project Husa-Dale build

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themadhatter · #1 Post by **themadhatter** » Mon Dec 05, 2011 5:31 pm

Hey guys as requested here is how i built my dale.

1st was getting the engine to sit in the frame, it went in kind of easy to start off with but it got pretty tight a little later on!!. i removed the rear shock and made a ally bar to take its place this was just to make a bit more space so i could measure the engine mountings and align the front and rear sprockets.

themadhatter · #2 Post by **themadhatter** » Mon Dec 05, 2011 5:37 pm

i had to make alloy collers that slid into the husaberg rear engine mount as the diameter of the husaberg swingarm bolt was smaller and i wanted to use a dale swinger so the geometry wasnt off too much.
it was quite handy really because it meant i could space out the engine to fit inbetween the swingarm mounting points to the frame, in doing this it helped massivly with balance, as i was able to mount the engine further back in the frame almost in the position of the standard dale motor. also this gave me the extra room for the exhaust too

themadhatter · #3 Post by **themadhatter** » Mon Dec 05, 2011 5:41 pm

then it was time to mock up front engine mounts that fitted to the original mounting point,
wanted it to look like it was factory standard, i did change the shape of these a bit later as these looked a bit to chunky.

themadhatter · #4 Post by **themadhatter** » Mon Dec 05, 2011 5:47 pm

then i had to cut out the rear shock support as there was no way my fcr 41mm carb was ever gonna clear it.
this i decided wasnt going to be too much of an issue as it was always going to be a road legal quad so it wouldnt need as much travel as a normal dale would.
this did bring its own ploblems as it meant i had to use a really short shock, eye to eye i believe its only 280mm long
( i think thats rite ill check on that to be sure, i know its short tho for sure!!!)

themadhatter · #5 Post by **themadhatter** » Mon Dec 05, 2011 5:54 pm

i taped the rear shock mount in place after tons of measurements and calculations, i found thati had to make up alloy spacers as when moving the mount lower down the frame spars it got wider, the spacers are billet ally so they had to be welded into place to make it strong
i got a ally welder friend in to do this as i have no idea how to weald ally at all!!
i lowered the shock mount so that the carb mouth just cleared it and that the float bowl was still accessable, well ish?. ha ha ha

themadhatter · #6 Post by **themadhatter** » Mon Dec 05, 2011 6:00 pm

shock mount spacers in place and ready to be wealded.
rear shock is a old style reft mount ducati unit, i sent it off to K-tec to have the shaft shortened by an inch this meant that my ride height is almost flat, unless i put on a load of weight that is!!

the shock was regassed to my weight and to make it a bit harder for fast road use.
and a white 15 stone spring was added.

themadhatter · #7 Post by **themadhatter** » Mon Dec 05, 2011 6:04 pm

new slimmer front motor mounts and alloy spacer tube were added, these fit much better than my 1st atempt, plus they look awesome too. with mounting the engine further back in the frame it alloud me to utalise the standard battery box mount, made life much easier i tell ya!!!

themadhatter · #8 Post by **themadhatter** » Mon Dec 05, 2011 6:09 pm

once engine fitted the bike i stripped it down and began the god awefull task of polishing everything!!!!
and just before you ask, yes that does include all the nuts and bolts on it too.
i think this part was bty far the most time consuming.
and if i was honest id never do it again!!!!!!!!!!!!!

themadhatter · #9 Post by **themadhatter** » Mon Dec 05, 2011 6:11 pm

one more of the frame in all its polished glory.

themadhatter · #10 Post by **themadhatter** » Mon Dec 05, 2011 6:24 pm

ok so now comes the good bit, assembly!!!
i got various parts powdercoated yellow or black then had them laquered in rainbow flake.
looks awesome in the sun trust me!
i fitted a walsh standard length steering stem and a brand new rad.
all bearings and seals were replaced.
at this time i re-fitted the engine, the sharp eyed among youy may notice that the engine is polished too.
i had to drop the original engine that i fitted as it was built by a complete numb nuts that had no idea of what he was doing!! it basically seized up. i ended up buying a 2008 race engine off a supermoto team in sweden. had it rebuilt by a specialist and now its perfect.
i fitted a moto ohlins damper that i had rebuilt, still not sure how effective it really is on the road as im not sure how to set it up so i just kept the same set up as the last owner.
looks the dogs danglys tho!!!