Twin talons

[JERSEYDEVIL]

as soon as the crossfire gets finished this is the next project that's taking priority. these are customer jobs for a member. started prepping them when i need to take a break from the crossfire, in whatever downtime i have. at this point they are both getting delivered to the sandblasters on monday, and will be somewhat custom builds. i will whittle away at them til the crosshammer is rolling, then will be priority til they are out of the shop.

welded cages and rebuilt motors are on the agenda among other things.

[bear]

to bad we dont live closer, blasting and painting are my forte! lol

[JERSEYDEVIL]

Originally Posted by bear

to bad we dont live closer, blasting and painting are my forte! lol

yep, i get treated pretty good though i trade off work w/ them alot and by alot of steel from them. they dont have a bender so i'm a handy guy to have next door as they are to me.

[JERSEYDEVIL]

finally got these back from the blasters and tonight got a good jump on them. one motor is about done and started thinking about the cage work.

[JERSEYDEVIL]

[TheFauxFox]

Nice work, JD! I forgot about this thread; can't wait to see how it'll turn out!

[bear]

Oh man, looks like you're getting ready to "double" your pleasure!!!

[JERSEYDEVIL]

got some more done

[JERSEYDEVIL]

[JERSEYDEVIL]

[JERSEYDEVIL]

knocked some more out today.

[JERSEYDEVIL]

[Miamieddie]

My son and his girlfriend are excited we've been waiting for this moment ..... thanks brother.

[JERSEYDEVIL]

knocked out a chunk this week and got one motor rebuilt, clutched and finished

[JERSEYDEVIL]

[ckau]

These look very neat, strong and effective. What's the dimensions, length and pipe sizes? what sort of results are the guys seeing?
I've been messing with different configurations for some time now searching for that "holy grail". It's one of my queer obsessions. I try to collect all the info , input and opinions I can get my hands on.

[JERSEYDEVIL]

well im learning everyday and the brain is constantly going. i love doing the cages causes it's where you get to inject style as a builder.
as far as the gauges go, i believe and am learning it depends on the application. the 400 is about 80/20 .095/.083 it tips the scales at 900lbs. it scoots great and gets airborn w/ no problem. on that buggy safety will never be an issue, i threw alot of steel into that, probably too much......got carried away ,b ut that was my first so i was learning.
the crosshammer i decided to go .083 on the main cabin hoops and down tubes, and .065 on anything that was non safety/structural to keep the weight down. i was just more strategic in the approach to keep the less is more approach.
i use 1/14" round, 1" round and 1" sq. .......thats what bender dies i have.
on these the speeds will never exceed the point of the 400 or 250 and weight is crucial on a 150. the main hoops and down tubes are .083 and everything else will be .065 . this will insure that in the worst case, a roll over that the driver will be protected and the weight will still be acceptable.
when building cages diagonals and bends are your friends strength wise, Ts and perpendiculars are not. that is something that will cause a greater deal of damage even if it does protect driver in the event it does rollover cuz it will cause a domino effect. all in all better than a bolt on cage.
as far as style i guess i just keep trying to keep up something different you wont see from a factory bolt on cage.

[JERSEYDEVIL]

started on the luggage racks

[JERSEYDEVIL]

ran into a snag , once i pulled the one bug out enough to step back and take a good look something seemed off. the tape measure agreed, one side was an inch longer than the other. i was off on my measurement somewhere. i cut an inch out of the left side of the rack, sleeved it and re-welded it. all fixed. turns out the other one will need to be done too......at least i'm consistent!

[JERSEYDEVIL]

cut this cancer ridden tube out too and replaced it

[JERSEYDEVIL]

finished off the rack, the tank will get sunken down in the rack about 2".

[Miamieddie]

I like it !!!

[JERSEYDEVIL]

well the other luggage rack was a lil off too, probably would even notice , but i cant live w/ that.
anyway here's the here's the pics of the fix. never been shy about posting the mistakes so maybe someone else can learn and either avoid them of fix them.

[JERSEYDEVIL]

w/ that out of the way i could finish the rack and figure out the fuel tank mounting.

[JERSEYDEVIL]

[JERSEYDEVIL]

[Miamieddie]

Nice big tanks for all day travel and fun. Nice.

[chuckorlando]

As always brother, good job.

Far as steel size and amounts go...... What that 400 was built for, you cant have to much. If you recall I hit that boulder in Tn in my 400. Threw me off the trail and into a downed tree at 30mph. That downed tree was the only thing between me and the side of that mountain. Bigger engines, and 2 strokes most certainly, things go faster and go bad faster. They fly further. Hell you were just a touch of luck from rolling on that jump. 095 dont weigh to much when your falling 12ft out the sky on your lid.

At the end of the day, that machine was built with utv racing in mind. Or maybe just reckless trail riding on the verge or stupid. ahahahaha

[JERSEYDEVIL]

Originally Posted by chuckorlando

As always brother, good job.

Far as steel size and amounts go...... What that 400 was built for, you cant have to much. If you recall I hit that boulder in Tn in my 400. Threw me off the trail and into a downed tree at 30mph. That downed tree was the only thing between me and the side of that mountain. Bigger engines, and 2 strokes most certainly, things go faster and go bad faster. They fly further. Hell you were just a touch of luck from rolling on that jump. 095 dont weigh to much when your falling 12ft out the sky on your lid.

At the end of the day, that machine was built with utv racing in mind. Or maybe just reckless trail riding on the verge or stupid. ahahahaha

hahahahaha ypu know i'm up for either or both.
it's like when i used to race cars. dudes would ask why i didnt move up in class. i would say i dont want to buy a new more expensive car. they would say just throw a sportsman motor in my street stock. the thing is even if i could get it to handle as good as a sportsman i dont think it would take the hit of the better more built up chassis at a higher rate of speed than it was built for deeming it unsafe in my eyes. well building a buggy is about the same mindset. you build it for what it's intended for. the 400 was built for a UTV race if it ever got there, and it might hold up. but it is safe. heavy but safe. a 150 i beleive you could go .065 all the way around if the cage is built right. even a tad thinner being welded and a better design than a bolt-on cage will more than compensate. i just think using the .083 just makes it that much more safe on the main & overhead hoops.

[chuckorlando]

I agree. The 083 wont tweak in a soft roll. Who aint soft rolled one? ahahahaha

We know the potential weak links. If it dont hold, we also know the path to fixing those links. Necessity, time, and money brother.

I miss talking about building. Much more involved then nuts and bolts

[JERSEYDEVIL]

Originally Posted by chuckorlando

I agree. The 083 wont tweak in a soft roll. Who aint soft rolled one? ahahahaha

We know the potential weak links. If it dont hold, we also know the path to fixing those links. Necessity, time, and money brother.

I miss talking about building. Much more involved then nuts and bolts

well we'll just have to talk about building here, now wont we.

[JERSEYDEVIL]

was darn hot today. welding is definitely a winter sport.
i believe all the frame fab is done. both tanks are mounted and the final tubes are in the cage. just have to finish welding and grinding them.
i changed the mount on the 2nd one because the dimensions of the rack were slightly different from the fix. i made the back mount welded on instead of a bolt on cause of less space. works good.

[JERSEYDEVIL]

[JERSEYDEVIL]

been a busy week, wife is out of town so the shop time got cut off this week. i got the welding and grinding finished on the 1 so i decided to go ahead and paint it so it could dry while i do the other. i think this is the last project i rattle can. i can no longer feel my fingers.

[JERSEYDEVIL]

[JERSEYDEVIL]

and 1 motor is done, we started it last week and heard a noise turned out it was the start clutch coming apart. fired it up this week and it started first crank and purred like a kitten.

[bear]

Man. don't you just love progress!!!

[JERSEYDEVIL]

wife went away for a week to MI so my shop time got cut down. back on it though, finished welding and grinding #2 and got the paint on it.
someone had cut the floor pan out from the pedals up so i weld some flat in and am going to make an alum treadplate insert to rivet in.

[JERSEYDEVIL]

[jmansracerocket]

looking good

[JERSEYDEVIL]

tanks are bolted in and i guess/hope the last of the fab is done

[JERSEYDEVIL]

missing floorboard

[JERSEYDEVIL]

let there be tailight!

[JERSEYDEVIL]

mock up and dry fitting, here's where i start to see it take shape. decided for the wiring relocation to go under the rack since there is so much space, something different for me instaed of putting the box on the rack.

[JERSEYDEVIL]

motor is in, electrical box is in, strut/arms are painted, hub bearings changed and i cut the electrical platform off of the swingarm. i couldn't resist and had to slap a front wheel on just to see.

[jmansracerocket]

i cant stand the stock electric boxes what kind of box is that that ur using there?

[zman007007]

you can buy those type of boxes from home depot, lowes. Just make sure they have the water proof gaskets on them. I used a small one on one of my crossfire.

[JERSEYDEVIL]

true that zman.
i use 2 different sizes depending on the project and the space.
some examples

[JERSEYDEVIL]

finished the box and started the wiring

[Miamieddie]

Man I can't get over how neat and organized are ur electrical box compared to my factory spaghetti bowl that came in mine. My two kids are starting to get a smile on there face. Awesome work john. I feel like a kid myself right now.

[JERSEYDEVIL]

Originally Posted by Miamieddie

Man I can't get over how neat and organized are ur electrical box compared to my factory spaghetti bowl that came in mine. My two kids are starting to get a smile on there face. Awesome work john. I feel like a kid myself right now.

thanks eddie.....doing my best!

[JERSEYDEVIL]

pace has slowed down a bit due to life....
but it's all about the wiring right now.......and the details.

[TheFauxFox]

"Slowed a bit due to life"

I HAVEN'T TOUCHED MY BUGGY IN TWO WEEKS DON'T YOU SAY THAT!

Just messin' around with ya! Keep up the good work! I'm still quarreling with my dad and trying to see when he can work with me on my reverse cable. I'm doing the most I can, but I've just run outta ideas.... LOL

Anyway I cannot wait to see this finished JD!

[Masteryota]

I haven't touched mine in 2 months. Dang life getting in the way.

[JERSEYDEVIL]

other than mounting and hooking up the lights and splicing in an inline fuse, it's wired. looks pretty clean, tried some new ideas and it was worth it.

[JERSEYDEVIL]

[JERSEYDEVIL]

well after 2 1/2 weeks of suffering through pneumonia, i'm finally back in the shop. i actually called a bunch was friends to see if they could give me a hand this past saturday to see if i couldnt put a dent in making up some of the time i havent been well enough to work. basically in a days time i had my trusty sidekick Jeff rebuilding the motor for the second talon, one buddy strip down another talon carcass for parts so i could discard the tub. 2 guys pulling 5 motors including my yerf motor which i suspect is about to throw a rod, judging by the noise in the bottom end. another bud sanding down and painting swingarms, one of which is for the second talon. one of my buddy's brought his teenage nephew so i had him manning the sandblasting cabinet prepping parts for paint. Jeff's brother'n law tearing down seats for ground up rebuilds. ive prepped a room for testing the waters to do seats in house. i see enough seats come through here that are rotten i figure there might be a niche. this project will test how well this will work out. in the mean time i was able to install a rebuilt in a customers yerf, fix the shift cantilever, replace shift cables and replace a carb, intake and brake pads on an older manco 150, then spend the rest of the day working on the talon. rebuilt the rack, bolted on the entire front end, pedals, headlights and other misc odds and ends. finished and painted the exhaust, and fired up the motor. all is left is a new master , cables and the seat.
BIG, BIG THANKS TO MY GUYS, AND THANKS TO MIAMI EDDIDE TO HANGING IN THERE W/ ME!
it's been a tough month but on a sidenote saturday was fun, kind of looked like a buggy factory. always fun to see quick progress!


oh and fired up the motor too
https://www.facebook.com/photo.php?v=671561322923013

[JERSEYDEVIL]

[JERSEYDEVIL]

[JERSEYDEVIL]

[Miamieddie]

Thanks john for jumping on this my two kids are stressing me to get there buggy. We've been following up on Facebook and these buggy are out of this world. Wasent expecting it to be this nice clean organized proffetional job.... glad your feeling better and thanks again brother!!!

[JERSEYDEVIL]

been working on the seats today.
my new in house upholstery guy came in and finished the butt cushion and we brainstormed what we wanted to do for head rests. i made some on the bender and welded them on now i just have to clean up the seat frame and paint it. should be done tomorrow, i'm looking forward to it.

[JERSEYDEVIL]

[JERSEYDEVIL]

got some pats painted and the 1st seat is almost done. i cut out the new seat rests while eric ( my new seat dude) upholstered the seat back. all the pieces are now cut for both.

[JERSEYDEVIL]

[JERSEYDEVIL]

well the seat is complete and we dry fitted it, i kind of like it.
definitely helps fill out the buggy. now it's starting to look like something!

[JERSEYDEVIL]

[JERSEYDEVIL]

trying to get the other seat done quick so i stayed late at the shop to get the other seat frame prepped. my upholstery guy is gonna start this one tomorrow so hopefully by thursday it'll be done. not much left to do on talon #1. talked to eddie and the plan is to pick #1 up this weekend. just gotta bolt on the painted parts , bolt in the seat, run the reverse cable and change out the master cylinder and bleed the brakes.

[JERSEYDEVIL]

ok, reverse cable is in, fenders are on, 2nd seat is under construction and the shifter is installed. eric and i discussed the pleats in the head rest because they bothered me. he didnt heat the 1st set because he prefers a blowdryer over a heat gun because he had had experience where heat guns were a lil too hot. i asked him to give it a try on the second set. turned out much better. well last night i must've made the head rest rails on the 2nd seat a lil taller so the headrests that i pre cut are not big enough. tomorrow i'm going to use the new headrests to replace the seat for talon # 1, because i just think they look better. then i'm going to cut new taller head rests for talon # 2. this will work out better i think because # 1 is for miami eddie's son's girlfriend and #2 is for his son who is taller any way. we ended up doubling up on the foam on # 1 to push her forward and up because she is a bit shorter. at this point i'm just waiting on the seat belts and to replace the master and bleed the brakes and hopefully friday afternoon.............TEST DRIVE.
ready for pickup on saturday!

[JERSEYDEVIL]

[JERSEYDEVIL]

seat and harnesses are installed. not much left to do and there wont be anymore pics of the entire bug til saturday. kind of want eddie and the kids to be surprised. still have a few tricks up my sleeve. so any pics will be close ups from here on in til Saturday.

[bear]

Ahhh, Christmas in August!!!!

[TheFauxFox]

Are those 4 or 5 point cams? How are they? They look good

[JERSEYDEVIL]

4pt cams i sell them out of the shop.
theyre great for the money, just a little long. now that ive got a guy w/ a sewing machine in here i'm gonna see if we cant cut them and re sew them so they accommodate the buggys a little better.

[JERSEYDEVIL]

just took the 1st test drive.....all is good, had to rejet but it runs great.
it's nice and tight , no rattles and almost feels new.
i got it all dressed up and she look's pretty hip. no pics til tomorrow!
hope you dig it eddie!

[bear]

He'll probably be beating on your door at 5a.m.!!! I know I would! lol

[JERSEYDEVIL]

well just called eddie he's just leaving.....3hr trip!
thats good cuz i just finished mocking up his exhaust for his reaction so that gives me time to finish welding grinding and painting it.
in the mean time here's a couple pics. i think itll be safe cuz he's on the road and the kids dont troll the forums from what he says.

SNEAK PEEK!

[JERSEYDEVIL]

well they made it here's a couple pics of the delivery.
they all took a quick couple runs down the road and once they were happy i stated working on eddie's baja reaction. turns out he had gotten a bum new carb that must have a bad diaphragm, i havent had a chance to check it yet. swapped the carb out and problem solved. i bolted on his new exhaust i built that morning, what a huge difference. well at least i know everybody left happy w/ a loaded trailer.

[JERSEYDEVIL]

here's some shots of the exhaust. it screams , wish i took some vid.

[Miamieddie]

One hell of a surprise JD. We didn't expect it to be look feel NEW!!!". We love it. She gave me a hug and thanked me for getting this buggy for her. Its many times better looking then the ones from the factory. And I'm not just saying that. Everything is so professional built. And i /we love the decals and her initials you put on her buggy. Now she thinks she's the sh***t!!! Lol. Thanks again for everything including my pita buggy I been trying to figure out. I would of never guessed it was the brand new carb. I just bought. Had a defect. Thanks my brotha.

[Miamieddie]

Oh yea. SON!!! He's building yours now. Your next. He loves his gf. Buggy JD so he's happy and can't wait for his.

[JERSEYDEVIL]

started assembly on the second talon tonight.

[JERSEYDEVIL]

got the electrical box mounted. wiring should start tomorrow.

[jmansracerocket]

looking good

[JERSEYDEVIL]

started wiring lets see how far i get

[JERSEYDEVIL]

wiring is 90% rear and dash are wired just need to harness the lights and slap a batt in. should be done the seat tomorrow, had to cut new headrests. i made all four at the same time but this second seat i must have made the highback frames a lil taller so the headrests wouldnt work, or at least look good.

[JERSEYDEVIL]

[JERSEYDEVIL]

well the wiring is done. i tested crank and spark and thankfully got it all good the first time. after doing a bunch of rewires and troubleshooting it is starting to get easier each time. as soon as that was done i got on the exhaust. ive noticed w/ all the carters, i think ive had 7 (owned , bought and sold), that they decided to put the battery tray based on what day of the week it might have been. eddie's first one was in front of the swingarm behind the seat, this one was in the front left corner. because of this i took a little different approach to the shape of the exhaust to avoid getting too close to the battery. i also added a little length to it. got it done and painted so tomorrow i should be able to fire it up then final assembly.

[JERSEYDEVIL]

[JERSEYDEVIL]

spent the day on this yesterday and knocked out a good chunk

[JERSEYDEVIL]

[JERSEYDEVIL]

seat's done

[JERSEYDEVIL]

starting to wind this down. should be test driving today. yesterday i had to find fender brackets, all the stock takeoffs i had were left side. i remembered having some new ones in storage, but that they were different so i dug them up to check my options. turns out they would work just had to modify the right side mounts to accommodate the brake stuff so i used a holesaw in the drillpress and that worked like a charm. lights, chain cable adjustments and seatbelts and it's a wrap.

[JERSEYDEVIL]

well eddie is on his way, it's finished, test driven and broken in.
here is the finished product i guess that's a wrap!

[jmansracerocket]

came out good

[zman007007]

looks great jersey

[Miamieddie]

Thank you john for both well built buggies. Feeling happy.