is the original C90 trials built in the USA but later to get written off in a car and trailer accident. What a terrible shame priceless.

 

Here Is the second version not quite as pretty.

 

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Martyn Wilmore, Bens Dad riding his version of the Jon Bliss Cotswold Super-cub.

 

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This Jon Bliss built C90 Cotswold "SuperCub" Trials bike is for sale.

 

If you are intrested in buying this bike you can contact me and I will pass you onto Jon.

 

The Price of the machine. is £2,350. NOW SOLD< Sorry.

*******

 

Story about this Later.

Skyteam ST50 TR,? 70 cc,

 

 

More later.

 This second build of the SCT is for the people that have asked me for details of the first build?

Well these people are very interested in the concept of the little bikes and would like to build one them selves.

So I will help them with details of the first little bike so that they can achieve there goal.

 

This is Number "Two" on the jig.Swinging arm and brake plates are on the swinging arm spindle.

 

SO

 

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The Start Of My Second Super-Cub Trials Mini-Otter.

In Sequenced photos. 

 

Frame first.

 

 

OK not a very good picture but we have a start.

 

All of the parts to the frame and the patterns you will need.

I may get these parts laser cut so that they will be in stock if you are interested?

 

 

If you  make these parts yourself you will need about two full days work and the use of a steel band saw, linisher, and lathe.

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15/08/2017.

These are now the photos of the second build,

in sequence so you can get an idea, of the time and  work put into this frame.

 

Seat post construction.

 

The holes were drilled using the Blue jig, so that they were centred,

 

Here is the measerments for the holes and the lenght to the top tube.

 

 

The through tubes were turned down from their original 14mm to 12  mm except for the 18mm that protrudes from the left-hand side, these were then dropped into the 12mm holes ready for Bronze welding.

 

 

The flat section I gas welded into the tube before bronze welding the through tubes. 

The upper tube is 54 mm long just enough to get a build of sif-bronze around it for a good joint........

 

 

More Tomorrow..

 

 

So I cleaned up and faced the steering head tube on the lathe.

 

 

Then the bearing cups.

 

 

Then I bronze welded the cups to the tube, using a new jig I had made, and then cleaned the head tube up before setting it in the jig for Bronze welding to the frame tubes.

 

 

Now tack bronze welded to the main frame.

 

 

And also the seat tube and subframe plate.

 

 

More of a update tomorrow.

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This is the next stage on from the top picture, but before any of the gussets, ETC, have been attached.

 

 

Upgraded to 7/8" tubing for the subframe, or seat tubes. this is the same as the "Hubbo" MM frame, and  seems a better choice for the same weight.

 

 

I have brought the engine carrying tube forward on this frame by eight mm.

just for better swinging arm clearance.

 

 

 

The same 7/8" tubing is used for the seat tubes.

 

 

Using this size tubing brings it in-line with the Mike Mills "Legend" frames.

 

 

 

The same size tubing is used for the rear bottom seat tube mounting, this will give more support,for the footrest, and give more room for attaching the brake pedal plates.

 

 

So I turned the jig around and then duplicated what I had done on the other side.

 

 

I then centred the seat tube ready for welding in the bottom brace tube.

 

 

Both seat tubes now fitted ready for suspension mounts.

 

 

So ready for mudguard loop and bottom brace today.

 

4 1/4",?

 

 

 

Yes 4 1/4" was right for the length from the seat tube to the end of the tube to the beginning of the mudguard loop.

 

 

 

The mudguard loop ended with me having to make New tooling to bend the loop, but it came out better than the "Hubbo" original in the end.

 

 

The tubes now fit the jig better than the "Hubbo" frame that was used to make the jig.

 

 

The bottom seat post securing cross tube took an hour to set up to how I wanted it,

Then I realised that after measuring the "Hubbo" frame  again that the measurements were right in the first place.

 

 

So the frame looks good so far, with a better fixing for the footrests and the seat loop right, it just remains to redesign the twin front down tubes to miss the engine cylinder head, but we will start that operation tomorrow, and I may not get it right at the first attempt now I have sacked "CAD" for a good eye.

 

 

 

Sunday saw me bending the offside frame loop, and I thought it looked right, but was hesitant to tack weld it in place?

I took the photos and left for home.

When I looked at the photos I was glad I did not weld the tube in, It may look OK to you, but my thinking was, do I really need under-run tubes?

 

 

The tube looks good I must say, but will it restrict the steering lock? and it needs to be 9" wide to miss the cylinder-head.

 

 

So Monday 21st August saw me make it into a proper "Mini Otter"

configuration by fitting a short front down tube of 1 1/4" T45 tubing and making up a through tube to bolt a engine mounting to, I intend to construct a structural tube and Alloy sump plate to take the bottom mountings and end with a front mounting to connect to the front down tube fixing.

Why not just connect to the four cylinder head bolts I hear you say? well I could and have thought about it, but this part of the engine is not really structural is it! and the rigid mounting may cause problems.

So What? is the other thinking, the bits for the motor are cheap why not try it and see what happens? Well I may do. time will tell. 

 

 

This is the spare engine for me to play with, the other NEW YX 140 motor is going into this bike.

 

 

So with the engine now mounted into the frame with the top mount that I made up. the front down tube did not look right.

So I made up a new jig tube for mounting the front tube on, to get it right.

 And then I tacked it and bronze welded the lot of the nearside with the jig pulled over to horizontal.

While it was like this I made up two spacer collars on the lathe for the seat tube mudguard loop and bronze welded that too.... A better day after one forward Two back for the last week.

 

24/08/2017.

 

So Thursday, I decided to go the  ,"lets do the cylinder head attachment route"

 

I looked beyond the "Trees" and removed the cylinder head studs and the rocker cover, and this is what it is.

I then fabricated a new 2mm steel cover and then a tread plate alloy spacer to go underneath this. Tread Plate? well there is an air gap underneath the steel plate to dissipate some of the heat.

 so then new steel 2mm flange attachments were made and tig welded to the steel plate.

And you can see, it turned out to be a good job.

I then started the under engine attachment that will be part of the sump shield assembly.

 so not a bad day.

 

Photo.

 

I may try this little motor in the bike before fitting one of the New engines I have.

 

 

 

Yesterday I finally got round to bronze welding some of the joints. 

A good tip is to not think,"Well I can weld this joint". Don't until you have tacked to lot together and made sure you have everything right. 

I finished welding the seat tube around the top before welding in the engine mounting plates,An as you can see left the frame in the jig, and manoeuvred that about.

 

 

The headstock joints were also welded making sure it was a complete job, as don't forget the fuel is carried in this top tube.

The hole for the filler will be drilled before finishing the back joint, so that the air in the tube can escape, otherwise it will blow back and spoil the weld.

 

 

Days work complete and bench tided for tomorrow.

 

I have kept as you can see, most of the tubes used straight, the seat tube although they look complicated, are only one slight bend with a plumbers bender, and the two subframe tubes hardly need bending at all just a touch with the bender,

 the seat loop made of the 11/16" tube was just pulled around a 5" former bolted to the face table, and then the two bends again done with the plumbers bender.

 

PS, the main tubes are in T45 tubing, but the seat tubes are just ERW so that they can be bent more easily.

I am told Colin Seeley used all ERW tubing on his frames 

 

 

 

I played with the sump shield as well, but It just did not look right so I am now going to use a alloy plate right through, this will need a couple of alloy welded joints though. but these could also be bolted.

 

 

OK here we are at the end of play on Sunday 27/08.

 

I have finished welding all joints, and fitted the flinch plates. I have also plumped for bolt on footrests. so have welded on plates to except these. 

I have finished the bash plate photos later. and we will see where we get too today.

I have also come to a disigion not to put fuel in the frame to keep the thing more simple.

I have been looking   t one of my GF tanks and decided just to fit one of these. and the lay up will just be in polyester resin? well I am using ASPEN fuel in this little bike, so there should be no problems.

 

 

So today after a bitter disappointed at the MGP, I went to work and fitted the "Lifan" engine back into the frame to find where the exhaust mounting should be.

I made New stainless steel bottom engine mounting brackets, and then had trouble lining up the New head steady mounting. but this problem was solved with two new holes being drilled, and a bit of adjustment work.

 

 

I finished welding the top engine mounting  and fitted the engine sump plate and frame after again having to sort the bolt holes.

I just don't like forcing bolts into holes, I expect them to be easy to fit.

I am beginning to like this little bike just like the last one, and also have taken a liking for the engine, and now need to know what it performs like.

 

 

We will see how we get on tomorrow.

 

 

Well we have got on well today, and I have finished the tank and seat mountings.

I have also fitted a bracket to take the ignition coil, just in front of the tank, so that it is in the dry zone but is still kept cool.

The 125 Lifan motor is stopping and I have sorted a new gasket set, and service kit for the engine.

I am liking this project more every day.

 

 

Blue by Friday.

 

07/10/2017.

 

Well after a weeks delay on the frame build, because of Horse Of The Year Show, work I have been back on it this week, and made all the parts and new jig bits for the swinging arm. And finally welded it up on Thursday,

It had taken three four hour sessions to get the swinging arm the way I wanted it.

 

As you can see I have altered this arm to the one fitted to the first "Super Cub",I have gone back to the "MM" type layout and are using Metalastic bushes the same as used on Honda"s and some Pit bikes.

There was nothing wrong with the one fitted to SC, one which was fitted with turned up Nylon top hat bushes. 

But just a case of knowing I have to use these Metalastic bushes on the Foster Otter builds, and thought it a way of trying them out on SC,two.

 

 

The threaded bar was fitted when I took the arm out of the jig , and tensioned inwards as the arm sprung outwards as it was removed,

It seems to have worked, because after finishing welding the under side, nd releasing the tension it has sprung back into the correct width 7".

 Yes I have got to run the right hand taking welt in on the bush carrier.

The heat was dissipated into my solid jig and made the joint a job to weld with a number 5 jet.

I have dressed the bush holders ready to press in the bushes after paint. 

 

 

Re-welded joints with number 10 jet fitted.

 

 

And then I welded on a side stand pivot bracket, Ahh Bisto.

More tomorrow.

 

 

 

 

This is the frame you should end up with.The steering head is the same as I use on all of my frames and the same dimensions as the Faber frames, this takes the L44643/10 tapered bearings used with the 1" stem of the BSA/Triumph "FourStud" forks.

Sitting below this is the filler Cap and neck, NOT for oil in this frame  but for the fuel. This little machine will be running on the Aspen 4T fuel, and the Glass-Fibre tank that will be made fuel proof will be made from standard polyester resin.

Filler cap details below, a breather pipe will be incorporated into the neck.

 

 

This cap I machined from Black Nylon, but you could use a 1/2" BSP brass filter cap and the appropriate steel  jointing tube if that is all you can get without the use of a lathe to turn this up.

 

I am going to stick with the  YX 140 motor unit for this bike too.

 We know the motor works very well in the first SCT, and we also now know how to tune it to our liking. Here it is in its delivery box.

 

 

Brian has been over for ten days in July and with the picture of a Seeley Honda and some data from a a friend of mine.

He came up with a new exhaust for this project,

We were waiting for a new front pipe to be delivered ,but it failed to turn up,so as Brian had to return to the IOM,we had to coble up a front pipe to see how the New exhaust performed.

 

Well brilliant is the answer, quiet like a 4RT and with a smoother delivery of power,

 the job looks good for the future, and the system only needs tidying.

 

 

The cobbled up part is in red.

 

We only fitted the parts onto the First bike that were needed to ride it for a trial run and this is it.

The first bike had been striped down ready to paint the frame so an hasty rebuild with the nesasary parts to get it mobile were used.

 

 

The welding will be tided up with a Tig, we only had a Mig to weld it and it was a bit hot.

 

I will create the front pipe out of 29mm Stainless tube.

 

More on the build has we progress.

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"Edge of Iceland Adventure."

 

I did a full log of this journey that Lee did on Blog-spot.

but Google are not being very helpful about me getting to it.

 So I will try and remember with the help of the Photos until Lee has time to make any comments and corrections.

As I say above the bike was left in the corner of the dusty workshop for two years before Lee decided to do the trip for one of his BMX mates from NewCastle that was in the States and  had been badly injured, his name Steven Murray.

This was the "Stay Strong" charity that was set up to help him.

 

Lee collected the bike from Warwick and arrived at my front door in Banbury at Noon on Saturday to start his Journey.

He left to catch a train through the chunnel, and rang me that evening at sixish to let me know where he was.

The plan had been has it had been on the Britain trip for him to let me know where he was going to try and get to and I would the next day let him know where there was a camp site at or near that location. well he was going to stay somewhere near Calais that night but had travelled up through Belgium when he rang me, and near to Antwerp.

He said he had pulled in to get fuel and there was a black sky like he had never seen before so had decided to stay in the Motel there for the night.

 The journey continued up through the Netherlands and Germany  on the Sunday and he needed a camp site near Hamburg .I found him one that was quite urban but he told me the next afternoon arriving early  and rang me at two o'clock in  Hirtshas Denmark, to catch the Faroe ferry the "Norrona" run by the Smyril Line. that leaves on the Tuesday morning at about eleven.

 

 

Picture of the Norrona. ferry.

Wednesday he rang me from the Faroe Island where is the midway stop. and said that the Norrona should arrive at about eight thirty on the Thursday morning in Seyoisfjorour Iceland.

 

Route was to be anti clockwise from the port taking the A1 highway(Route One) that has you will see is little more than loose tarmac and gravel in places. the red marked is Blonduosbaer.

 

The journey continues here.

 

These are three superb photos Lee Photographed in Iceland they are available from him turned into framed pictures.

 

Iceland  second trip taken in January.

 

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This shot again from the second trip taken at 3.30pm  in January. near the Route One.

It is a memorial.

 

This shot is from the  trip in June taken on the 9th 2009. My favourite shot of the whole trip.

Here below is a map with Route One marked on it.

 

 

Starting from the centre top blue dot and going anti-clock wise each one is roughly one days journey and about the route Lee took.

 

Bloudes filling station.

One of only a few on the Route one.Well probably more than a few.

But some are quite a distance apart. And not all of these are the same.

 Some are only pumps that except credit cards but you will need a Pin number.

Most however are more like social gathering places for not only visitors, but also the locals.

Most have shall we say eating facilities, some near top end restaurants, but the best part is that they also sell other good from agricultural machinery at one end, to groceries and provisions at the other, and most are open twelve hours a day, and most days, unlike local stores that sometimes only open two days a week. Favourite food seems to be there take on the "Hot-Dog" sausage.

 

This is Borgarnes and the bridge across the estery. this is the second largest road bridge in the country and a essential link to Borgarnes and the "Route One" Highway.

 

And a coloured shot of the same bridge crossing.

 

These Icelandic sheep have far different wool to most sheep. I wonder why that is?

But it is put to very good use in the country it is grown in.

 

 

  These socks are a made from the fleece of the above sheep and not only do they keep your feet    warm they are virtually waterproof too.

the inner softer part of the fleece acts as the insulation whilst the outer with its natural oils is virtually water proof has I say.

The fleeces are sorted and then washed but with very little detergent so not to remove the oil.

 Then spun and mostly hand knitted into socks mittens or the famous Icelandic pullovers.

 

  Lee says they were a life saver in the extremely low minus temperatures on the ride.

  The gloves he bought were also just has good.

 

 Unfortunately it seems that they are literally kept in Iceland and know one exports them to other countries.

 Well not yet anyway.

 Most socks sold as being Icelandic have never seen the country.

So if you go there buy as many as you can for these are the only genuine items.

 

 

To Continue

 

 

 

 

 

 

 

SAT 14th May 2016.

Right I will continue with the story later now I can get back to this web site, it has only taken me  TEN hours today to achieve this and I was dumped by the Freeola team at One Forty five,and I know to you guy's it is only a job.

But the problem did start on Friday the thirteenth.

And they did sort it out for me later 

Thanks Guy's