Transformation - Pursang to Bultaco TSS Road Racer...
Before
After
The original bike - 2008
We started with a 1972 Bultaco Pursang Model 86 motocross bike.
The Bultaco Pursang motocross bike
The frame on the original motocross bike
The workings
On display at the World Golf Village "Riding into History" show
Dave at the Lake City, FL Motocross (2008)
The work begins - December, 2012
Getting ready to re-assemble the engine & gear box
The crankshaft & transmission
New piston and rod
Setting the timing
The Yamaha front brake
The front brake shoes
The front drum
Fitting the brake assembly to the forks
Over all picture of the progress
Getting ready to spoke the front wheel
Prepping the rear hub
Beginning the frame modifications
Fabricating the rear sets
We screened off the brake scoop inlet
Modifying the front forks, springs & damping rods
Fitting the front hub spacers
Fabricating the shifter
Bolting on the shifter side rear-set
Brake side rear-set
Rear-set frame mod
Shifter linkage mockup
Overhead view of the linkage
Aligning the rear wheel
Left side front wheel
Right side front wheel
Checking overall fit & alignment
Left view
Another view
A view of the rear wheel assembly before modification
At this point we needed to finish the front to determine where to attach the rear shocks & seat mounts
A bolt in the axle to keep it from turning & enable removal
Working out front mounts & cables
An over head shot of working out how to mount the front fender
Fork to front brake hub stay fabricated
Air exit screens installed
A close up of the front linkage & mounts installed
Brake, clutch & clip-ons fitted
Time to fit the bodywork - March, 2013
TSS style fiberglass bodywork
Fabricating the tank tie-down
Another view of the tie-down
The steering damper is mounted
Fabricating the rear shock mounts
Right side view of the mount fabrication
The left side shock mount plate
The welded plate
A rear view of the shock mounts mock-up
Shock mounted, ready to fabricate the new tail frame
New tail frame welded
The seat mounts are welded
Checking the fit of the road race tail
Another view of the new tail piece
Completing fabrication of the fairing mounts
Pipe & clip-on cutouts finalized
Beginning to fit windscreen
The rider view of the windscreen
We made up some aluminum airbox covers
The right side airbox covers
Captured bolts installed on the tail piece
The 1st version of the front fender mounts
The inner fender is installed
A close-up picture of the airbox covers & fairing side mount
Fitting the seat cover frame to the tail piece
A close-up of the seat mount bolts
Test fit of the seat mount & tail piece
The 1st version of the tach mount
Our seat foam is cut out
The bike is starting to take its final shape
Drilling the windscreen mount holes
A rear view showing the tank mount strap and tach
The finished seat on the tail piece
The frame is back from powder coating
Powder coated pieces
Rebuilt engine getting a final cleaning
The right side of the engine
Starting the final assembly
A nice picture of the modified frame
The wheels are on!
The cables & linkages are adjusted
The exhaust pipe is on for a final check of the fit
The final over-all check before paint
Time for paint! - 02/25/2014
The painted fenders
The red & silver fairing
The painted tail piece
The red & silver tank
The left side of the tank before pin stripping & decals
The rear fender is mounted
The tail piece is on
The front fender is mounted (version 2)
Steering damper is on
Ready to mount the fairing
The fairing & tank are on
We're ready to put on the stripes and stickers!
We put on the yellow/black pinstripe, Bultaco decal & tank emblem
Finally! The finished bike - March, 2014.
"Built to Go"
