redmarque

Thanks guys! :cool: it's a great feeling to finally hear the engine start and run! I'm wasn’t entirely sure on the motors history, only that it had done about 20k before being plunged at 30mph into the side door of a car… btw it was a true red VFR as one of the fairing stays had a small piece of plastic still attached! Motor sounds good though. I’ll post a clip of it running once I’ve sorted a few issues! Major Issues! Oil take-off on right side of the engine is leaking badly!! – order and replace o-ring Oil cooler union joints - replace o-rings If still leaking – make new unions using old oil coolers mounts. Thought I’d make a list of other things to do before road test! Re-wrap wiring loom Secure loom to frame / resolve issues where wiring is close to engine Wire in radiator fan Wire in PAIR solenoid Find / fit bolts to secure foot pegs to engine Thread lock all bolts suspension linkage front and rear Cut and measure earl’s brake lines and clutch line Route hoses and attach hose ends Measure and make caliper spacers Make bracket / mount engine stop tilt switch Weld on battery box rear mounts Weld on ignition switch mount Order /fit coolant system jubilee clips for air bleed to radiator As to bodywork I’d thought that a half fairing a bit like a Suzuki SV650 size would suit well? Maybe with some Britten influence? Fork legs definitely need fairing in. Quite keen on KTM’s RC8 styling with angular shapes and sharpish corners – should make it easier to make the fiberglass moulds? Tail section will have to be minimal and wrap around the underside down to the rear shock - Rossi M1 style. I’m thinking of cowling in the radiator as a separate piece to the top fairing too. New oil cooler o-rings are coming in Tuesday plus P-clips and spiral wrap for the loom. So sound clip soon!

Set the scene: Dr FrankenViffer's Lair it's dark and gloomy; a slight chill is in the air. Dusk has fallen Dust hangs in the light shed by florescent tubes. Energy is building as the 12Ah battery charges for 4 hours. Voltage now reads 12.9V Dr FrankenViffer patiently attaches the terminals using a 5mm allen key wrench. One last check of his subjects electrical connections.. all fluids have been added in the correct quantities. He apprehensively turns the key to the ON position…. 3 lights appear, one green.. neutral, first red, oil pressure then the last, FI Now the moment he has been waiting for… Gripping the throttle tube gently he presses the starter button… Vrroooommm! The throaty roar of a V4 IT LIVES!!!!!!!!

Cheers Seb, Ah yes, the bank sensor - the one we all hope never has to operate! I've moved it to under the fuel tank just behind the battery - havn't fixed it to anything yet, but it was upright last time a looked :fing02: I think the issue could be to do with the clutch diode circuits from the neutral light switch and clutch lever, so trying there first.

OK some more progress! Radiator and oil cooler are on. Re-routed the upper radiator pipe with an 90 elbow now that the rad is in a higher position. I'm pleased because it looked like scraping the floor if cornering hard before! Re-used the alloy pipe guide on the return pipe to keep it out of the way. PAIR system is going to stay until after VOSA SVA - they test emittions :fing02: Fan has been moved 6mm closer to the radiator and trimed the edges of the motor body so to get everything as close as possible. The new mounting brackets. Oil cooler view from right side. Oil Cooler is from a old CBR1000 nice to have 4row instead of the stock 2. Earl's oil hose and connectors. Earl's do steel bosses which I had welded to the stock engine take-offs Plugged the battery in and connected the loom together during the week - turned the key - nothing! now in the process of diagnosing what's wrong! - always thought the electrics were going to be the worst bit!

Wiring the beast.... ECU is now mounted on top of the airbox.

Spent some time re-welding one of the front exhaust tubes for a better fit around the oil filter, then re-wrapped and sealed the tape. Exhaust is an old CBR600F4 ART end can with modified link pipe. hanger's still to be made, but will be OK to test the engine. I like the MotoGP positioning leaves a nice empty area between the rear wheel and seat unit. Next step is to re-mount the radiator and oil cooler. Now that the linkage for the suspension is in place the radiator can be mounted about an inch higher than before. So many little details to finish! :fing02:

I had exchange of emails with Paul when I started the project, as I send him tips of strange bikes from around the internet. I'd rather wait until the bike can be ridden please! (as it would be very embarrassing if after all this it didn't work!) The front shock has a guestimated spring fitted and is over damped, but will be good enough test ride on. Larry Web owner of www.pdq1.co.uk PDQ Motorcycle Developments has recommended that I have a custom nitron shocks made once complete. (Larry worked with Norman Hossack on road based conversions a few years back) PDQ is also featured in the book Motorcycle Road & Racing Chassis: A Modern Review of the Best Independents Lots of lovely pics of frames if you like that sort of thing. :blink: Linky Amazon PS. I have a confession.... It was me who sent Paul a link to Toro's bike. :blush:

Hi Seb, that's a good idea - I thought I might turn up some black pvc on my 50's lathe to make frame plugs. Off to look at your Vf750f post for other ideas now! :blush:

I was an IT Manager of a small investment bank too - they joined it with 3 other businesses, hence redundancy :fing02: Ah! and I used to be a family man until the ex-wife did the dirty. Now I have my kids 9 and 4 year old every other weekend. So more garage time evenings and weekends. Here's a close-up of the "bridge" (It reminds me of one) frontend. Note the new scissor linkage Big thanks to all VFRD for the encouragement! :wheel:

Thanks Phantom! I'm not really worried about work yet as i've already got some part-time contract IT work lined up! :laugh: i've sand blasted the frame after recent mods them primed in black to stop it rusting. (also was fed-up at looking at browning steel!) I didn't think the financal outlay of powercoating was worth it yet. Tabs to hold the battery carrier, brake lines and bodywork mounts are still to be added. Once it passes the UK Single Vehicle Assessment and has a title the extras can be done.

To be honest progress on the hossackviffer has been very slow! :goofy: Life gets in the way of a good project! I've had to cut and move the rear suspension mounting 25 mm left and re-weld! Remake the frame - engine spacers Move and weld on coil mounts The steering scissor linkage has also been remade to allow for full suspension movement Notched out the tubes in the forks to allow for greater turn on the steering lock re-designed the rising rate front suspension linkage using a rear suspension dog-bone. Replace front shock spring and much more! BTW I've put the rearsets on hold until everything else is working! Hopefully I've got the time to get her running soon, as I've been made redundant last week!

Thanks for the complement! :pissed: Unfortunately I’m planning on a 1000cc V-twin version if this front-end is successful. Possibly in aluminum too. If you're still mad and would like to build your own PM me and we can discuss offline :fing02:

Frame and swingarm are going to be satin black - undecided on paint or powder coat? tank,bodywork and wheels in gloss black (always did like vintage bike look) Was thinking of sandblasting and lacquering the engine once it's been for a test run, should make a nice contrast. I've been labouring on the loom for some weeks now too :goofy: , it's been completely stripped and shortened. Standard connectors are being replaced with waterproof ones like ducati use. :musik20:

Yep totally agree 5th Gen pegs are grim! :fing02: Hopefully I will offer a group buy if anyone's interested after the first prototype set is made - i'll need to measure up on the 5th Gen rear master brake cylinder as this ones a CBR600RR one - also the banjos on the 5th Gen rear brake are hardlined to the Combined Braking System, so positioning maybe an issue. Cheers Dude! :goofy:

Projects hossackviffer's going a bit slow recently (5 weekends in a row with my kids) Meanwhile the both rearsets are in CAD. I've mocked up the design in 10mm MDF board. The 10 holes will be threaded for 6mm grub screws to allow the swingarm bolt to be recessed. Brake cylinder mount will be 6mm thick Ali. I've sourced rear Yamaha R1 footpegs which will need to have a slot cut though the middle for the return spring. Lever pivots will be bushed with bearing bronze to prevent wear.

Thanks for the encouragement! The hoses i've used are all made from straight sections and 90 degree beds from Ebay. 1" from thermostat to rad, 7/8 for the pump to cylinder heads and 1/2 for smaller bore stuff all joined with aluminium joiners and stainless hose clips. If you need to get a straight pipe to go around a curve. I fabricated a hose cover from sheet ali - i'll find a pic tonight to explain better. hope this helps! :biggrin:

My mistake! it's supposed to be the right side! from what i've done so far - Do you think you could make these Tok? :biggrin:

There very nice rearsets too.. Mounting on the 5th gen engine/swingarm would be interesting?

After much adjustment, fabrication and head scratching (standing and looking at the bike) :biggrin: I've finally got around to the rearset design! way way back last year I decided that the stock 5th Gen footpeg hangers look disgusting... The structural elements of standard 5th gen hangers are very good - especially using the swingarm pivot as a mounting point. But as you know there isn't any adjustment! I've tried various designs trying to allow for some forward and aft movement - none of which look any good! Here's attempt number 14 (left side rearset) It has height adjustment only - 3 positions at 36 degree increments. Brake lever in this pic is shown lower than final design so that it can be seen against the hanger Heal plate design is to be finalised afterward as 3mm plate aluminium can be easily fashioned by hand. Would most apreciate you guy's input! :fing02:

Wow! those are awesome! :fing02: :blink: :dry:

The other side... :biggrin: Exhaust system is coming along, i've modifed the front down pipes to miss the radiator and cooler. Early cbr600 pipes have that same size header tubes Stock pegs are a temporary solution until I finish the bespoke rearset design, also good to take measurements from for the rearset relationship to engine and swingarm mountings.

As requested a 'cockpit' view. My, what a mess! :fing02: I've modified the standard oil cooler take-offs to except earl's hoses Sanded down and painted the throttle body side plates Satin Black, will change out the standard bolts to stainless (shiny) Didn't realy like the huge standard caliper so i'm modifying CBR600RR rear caliper to fit above the swingarm - should keep the dirt off and look trick. I'd like to put the hose though the swingarm aswell

Thanks! :idea3: I take it from your username you aren't the 'one' then? Firstly i'm really no engineer! I started life with one of those father's who gave me technical lego and was a member of the Vintage Motorcycle Club! I left school at 16 and went to the local college to do a foundation in art and design - went onto Central Saint Martins College of Art & Design in London to study honors Degree in Product design. Somehow after finishing (spending more and more time with computers) I've ended up as a IT Manager for an investment bank! I had a lot of 'help' on this project but have tried to do as much as I can myself - I guess you could say I had a fair idea what to do, but only after reading Tony Foale's book and working with my now good friend from essex wheels and engineering. As for a kit? who know's? I'm pretty sure that it 'should' handle well, i've even thought about adding a steering damper! :blink: I can't wait to see if it works! :pissed:

Tony Foale experimented with this as well. Apparently not as weird as you might think. Yes that's right - the riders he tried it on got used to the change very quickly. Interestingly the old Ner-A-Car has a 3-1 steering ratio on it's centre hub steering http://thekneeslider.com/archives/2007/10/...r-vintage-fest/ It's seams that most of the 'new' ideas have been done way before! :idea3: