Jump to content

Recommended Posts

Just finishing up the last few bits on this build, figured it was time to share here. This will be a long multi-segment post, so keep checking in till the finished pics pop up. 

 

The (rough) design brief... CBR1000RR tail, F4i RSU fork swap, handlebar and riser conversion, round headlight, front mount radiator, custom exhaust header with low/underbelly muffler and exit, powdercoat lots of parts. Overall, the usual crisp, clean, loaded-with-details build with a P51 Mustang - airplane inspired theme.

 

Starting with a reasonably clean albeit slightly higher mileage '99 model:

 

20160827_222947_zpsy5fnuwrc.jpg

 

20160829_181553_zpse4brbp0f.jpg

 

20160829_184202_zpspefgulbn.jpg

 

20160829_184547_zpsrzo6nrxd.jpg

 

20160903_164538_zpsgg0ut3nh.jpg

 

20160906_153945_zpszrliosev.jpg

 

20160903_165209_zps4e6972xc.jpg

 

20161102_171546_zpsulbztqck.jpg

 

Coolant drained, rads off, brakes (mostly) bled out, rear axle nut cracked loose. On track for fork swap by weeks end

Washer fluid bottle makes a good drain catch for coolant streaming from the drain at the pump

20161103_170147_zpsblrvzwvm.jpg

 

20161103_175507_zpsk1o4irbt.jpg

 

Not much, but at least it looks a bit lighter with the side rads gone.

20161103_175540_zpsk8ctpv8l.jpg

More disassembly. 

20161105_205631_zps7bkakou8.jpg

 

Removed hand controls, linked brake system, clutch slave, pair system, other misc stuff.

20161105_205756_zpslvrdvan0.jpg

 

She's pretty grungy, got my work cut out for me to make it clean and shiny again.

20161105_205739_zpsf7vyvs5k.jpg

 

20161105_205805_zps0kyj9ymb.jpg

 

Always gets worse before it gets better... 

20161105_205822_zps7lmz4cz9.jpg

 

Found a broken airbox lid

20161105_210127_zps5omzwz8z.jpg

 

Fitted the F4i forks and triples, and a set of brake calipers. The VFR wheel fits almost perfectly. 

I did have to cut off the F4i steering lock stops to fit the lower, will make new ones later.

20161106_000243-1_zpsvqto2ptr.jpg

 

20161106_000259-2_zpsxzscn8fb.jpg

 

20161106_000321-1_zpsc9c3lteq.jpg

 

Then I offered up the CBR tail

20161105_235453-1_zpspg0fepbh.jpg

 

I'm happy with how the shapes will blend. With the right blend panels and paint, it will look factory.

20161106_000216_zpsde9gvbmc.jpg

 

20161106_000231_zpshqiuiete.jpg

 

 

 

  • Like 2

Share this post


Link to post
Share on other sites

Here's something you don't hear every day  (video)

th_20160829_192611_zpszk7rm3nd.jpg

 

Head bearings will need replacing. The saloon door action ain't gonna cut it! (video)

th_20161105_214625_zpsssyp9xpk.mp4

 

 

Here's most of the stuff that's come off...

20161112_112805-1_zpsfr1lrqlf.jpg

 

Gas tank drained & off

20161112_174927_zpsipwinr5k.jpg

 

Wiring harness (a lot of it!!) out

2016-11-12%2022.21.42_zpsplukbhtl.jpg

 

Fairing stay tab removed, still need to remove the other one

20161112_225539_zpsipq3ft6p.jpg

 

Quick mock up with oem tank and Hornet headlight

20161112_231644_zpsuiztgji1.jpg

 

Same but with a 2002 VFR tank

20161112_233444_zpsqhscqzjg.jpg

 

Going to use the 02 tank as it looks much better with the tail, and the seat fit is just about perfect.

20161112_234754_zpsxolrf3wd.jpg

 

Did a little test fit of the front mount radiator, should work out real nice

20161112_233412_zpsi5dtmjd5.jpg

 

Other side

20161112_234810_zpsrskvj1ds.jpg

 

Handlebar and risers on the way, hope they improve the look of the headlight!

  • Like 2

Share this post


Link to post
Share on other sites

The 2002 tank is not a direct fit, the tank hits the airbox lid before it touches the mount. Also, the hole pattern is different on the rear flange (front is a direct bolt-on though)

I figured out that a 1/2" aluminum adapter would suffice, and made one. 

20161115_194725_zpsvdvljfqy.jpg

 

20161115_195407_zpsmkzmpz5r.jpg

 

20161115_203305_zpswobruxsc.jpg

 

20161115_203457_zpst3watnof.jpg

 

Next up, Taking a little more material off the frame so I can get the subframe positioned just right, then make the mounts for that. 

20161115_203600_zpsinffoifd.jpg

 

20161115_203610_zpsu4l0gasg.jpg

 

Share this post


Link to post
Share on other sites

Risers in

20161126_143122-1_zpsim3qujit.jpg

 

Adaptors rigged up

20161203_173325_zpsxnfkeuoq.jpg

 

Shock swapped for 954 unit

20161204_141607_zps95mejslj.jpg

 

Now "sittable"

IMG_20161204_144455_zps2x6uebdb.jpg

 

Swapped in some CBR1k stick coils

20161204_141621_zps1jdknd1g.jpg

 

20161204_141636_zps6buupyli.jpg

 

And started on the front upper rad mount

20161204_151546_zpsqgvnqpjb.jpg

 

20161204_151824_zpsiqhuyiwi.jpg

 

Share this post


Link to post
Share on other sites

Test fitted VFR800 fan to the 750 rad, looks like it will work just fine with new mounts

20161210_163211_zpsfc47fxvp.jpg

 

Made some temporary hangers to sort the rad position

20161211_121744_zpst1aryrtt.jpg

 

20161211_121808_zps87r1wdur.jpg

 

Not bad for a first guess

20161211_121722_zpsafs5we3h.jpg

 

20161211_121733_zpsasw4sm9l.jpg

 

20161211_121757_zpsuewimpe1.jpg

 


Need to order a 750 left side rad hose, finalize 3 brackets and mount fan, overflow to finish out cooling system.

Share this post


Link to post
Share on other sites

Polished gas cap (Thanks Bill!)

20161212_153505-1_zpsm7tgv27q.jpg

 

Made & welded mounts for rad fan

20161228_121620_zpsxpaicboo.jpg

 

20161228_214349_zpsnrccxxms.jpg

 

All done

20161228_215524_zpsc6jy5mn8.jpg

 

Also mounted the risers to the upper triple. The risers hung over the edges of the triple a little and I didn't like that, so decided to fill the gaps with weld. This is in addition to bolting them on, powdercoat should finish the blend on the unwelded sections.

20161229_122841-1_zpst7ij5jcb.jpg

 

IMG_20161229_125813_047_zpscaua90wl.jpg

 

Headlight mounts almost done, pics coming

20161230_094953-1_zpsqxlcmkpa.jpg

 

  • Like 1

Share this post


Link to post
Share on other sites

There's an F4i shock in there now. Had to switch due to reservoir interference with my subframe mounts, now have to make a res bracket, no biggie. I think it'll mount horizontally across the bike and be hidden from the back by the upcoming license plate bracket. 

20161227_110713_zpszmttrtln.jpg

 

Bought a bottle of simple green and tested a few spots on the motor and wheels, looking good with a little help from an old toothbrush. Hoping all the crud comes off pretty easily, I hate cleaning motors! Breaking down for powder soon so will find out soon enough I guess.

20161228_225510_zpsvqresqoe.jpg

 

20161230_124905_zpskse4h7ms.jpg


As promised, headlight brackets done save for powdercoat. Light bucket is nice and tight to the frame, once I finish cleaning the old fairing bracket mounts off it will sit lower to give space for ignition and fly screen. 

20161230_122654_zpsrz6t1tlu.jpg

 

20161230_124745_zpsnwuza4ly.jpg

 

20161230_124654-1_zps7noibcq9.jpg

 

Good start to the undertail/tray thing

20161231_162451_zpshqwuge2v.jpg

 

20161231_171508_zpsuq4mtpqm.jpg

 

Nice little spot for dzus clips on the subbie

20161231_171756_zpss5pzun3v.jpg

 

Trimmed the sheet and the shut line till I liked it

20170101_130321_zpssv8pfbx9.jpg

 

Then pinned it in place and welded the rear to the cross bar

20170101_150619_zpsqak6f5qa.jpg

 

Both sides

20170101_150508_zps1taoidmx.jpg

 

Need a bend at the bottom... no press brake... make do with suitable implements

20170101_151431_zpsqesepwcx.jpg

 

20170101_151522_zpsympsjvml.jpg

 

20170101_151544_zpsvvgwfvl4.jpg

 

Tada

20170101_152254_zpsseikh1gx.jpg

 

20170101_152339_zpscqgjmshz.jpg

 

  • Like 1

Share this post


Link to post
Share on other sites

A buddy polished my gas cap years ago after he got himself a polishing wheel. Kept it for a while, but gave up on it 'cause it was too bright! But it wasn't a show bike.

  • Like 1

Share this post


Link to post
Share on other sites

I picked up a set of the stock CBR seat filler panels, but forgot a pic. They are one of those things that ebay sellers charge $30 for, even though they only cost $10 new. Always pays to check these things!

I did take pics of the CBR1k masters, and the new Delkevic header. I chose the header specifically for its poor design. The workmanship is adequate, but the many pieces and hokey collector are not what I would consider ideal for flow for performance or stock replacement. However, it makes a nice starting point for a one-off design as all the tubes are already separated.

20170106_182254_zpswcfg5bje.jpg

 

20170106_182232_zpsb6guwizp.jpg

 

New rad brackets

20170113_182112-1_zpsibsvvaq7.jpg

 

CXRacing oil cooler (thanks for finding this little guy Robbo!) with XRP TiTech fittings

20170120_150536_zpswsy4pbna.jpg

 

20170120_150550_zpspkljrw6e.jpg

 

Wanting bare aluminum look on masters, so disassembled them and dropped them in a bucket of old brake fluid. I don't see why it won't take the finish off nice and easy? (SPOILER: it didn't work!)

20170204_174347_zpsk3hobvvg.jpg

 

20170204_175211_zpsekalvoby.jpg

 


Need to make parts for this oil cooler mount tonight, I'm excited that it fits where I wanted it to!

20170204_204351-1_zpstgj86aer.jpg

 

Simple Green to the rescue on these gnarly parts

20170208_170053_zpslexibcgc.jpg

 

20170208_170213_zpsqdto8lfa.jpg

 

This was the start of the new rearset adapters. I'm fitting 954 Sato bling to this old girl

20170209_183537_zpsgd2bxcpk.jpg

 

Initial sketches turned into a paper template that did fit, but didn't please me

20170211_154231-1_zpsqkkkcf9g.jpg

 

So I adjusted

20170211_171806_zpsgngnis51.jpg

 

I think it was the right choice

20170218_141729-1_zpsx4ksaj12.jpg

 

20170218_142756_zpsmxkwrgez.jpg

 

I have a couple machining ops left to complete on them, and a couple spacers to make, but I like them so far. Peg location is stock in lowest, forward-most position, and gets racier from there.

I'm also just about ready to hang the oil cooler. I chopped the factory cooler lines to rob the pan fittings, and tig brazed steel -6 AN adapters on with silicon bronze wire.

IMG_20170218_182501_313_zpsiq0tgmzk.jpg

 

20170220_161103-1_zpstn7yczux.jpg

 

Took a few measurements for top mount brackets for the cooler, work those next. Once I get a big list of oem gaskets and other parts on order I'll break down for powder, clean the motor, mount the new tires, etc...

  • Like 1

Share this post


Link to post
Share on other sites

This oil cooler mount is almost done. I picked a slightly better spot which will require moving the cooler to change the oil filter. Only 2 bolts, I've seen worse on factory bikes.

Started with these to test the theory 
20170223_165939_zpsfi0drcep.jpg

 

20170223_170000_zpsfo42r7lx.jpg

 

Sketched out some changes

20170223_165900_zps6vvnteyx.jpg

 

Drilled these unused holes out to 10mm from 9mm

20170224_173527_zps9andmoyg.jpg

 

Which allows me to hang the cooler with stainless bolts 

20170224_173748_zpsu7wytp9v.jpg

 

20170224_173811_zpsmjivbcxm.jpg

 

20170224_173855_zpspfkefbdp.jpg

 

Nice clearance all around, should work well. 

The brake fluid soak didn't work too well, so I bead blasted the clutch master. I'll probably end up brushing it, but I'm considering a primer to lend to the airplane style control appearance.

Picture of mystery part to keep you guessing 

20170222_165748-1_zpsxwcxv9fg.jpg

 

Oil cooler mockup done, made 2 hoses to mate to my custom fittings

20170225_180637-1_zpsjdecxn6q.jpg

 

20170225_180726-1_zps6vskdozf.jpg

 

20170225_182054-1_zpsx94uqb4m.jpg

 

20170225_183030-1_zpsihe8ydwt.jpg

 

Left side 

20170226_132959_zpsm1rnnzsx.jpg

 

Right side 

IMG_20170226_133850_762_zpszo0ylvcs.jpg

 


Also painted the masters with a green self-etching primer that fits into the theme nicely

20170226_152336_zpsdcz01qoq.jpg

 

20170226_151801-1_zpsliufwxeb.jpg

 

Masters done

20170227_180546-1_zpsopeplh1s.jpg

 

20170227_180559-1_zpsxzspycvq.jpg

 

Blasted and painted the perch clamps, fitted stainless bolts, fitted new fluid nipple to clutch master 

20170301_182808-1_zpsdx1jz7ea.jpg

 

And began the reshaping of the front sprocket cover

20170301_182947-1_zpsckzubxqq.jpg

 

Share this post


Link to post
Share on other sites

That weird lookin part I posted a while back... it goes here

20170304_130551-1_zpsmzz0fc4v.jpg

 

And it serves to mount this on top of the risers

20170305_141510_zpstxwigzmk.jpg

 

Yes it sits tall, making a stanchion that doesn't look goofy won't be easy... let's make it less tall first

20170304_130939_zpsyunr5y7x.jpg

 

Mill the riser caps down

20170304_150116_zpsi5tqkxbq.jpg

 

20170304_150848_zpsxnpgr69p.jpg

 

20170305_104642_zpsc5mbat8j.jpg

 

That's better

20170305_141446_zpskh7pjyfq.jpg

 

Mocked up with mirrors, masters

20170305_141341_zpscwgc1dg0.jpg

 

The front brakes needed some help, queue up new seals, pads, brake cleaner, toothbrush, brass brush, metal polish... etc. And time. Lots of time.

20170317_171945_zpsma5cs0lk.jpg

 

T45 torx, in case anyone is curious...

Halfway

IMG_20170318_170200_398_zps4unoo2df.jpg

 

Some time later... a pretty pair of nuggets

20170318_133742_zps42r0japy.jpg

 

Extraordinary golden glow courtesy of my scrubbing and an instagram filter

IMG_20170318_170800_185_zpsqlceiwfi.jpg

 

I actually bead blasted the pad springs and bolt heads, then rubbed them down with maroon scotchbrite to shine them back up a little.

 

Need to make this less ugly

20170307_155851_zps2lzqo4kc.jpg

 

  • Like 1

Share this post


Link to post
Share on other sites

Tires on... Diablo rain Race... because airplane theme...

IMG_20170414_211726_293_zpsd3elmo0t.jpg

 

Samco hoses for the radiator inlet/outlet... standard 99 replacement on the right, 94-97 VFR750 hose for the left

Small hose in the pic is wrong, Racebikebitz mixed up the part numbers, they're sending the correct one gratis. Takes 4-5 weeks though...

20170406_154253_zpssbgu3vis.jpg

 

Finished up the rearset adapters by adding the last counterbores

IMG_20170422_165345_149_zpsllaxkhhx.jpg

 

20170422_123442_zpsg954g2iz.jpg

 

After midnight things get a little fuzzy

20170422_210113_zpsikmuf9ve.jpg

 

Let the lunacy begin...

20170423_050404_zpsygcbqiop.jpg

 

Steel bolt welded itself into the aluminum... so I welded another bolt to it and spun it out

20170423_013839_zpsycgdy9tr.jpg

 

Finished cleaning up the front fairing mounts

20170424_162640_zpsypz4nsan.jpg

 

Found the robotic O face a bit disturbing... so welded it up along with the coil mount holes on the sides... swapping to stick coils so don't need the originals.

20170427_063241_zps5twepolf.jpg

 

Then smoothed those out

20170429_214311_zpsxeky5ymt.jpg

 

Also buzzed in a couple sections of rod stock, to be utilized at a later date 

20170429_181724_zpsdisfdxkt.jpg

 

60k miles has done us no favors in the cleanliness department, the swingarm is the filthiest part of the whole bike. Well, except for the front sprocket area

20170423_052245_zpscdkcfmqm.jpg

 

That's the arm disassembled, with a couple reference pics for later. All these bearings and the ones in the axle cassette are being replaced with new.

20170426_181925_zps4iewrjl8.jpg

 

20170426_180527_zpsbvlfjlfp.jpg

 

20170426_180542_zpsgugh973f.jpg

 

Amazing what simple green, Wd40, brake cleaner, and a scrub brush will get you

20170429_170552_zpsfs6lqza5.jpg

 

20170429_170552_zpsfs6lqza5.jpg

 

Prep that for powder

20170501_163652_zpsz3enrgqe.jpg

 

20170501_164334_zpsnnzjnjle.jpg

 

20170501_164400_zpsh9in2lzd.jpg

 

Always a sad moment for some reason...

20170429_135257_zpsaoyvv4iu.jpg

 

Frame and arm ready

20170501_204453_zpsrjxknq2c.jpg

 

Swingarm/kickstand cushion thing also

20170501_202417_zpsr9amnhiy.jpg

 

20170501_202433_zpsmaau2xds.jpg

 

In the past, I've had parts messed up by coaters. The worst was when one of them masked front rotor mount surfaces on one side of a bike wheel, and not on the other. And didn't plug any of the holes for blasting. It was a real "can't fix stupid" moment. By masking off the parts myself, I'm in control of 1 extra part of their process, so 1 less thing that can go wrong. 

My tape is removed and replaced by a temp resistant type after blasting. I also take lots of pics of the individual parts to share with the coater, and also for my records in case something does go wrong. On top of that, I flag areas on the masking to indicate no blast/no powder, or blast ok/no powder. I use a good heavy masking tape, so you'd have to be doing something wrong to blast through it and ruin edges under normal circumstances. The edge definition of the powder comes from the job the coater does with the high temp stuff.

I've done a bunch of sandblasting, but now just have a medium size cabinet at home for glass bead which is good for paint prep and light cleaning on things like bolts and brake rotors.

 

Disassembled the hub, sprocket bolts were not tight... which reminded me the axle nut was not tight either... good thing she's being gone through. Cush rubbers were hard, cracked, and basically shot. Already have new ones on hand 

20170501_202359_zpsyr1ny4k8.jpg

 

Finished shaping the lightened sprocket cover/clutch slave holder and cleaned it, this will get powder too

20170430_125656_zpsodtylvq6.jpg

 

Trying to figure out how much of this rats nest can be ditched... so many vacuum lines... so much dirt... lol

20170501_202453_zpscbzhh6rm.jpg

 

  • Like 1

Share this post


Link to post
Share on other sites

Made adjustable steering stops, drilled and tapped the existing dimpled locations and bolted them on.

20170504_163558_zpsyrhz2f1f.jpg

 

20170507_125945_zpsr9aalqpq.jpg

 

The motor was really grungy, 60kmi worth. I soaked the block all over with alternating rounds of wd40 and simple green for about a week, which helped a lot.

20170507_122150_zpsh3rkxf0x.jpg

 

20170507_122222_zps75lfgyw6.jpg

 

IMG_20170507_124440_509_zpsr7pldxup.jpg

 

In between scrubbing sessions, I picked this up from the powdercoater:

20170513_123310_zpsc4cynnfy.jpg

 

I popped most of it on the block so I could get on with deep cleaning

20170513_184624_zpsi25onacp.jpg

 

20170513_184548_zpsbapu2bif.jpg

 

20170513_184256_zpsuf1kloj1.jpg

 

20170513_184451_zpsknhexklp.jpg

 

20170513_193223_zps8jhhthb1.jpg

 

20170514_124430_zpsdkybtwaj.jpg

 

That's about 8 hours of scrubbing there. Worth it to see a nice clean lump, especially because it will be pretty visible. 

I have more stainless bolts on order to finish out the side covers.

I also reassembled the cush drive hub with new rubbers.

20170514_133612_zpsdxk9z5np.jpg

 

20170514_133546_zps80v6pqfa.jpg

 

Blasted and painted rear master, rearset assembly preview

20170514_143614_zpsrt50jfaf.jpg

 

  • Like 2

Share this post


Link to post
Share on other sites

Seat!

20170516_133743_zpsfzkcbq3o.jpg

 

20170516_133814_zpsfgoe5uks.jpg

 

20170516_133846_zps3fc1ka6p.jpg

 


New PBI 15T front sprocket. Was going to install the slave, but I forgot that some of the dowel pins were rusted and junk, so had to buy a handful. 

20170517_194303_zpsorp6rj8u.jpg

 

Time to do something with these

20170513_123317_zpsad3p06pa.jpg

 

First up, fit new bearings to the arm. The radial bearings popped right in as expected

20170527_162439_zpsfqwslxae.jpg

 

The needle roller bearing... well that one was a bit more difficult... I had to get a little creative.

20170527_173051_zpszhtvlqge.jpg

 

20170528_205432_zpsqvizr4v8.jpg

 

Detail line on the socket made a nice easy visual for setting depth to the required 6mm...

20170527_173312_zpsllaj6apk.jpg

 

Then it was time to move this lump off the cleaning cart and back to the table

20170527_175631_zpsyktwau08.jpg

 

Add the spacers to the arm and have a fit check

20170527_180026_zps3venywu2.jpg

 

Then pop in the pivot bolt and rearset

IMG_20170527_190215_455_zps5az4pcgs.jpg

 

Finished up installing all the engine covers 100%, they all got new paper and rubber gaskets. Last thing was to put a finish on the clutch pressure plate.

Same green primer I used on some other parts

20170527_182404_zpsmranvdq2.jpg

 

Then some fancy tape work to lay out a USAF-looking star

20170528_130153_zpsz2fkgqgz.jpg

 

20170528_130027_zpsdrrzfizu.jpg

 

After a shot of gloss white, I busted out the Kafka #1 for some shaky line action...

20170528_132639_zpsy9rg5v5p.jpg

 

20170528_135651_zps8xhj4jcw.jpg

 

The yellow zinc coating on the factory clutch bolts was just right for an ammunition effect

20170528_145911_zpstrvifdf2.jpg


Then finished cleaning the axle/rotor by glass bead blasting, replaced the bearings in the cassette, cleaned the caliper hanger, chain slider, and lower guard and all the bolts for those and put all that stuff together.

20170528_174423_zpsfr5drnas.jpg

 

20170528_172127_zpsqtmoisra.jpg

 

20170528_172151_zpstzk3awlc.jpg

 

20170528_174352_001_zpsjtfa0u31.jpg

 

Stuck the triangles in to hold the arm up

20170528_180201_zps7sifoxvh.jpg

 

20170528_180233_zpsizb2tlmb.jpg

 

Then heaved the wheel in for a look

20170528_181521_zpsyneurl18.jpg

 

  • Like 2

Share this post


Link to post
Share on other sites

20170529_212752_zpsbkiqzs07.jpg

 

Next up the rear caliper rebuild. This thing was dirty just like the rest of the bike, you'll have to take my word for it as I forgot the before pic. For those that don't know, the 98+ VFR's have front and rear linked brakes. Since I'm using a conventional unlinked front end, I have to modify the rear caliper to keep it. I swapped the rear master out for a CBR600 unit to improve the pressure ratio, and drilled the caliper to connect the large center piston to the smaller outer pistons. 

You can see the hole I drilled at 3 o'clock in the center piston bore. If you look close, you can see how it connects to the port passing between the 2 outers

20170529_144042_zps9f78orft.jpg

 

Polished pistons

20170529_213230_zpsr2f5h1ad.jpg

 

The old banjo bolt hole for the center piston will be blocked off by the bolt in the pic. A single line will feed all 3 bores from the CBR master. Also, caliper connecting bracket before cleaning:

20170529_144956_zpstq5vbex5.jpg

 

Bracket after cleaning + new parts 

20170529_150212_zpsjjgx7yxh.jpg

 

Pistons in

20170529_151305_zpsu9pkeq2q.jpg

 

All together

20170529_170918_zpsvfbm4m1z.jpg

 

And installed

20170529_171324_zpsrytnvelj.jpg

 

  • Like 1

Share this post


Link to post
Share on other sites

Then I swapped out the old oil filter for a new Bosch 3300, and installed the oil cooler with a sticker on top

20170529_174244_zpsxlwa7vgj.jpg

 

20170529_214707_zpsdjjc7ttj.jpg

 

Next up, this dirty thing needed a refurb

20170529_215017_zpsvgn03mrj.jpg

 

Original 60k tstat??

20170529_195825_zpsmfiz9vdv.jpg

 

20170529_195032_zpsbibejuh4.jpg

 

Tstat housing after bead blast and a bit of refining

20170529_215214_zps7adirl9f.jpg

 

Much better

20170529_215102_zps9htfrqxm.jpg

 


And back together with new tstat, o ring, and hoses. 

20170529_215350_zpslcumpxqc.jpg

 

20170529_215326_zpsdwknopzi.jpg

 

Frame prepped out. All threads cleaned and new tapered roller bearing races banged in.

20170530_115224_zpszco0g7ky.jpg

 

 

  • Like 1

Share this post


Link to post
Share on other sites

Sometimes it pays to have a lot of experience with one kind of bike... helps to know what to look for... like these baked out coolant joint o rings 

20170530_124001_zps5hatmd2g.jpg

 

Look at those crusty things on the table, they were already failing. Quick bead blast brought the joints back to life though

20170530_143052_zpsv6a2iwdt.jpg

 

New o rings and a bit of scotch brite scrubbing on the mating surfaces finishes out that chore 

20170530_143251_zpsmc60nwto.jpg

 

Rinse and repeat for the side joints, these weren't as bad, not baked in the heat of the vee.

20170530_130735_zpsedqscj5e.jpg

 

Then I dropped the frame on for a bit of scenery while I got going on cleaning the throttle bodies.

20170530_150732_zpsh4yqsax0.jpg

 

20170530_150803_zpszkgj1wbc.jpg

 

Theme check...

IMG_3591_zpsajxnpyi8.jpg

 

Spitfire%20D-FEUR%202010-10-301_zpsucbbe

 

20170531_145034_zpsrzahtus0.jpg

 

The top shock mount needed to be made longer to accommodate the 1/2" spacer I added to raise the rear. Accomplished by replacing the factory bolt with a longer one. Cut the old bolt, punched the spot welded head out, turned down the head of the new screw, tack weld that in place then a coat of paint.

20170531_144923_zpsbjukptiy.jpg

 

20170602_221927_zpsagqjis9a.jpg

 

20170602_222000_zpsxgyijxsg.jpg

 

20170531_151839_zpsgivtzsmy.jpg

 

20170531_152311_zpsyqa2g7ip.jpg

 

It's in place here. I added the horizontal shock reservoir mount, but forgot to take pics along the way. I have the res mounted to it now, but need to trim the hose clamps before I take a pic of that.

20170531_153307_zpsz0bm5eis.jpg

 

20170531_153251_zpsc5tfk0oy.jpg

 

Paint samples

20170607_190225_zpsdxjcefrb.jpg

 

Fine silver brushed with white, green, and gray scotch brite pads before and after clear. I tried drawing a few different styles of rivets in pencil before clear.

20170607_190251_zpsz4hh5mkr.jpg

 

20170607_190300_zpsnojq8ky2.jpg

 

20170607_190308_zps1qfdyowr.jpg

 

20170607_195346_zpsuwpcutaa.jpg

 

20170608_171342_zpsztrrrtrf.jpg

 

20170608_171355_zpsvozqv202.jpg

 

20170608_171432_zpsngerfkeh.jpg

 

  • Like 1

Share this post


Link to post
Share on other sites

New All Balls tapered bearings in the frame and triple, front end back on

20170610_221243_zpsv4huvqnc.jpg

 

20170610_183717_zpspbknv5cz.jpg

 

20170610_183832_zpszayrpci4.jpg

 

Pipe ideas...

20170611_115254_zpsxzudwqt2.jpg

 

20170611_115438_zpso6ejvg2f.jpg

 

I've got some of these on the way for the paint

20170620_121346_zpsnpyvlaa0.jpg

 

This is a sample of the paint. It's really hard to get a pic of the colors. The greens are both Toyota colors, Spruce Green and Army Green. The Spruce almost looks black until the light hits it just right. 

20170621_172805_zpsbzbofm9r.jpg

 

20170621_172817_zpsslvfwsqe.jpg

 

20170621_172839_zpst3lki2w4.jpg

 

20170621_172907_zpstxrobdgc.jpg

 

20170621_173006_zpsgq3ljsik.jpg

 

 

20170621_173152_zpsifsscs7t.jpg

 

20170621_173240_zpsbwmpsq3c.jpg

 

20170621_173313_zps9yhprskw.jpg

 

20170621_173403_zpsxoj5mdjh.jpg

 

20170621_173557_zpsfm4kldgk.jpg

 

  • Like 1

Share this post


Link to post
Share on other sites

Brake lines were once again an easy 15min phone call and less than a week's wait from Core Moto. Translucent orange hose, polished stainless banjos, gray tags.

20170622_162440_zpsufgi2lob.jpg

 

20170622_164300_zpsfv1wo50y.jpg

 

Core Moto has a great selection of colors and fitting styles. I was able to pick just the right bends for all the banjos so the hoses flow smoothly everywhere they need to, and the hardware they supply is super nice too. 

20170622_164343_zpslshjxdii.jpg

 

 

  • Like 1

Share this post


Link to post
Share on other sites

Puzzle pieces

IMG_20170624_174638_745_zpsinn4k4hx.jpg

 

20170624_182134_zps8wyuutfo.jpg

 

20170624_182212_zpsttxm1u8w.jpg

 

20170624_190211_zpsjcth0kb3.jpg

 

20170624_190227_zpsujnoy6bz.jpg

 

Kickstand is back on too

20170624_173819_zps2srpkoh0.jpg

 

20170624_193828_zpsboy2s5rm.jpg

 

IMG_20170624_212954_826_zpsf85fkgpv.jpg

20170624_231108_zpsdrxh53tl.jpg

 

 

20170624_231134_zpsxlqac3r5.jpg

 

Baffles

20170624_231022_zpslnszrsou.jpg

 

Slip fits made possible by hacking this shit apart

20170625_000018_zpsx8rz8isc.jpg

 

20170624_214058_zpszaqqto9m.jpg

 

20170624_232437_zpsothjtqjk.jpg

 

20170624_233026_zpsqt2sxhcz.jpg

 

20170624_235407_zpsdhj8jso1.jpg

 

20170624_235318_zpsfzv4agmn.jpg

 

20170624_225605_zps21pmrmit.jpg

 

20170625_011109_zps3uqnwnq7.jpg

 

  • Like 1

Share this post


Link to post
Share on other sites

Damn! Nice work Seb. The only thing that frightens me more than your talent, is the K&N oil filter on the motor!

  • Like 5

Share this post


Link to post
Share on other sites

20170625_011123_zpsvl9t6okv.jpg

 

20170625_011139_zpsyvccmlnm.jpg

 

20170625_011246_zpsvp6osfhn.jpg

 

20170625_011214_zpstamd9fev.jpg

 

20170625_011425_zpssxd5tm4u.jpg

 

20170624_230830_zpsysoohz3l.jpg

 

20170624_230926_zpsni77uxnz.jpg

 

20170625_002225_zpsdtfltluq.jpg

 

IMG_20170625_004130_207_zpsu4zovglt.jpg

 

Final assembly on the cans. 

Brushed the tubes with 100grit paper

20170701_131821_zps9wwxvic4.jpg

 

Then trimmed the perfed cores to length

20170701_141044_zps1tqiysgn.jpg

 

Tacked on inlet reducers

20170701_143534_zpseksjqsi5.jpg

 

Wrapped the cores with SS wool

20170701_145146_zpsydrz1gww.jpg

 

Inserted cores

20170701_150412_zps7bfy3k4c.jpg

 

20170701_150446_zpsx6jhpddq.jpg

 

 

20170701_170338_zpsvwfffe6f.jpg

 

Tacked in my connector spacer things

20170701_170741_zpskamvft1s.jpg

 

20170701_171859_zpswssqrzz9.jpg

 

20170701_195555_zpsq3yzfytf.jpg

 

Inlets are a little funky, unequal length to make tying in the tubes easier. I used silicon bronze for something different, and to build up a bit of material at the joint. 

20170703_150715_zps6cv6rwqg.jpg

 

On the shorter one, I actually had to resize an oem inlet to fit the 2" tube. A few slices and a squeeze and GTG.

20170703_155310_zpsvmot0eoe.jpg

 

20170703_161923_zpsjohaysud.jpg

 

All done.

20170703_164133_zps5hoefbjt.jpg

 

20170703_163945_zps7uy7urrg.jpg

 

 

 

20170703_164054_zpsrczticgj.jpg

 

20170703_164120_zpsbfwybapl.jpg

 

  • Like 1

Share this post


Link to post
Share on other sites
Just now, Duc2V4 said:

Damn! Nice work Seb. The only thing that frightens me more than your talent, is the K&N oil filter on the motor!

 

Keep looking, it was taken care of! LOL 

 

I run Bosch filters

  • Haha 1

Share this post


Link to post
Share on other sites

Next up, I had to firm some things up to allow me to run the joiner tubes properly. Can't have a bunch of play when trying to do precision work!

First I tacked the rear down tubes. The clamped joints will be welded solid, the slip fit will move to the merge collector.

20170703_170540_zps47hrnzh0.jpg

 

Next needed to hang the cans. Got lucky and was able to re use another piece of the Delkevic donor header. The bracket that was the bump-stop for the (now non-existant) centerstand became the hanger for the cans.

20170703_185331_zpscsms3zsf.jpg

 

It did need a small filler piece added, but what's another weld at this point?

20170703_185137_zpsrqcmwgaj.jpg

 

20170703_185429_zpsmsrdgpqb.jpg

 

Now I can start adding joiner sections. Front bank routing will be pretty easy

20170703_185828_zpstxj8hzwn.jpg

 

Rear bank not so much

20170703_185659_zps1fpvrwv0.jpg

 

IMG_20170703_193442_238_zpsax7hmd81.jpg

 

Just a little slicing and dicing...

20170703_223348_zpscsoz2fze.jpg

 

Think I got'er

20170703_230803_zps4e4gb5go.jpg

 

20170703_231926_zpshv5nhw6r.jpg

 

20170703_231002_zpsoco51yjq.jpg

 

On to the front bank... would have like to do this just a bit different, but I cut myself a little short on material and didn't want to wait another week for one more section of bend to show up in the mail. So I reused another Delkevic piece, the one I cut the bracket off of. I'll clean that up later. 

20170704_015541_zps4o1ul0p4.jpg

 

I was able to fuse most of the pieces in place, but as I don't have any fancy tubing clamps, the pieces move a bit when tacking and I ended up taking it off so I could tweak the pieces back by hand before fusing them up for good. 

20170704_011753_zpswhn1nl8u.jpg

 

20170704_011706_zpshankpwuz.jpg

 

20170704_032021_zpshp8dgmua.jpg

 

Exhaust done :)

IMG_20170705_222641_199_zpsjvjawkhs.jpg

 

20170705_135603_zpsfyll2rqs.jpg

 

20170705_195639_zpsnjlvu5ts.jpg

 

20170705_195610_zpslv8yk2kk.jpg

 

20170705_195405_zpsvnfntpfb.jpg

 

20170705_195601_zps9uvypniz.jpg

 

20170705_201520_zps1evo87uq.jpg

 

20170705_195241_zps3dfzzz7d.jpg

 

IMG_20170707_192857_887_zpsvktzi44u.jpg

 

 

  • Like 2

Share this post


Link to post
Share on other sites

Join the conversation

You can post now and register later. If you have an account, sign in now to post with your account.

Guest
Reply to this topic...

×   Pasted as rich text.   Paste as plain text instead

  Only 75 emoji are allowed.

×   Your link has been automatically embedded.   Display as a link instead

×   Your previous content has been restored.   Clear editor

×   You cannot paste images directly. Upload or insert images from URL.

Sign in to follow this  

×
×
  • Create New...

Important Information

By using this site, you agree to our Privacy Policy.