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Andy Stannards Transalp Thread
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TOPIC: Andy Stannards Transalp Thread

Re: Andy Stannards Transalp Thread 6 years, 4 months ago #9922






Re: Andy Stannards Transalp Thread 6 years, 4 months ago #9923

Hi...all...and Happy New Year......I have added a couple more photo's by editing to the previous posting, of the thinner shims bonded in place and a dry trail run of the thicker .010" thou's rested in their place before bonding, the .012" thou's were to tight and would not all fit. Am going to add a couple more photo's soon of the finished shaft that is all ready except for the waiting game of JB Weld to set. The new sprocket is now a perfect fit on the bonded built up splines, and I am very tempted to replace the chain and original fixing method and ride out ! BUT NO....I know this worked on my previous experiment, so I am not risking wrecking all the graft and will continue in my quest of the wider modified bolt on sprocket idea that is very close to fitting. Sorry to take so long over all this....will keep on posting info as I go.....Andy

Re: Andy Stannards Transalp Thread 6 years, 4 months ago #9924

FOUR MORE PICS....Showing final bonding of the .010 thou shims, two after removing the sprocket that was making the angle correct while the JB Weld set enough...and two showing how good they are....like it when a plan works......Such a good fit, that there is a high spot somewhere that is now stopping me pushing the modified sprocket " set of three " back on the last .005 thou....Damn...not good enough Andy.... 















Getting a bit wary of this being a bit of a tooooo ! good a fit now, thinking of distortion of the special sprocket parts when or " now " A BIG IF " i hit them with the welder ? Let alone cracking them ?

I FOUND IT..FIXED IT..AND BOTH WIDE SPROCKET SETS NOW FIT LOVELY...............I was going to tack weld the front spacer to the sprocket...but am now giving this a miss...there isn't any more than a thou to play with between shaft and sprocket splines
Last Edit: 6 years, 4 months ago by East Coast.

Re: Andy Stannards Transalp Thread 6 years, 4 months ago #9925

Hi T ALP.....Glad your still out there and watching me...also glad your still giving the thumbs up too. All 3 parts do fit on the shaft together, including the spare set, as I am making two, The new thinner specials sprocket extensions have still to be drilled for clearance for the caphead bolts that are joining them....AND YES...You are correct saying they cannot be bolted when in situ on the shaft. The bolt hole centres are spot on and are no problem, but as the threads were cut separately you cannot bolt through. It goes a nats nugger out of tue and locks up. I thought I would M6 tap through the original thick sprocket while clamped together, and reshape the thread in the extension sprockets slightly, as they are only a few thou out ? = NO NO Far to hard..... JB Weld claims a shear strength of 3900 psi, and I found somewhere that a square inch bond can hold " 900 lb "....Who knows if the stuff is capable of my intensions, but the spline to sprocket angles and clearance fit are far better than I could have ever expected, and the engine kforce will be pushing face to face etc. If it were a much more powerful machine I would be apprehensive....as said previously....SUCK IT AND SEE....The welding is only going to be a couple of spot welds to back up the bolts, maybe six 4mm tacks..only 38 lb/ft of torque....The distortion I am worried about...I work in engineering and even sticking things in ovens change their shape drastically, and I have not got a lot of tolerance in those splines. To line them up before welding I am going to twist anticlockwise to butt against the unworn part on the splines of the shaft and am bolting and bonding at the same time.....WISH ME LUCK......Andy


PS...i'ts also getting a new SRF 525 H Heavy duty O ring chain, which is 2 links longer as it's having a 49 tooth rear instead of a 47 standard one, a bit off the top end and a maybe a couple of mpg less, but a bit less stress on the repaired front end, especially shifting 17 stone of me about.......


A QUICK EDIT HERE......A guy called Ernie has replied to a question I sent him on 7-1-2014.....He has done a similar repair on an older six spline transalp that is still OK after 10.000 mile and without the wider sprocket....ie...BRILLIANT NEWS
Last Edit: 6 years, 4 months ago by East Coast.

Re: Andy Stannards Transalp Thread 6 years, 4 months ago #9926

Hi again all.....Forgot to mention the bike is also getting a new SRF 525 H, Heavy duty " O " ring chain, the new front drive sprocket is a standard 15 tooth, BUT it's getting a 49 tooth rear instead of a 47. I wanted a bigger one such as a 51 or 53 tooth but could not locate one. Not interested in speed, and the mpg is brilliant ! so if I lose a couple of mpg it does not matter...worst has been 45mpg trying to stay with an R1 Yamaha mate...and best has been 69 mpg....AMAZING...and YES.. I have bought the correct chain with 2 extra links ! I also use Esso " super " unleaded that makes this machine run lovely, well worth a couple of extra pennies...the 2.8 v6 4 motion Passat estate and Honda CRV love it too.....Andy


Cheers Phil....Since figuring out this fix design and doing a bit of googling research...it appears I am not the first to come up with the shims idea ! ! DAMN ! Back in 2007 a guy called ernie on this site done a fix on an early 6 splined shaft that worked for several thousands of miles. He apparently used stainless steel welding wire layed in and bonded to fill the gap. So " I " may AS USSUAL be going over the top with my superwide " NO WOBBLE " sprocket fix, but if it works, there may be a lot of Transalps, Africa Twins, XL600's, Dominators, KLE500's, VRF's and many other bikes " NOT JUST HONDA's "' saved from the scrapper that use this stupid retainer fixing method. Another good thing is any future wear, if any, should be on the shims that can be replaced. Only drawback is my super sprocket is only going to be removable with heat "150 degree C " and a gearpuller...the shims should hold on until 300 degree C...but it can also be returned to the standard Honda original fixing method as well ! as I have not interfered with the washer groove.......Andy


Hi all......Cannot take a chance with the welding....absolutely no play backwards, forwards or sideways when the drilled for bolts spacer is bolted on to the toothed sprocket. My experience tells me even a thou twist in any direction will lock it up, and would not fit back on....This thing needs a very hard push now ! when it's only just bolted....It'll ruin it if I weld..The two high tensile 12.9 cap head bolts should be able to take any strain transmitted through to the spacer anyway.Next job is remoulding the plastic cover to fit back on over the longer wider set up bolt heads.I will put more photo;s on soon....Andy

Re: Andy Stannards Transalp Thread 6 years, 4 months ago #9927

ErnieC
Post subject: Re: Worn gearbox output shaft
Posted: January 5th, 2015, 3:03 am
Joined: January 22nd, 2007, 5:10 pm

Posts: 136
Location: North East England


THIS SHIM FIX WAS PREVIOUSLY DONE BY ANOTHER MEMBER, BUT WITH A STANDARD SPROCKET, AND I HAVE ASKED A QUESTION ......


His reply is.....Hi all, just to give you an update on my original fix; it is still working well after 10,000 + miles Ernie.........


YES YES YES.....Thank you very much Ernie....from Andy PS....This means my Transalp should be passed down to the grandkids in about 15 years
Last Edit: 6 years, 4 months ago by East Coast.

Re: Andy Stannards Transalp Thread 6 years, 4 months ago #9928

Hi...Both superwide sprockets are made, and fit absolutely perfect....Only just go on, with no movement at all...rotational or in and out or wobbling on shaft....No Loctite yet either, but am using low temperature release as well...Tack welded retainer on rear as a spacer just in case I did end up with movement and a rattle later....That will also use rear of the splines for drive...Am not welding the spacer / driver to the driving toothed sprocket, as would not fit on if I did.... Tightening the outside caphead bolts the last 1/6th of a turn locks it on the shaft too....NOT IN MY PLAN....Am trying to add some pictures of the very nearly finished bits in position....Andy...may be riding it by the end of January if I am lucky.....Yes...the pictures worked...and another yes...I have gorilla size hands














Re: Andy Stannards Transalp Thread 6 years, 4 months ago #9929

THANKS....Hopefully this job will last forever, as its now got a massive 22.9mm drive width, an extra 68%..and just in case I have a complete spare idemtical set including the wire lock caphead bolts...should outlive my biking time anyway...got to be good for another 30.000 mile......maybe not then if I do 3k a year...Andy

Hi again....The final bit of my puzzle,... before it goes back together..the front cover modification...extended to clear cap head bolts..NOT PRETTY..NOT UGLY..Will do the job..It's got 2.5mm clearance underneath inside...good enough, and isn't going to attract attention like a top hat insert would have...could do with tidying up though.......Andy











IT A TOOK A HELL OF A LOT OF HEAT AND PRESSING
Last Edit: 6 years, 4 months ago by East Coast.

Re: Andy Stannards Transalp Thread 6 years, 4 months ago #9930

East Coast Edit: Buy that man a beer top job that! Well played Andy!

From a different thread...

Hi Easy Coast....It's a YES on the drilling and tapping post, I thought you has seen it, on the Transalp " knock knock knock " posting A bit of a mess in the write up and pictures department as I am adding bits as I do it. I joined in on it as someone had the unknown knock symptoms. I had not seen the wire repair fix before I started doing my cut up feeler gauge shimming fix, but have found out since. Have a look at it. I originally done a quick fix loose packing out the old worn out sprocket and went for a ride to check it out, just a couple of mile and all was OK. Bike is not being used as I have two nice warm cars for winter, so am having a better go at it. The super wide sprocket is now finished and fits a treat, to good if that's possible ! Tried the quick loose shimming with a new front sprocket as well, using the normal washer retainer. I have since set about doing a mucho better job including trying to utilize the whole spline area on the shaft with e special modded sprocket set. I have not ridden it yet with this all put back, as I have rear wheel bearing to do as well...VERY TEMPTED...but 50 % of my workmates have bikes and are not letting up on me riding without the new sprocket on the back...Their right as it would not do the new chain any good...and I'm in no rush. Very very scary attacking the drilling and tapping, which was the first thing I done back in October. If I could not drill it I would have stuck with just the shimming up...that's gone really well...HAVE A LOOK AT THE KNOCK POSTING PAGES TWO to FOUR.....Andy


Definitely a super fix you've come up with there Andy. Seriously impressive and I don't think you'll ever be needing to think about the spines again for some time if indeed ever again!

There's nothing more motivating than the words 'can't be done' and out of all the solutions I've come across on the internet this by far looks the most elegant and robust

Cheers for posting all your progress too

EC
Last Edit: 6 years, 4 months ago by East Coast.

Re: Andy Stannards Transalp Thread 6 years, 4 months ago #9931

Hi East Coast..Thanks for the big praise up..does this mean I am now officially famous..and i'm not even a real biker, biker too ! but not bad at fixing things and am a bit of a fuss pot....Me and the bike are on it too, i'll be running from the paparartsie soon ?

Re: Andy Stannards Transalp Thread 6 years, 4 months ago #9932

andy stannard wrote:
Hi East Coast..Thanks for the big praise up..does this mean I am now officially famous..and i'm not even a real biker, biker too ! but not bad at fixing things and am a bit of a fuss pot....Me and the bike are on it too, i'll be running from the paparartsie soon ?


Internationally famous in fact ...I'll certainly be after your autograph when we have the privilege of meeting you ...which reminds me, a date has just been posted for the safari (an annual ATR gathering at a campsite in Banham). Keep an eye for it as it'd be great to have you along!

I've just had another read though and made an adjustment to the order of a couple pictures and made an amendment to one of my comments (I'd not zoomed in enough to see the 10 thou shims ) One question I did have was how did you manage to tap or drill out the spacer bolt holes to get a snug fit against the sprocket in the end?

..... bolt hole centres are spot on and are no problem, but as the threads were cut separately you cannot bolt through. It goes a nats nugger out of tue and locks up. I thought I would M6 tap through the original thick sprocket while clamped together, and reshape the thread in the extension sprockets slightly, as they are only a few thou out ? = NO NO Far too hard.....


Cheers again,

EC
Last Edit: 6 years, 4 months ago by East Coast.

Re: Andy Stannards Transalp Thread 6 years, 3 months ago #10012

Job's all done...Have ridden 680 mile so far...but lovely...49 tooth rear end in traffic is mucho better..and max torque at 5960rpm...72 mph...perfect...for me anyway !......EDITTED...75 mile now...unfortunately still a bit cold for me ! rest of info and pics on XRV.ORG...under " knock knock knocking " post if anyone wants a look.....EDITTED AGAIN 26th March...680 mile now...not a lot I know ! BUT...all still good, and have given it some hard accelerating, and fast 25 mile motorway stuff...29 March.. NOW 680 mile, and had to open her " right up " a few times full throttle on a slip road because of some nasty car driving " prats " trying to stop bikes getting onto a dual carriage way and deliberately changing into the slow lane at the same time as doing a pedal to the metal. Not my normal riding style but had too....Well all is still holding together and if it was going to break, it would have been then...SO IT's FIXED ! ! EDIT'ED AGAIN...Given it some real stick and a lot of mega hard accelerating now, is at 680 mile and is all thoroughly tested out and holding up nicely...SO !..that's it lads..IT's ALL FINISHED...1st June EDIT..1000 mile plus a few and still good.....
Last Edit: 5 years, 11 months ago by andy stannard. Reason: a mileage update

Re: Andy Stannards Transalp Thread 5 years, 7 months ago #11006

Done just over 2200 mile now since my fix it jobby, and all still perfect after 8 months of pleasureable riding....EDITTED..Sat 13 May 2017..Done over 5,000 mile now and all is still all perfectly ok !
Last Edit: 4 years ago by andy stannard. Reason: just updating mileage and success
The following user(s) said Thank You: Trevor Pastrami

Re: Andy Stannards Transalp Thread 5 years, 7 months ago #11009

Well done mate, there is nothing more satisfying.
THE END OF THE ROAD IS THE START OF THE FUN
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