luigi

Hi to all!!!

I'm back to continue the work!

Ciao, Luigi.

I'm confident in the welders professionality (and in their patience.. )

This is the first forum where i post news about my project, don't worry!

Ciao, Luigi

Io ho iniziato questo progetto molto tempo fà con l'unico obbiettivo di realizzare una versione quanto più possibile adatta alla pista.

Di consguenza peso e manoggevolezza sono entrambi due fattori che fanno parte delle realizzazione di questo progetto.

Non ho dei valori di riferimento, anche perchè il trasformare una VFR 800 del 98 in una racer comporta già un notevole lavoro anche solo per avvicinare questo punto di arrivo. Dei numeri si potrà parlare solo in seguito.

La superficie radiante è stata aumentata a prescindere dagli eventuali interventi previsti sul motore (che comunque avrei in programma).

L'aumento della superficie è stato anche un "obbligo" per il fatto che, spostando i radiatori frontalmente, lo spazio a disposizione mi ha costretto a sfruttare ogni centimetro disponibile. Considera poi che ho rimosso il radiatore dell'olio sostituendolo con uno scambiatore di calore di un CBR, quindi un certo aumento dell'efficienza del sistema di refrigerazione era necessaria. Inoltre dalle voci raccolte nei vari forum, l'aumento delle temperature del VFR usato in pista è un fatto diffuso, quindi ho pensato di dare una bella "ripensatina" al tutto.

Tieni presente che il VFR che ho usato come base è un mezzo che ho acquistato incidentato e radiato, quindi non è assolutamente previsto un suo uso in strada.

Se hai già qualche foto del tuo progetto pubblicale, sono sempre interessato a vedere progetti di personalizzazione, anche solo di estetica.

Ciao Luigi.

Complimenti Luigi. Gran bel lavoro, soprattutto i radiatori, mi affascinano.

Grazie!

Purtroppo proprio il radiatore inferiore mi sta dando un pò di lavoro.

Infatti con la larghezza che aveva nelle foto che vedi e per la sua posizione, era certo che alla prima piega toccasse terra, perciò lo sto modificando nella parte bassa rimuovendo uno dei due elementi originali che lo componevano, applicandone uno più stretto. Ora tutto il blocco non sporge più.

Una volta eliminati due piccoli trafilaggi dovuti alle numerose saldature (d'altronde sapevo di questo rischio) posterò la nuova conformazione.

Ciao, Luigi.

Luigi, here is a link to my thread, because it's easier than....

http://www.vfrdiscussion.com/forum/index.php/topic/76261-vfr8-streetfighter/#entry916303

Very interesting, keef.

Now i've gave a fast sight to your thread, but i will keep for me some time to read it with more attention.

Honestly, i never tought to the Suzuki TL / SV radiator for my mod. I always keep the OEM radiators the starting point for the work, but i i see that many other coolers works great. My first goal is have cooling power enough to control the engine heat and the oil temperature in that hard situation that is the thr track use, where VFR often shows his limit with cooling.

Good to see you still working on this thing, Luigi!

Thank you Phantom.

I had many reasons to suspend the work, but the dream to see her running is always alive.

Hope to finish everything for the next racing season. In Italy there'a a class where the VFR can start...

Thanks Switchblade.

Hi.

Yes, the water leakage is the great doubt abou this work, but i'm confident in the welders experience.

I have no idea about dimension and shape of the TL1000R, but could be interesting some pics!

Thank you slowbird i'will keep you all update.

Ciao, Luigi.

Hi to all.

I know, it's an old never ending story about this project but, since i never lost the hope to finish it, i restart the work to have a 5th gen VFR to use for track days.

So i would like to show you the latest modifications on the exhaust system, the front fork and the cooling system.

As you can see i've installed the two complete fork legs coming from a 2008 Suzuki GSX-R 600 (i know that in US there's many VFR that uses the VTR SP fork, but in Italy this kind of suspension are not so easy to find used and the price are anyway expensive.) The clamp are designed by me and are manufactured on CNC. The clamp offset are reduced to 30 mm from the stock measure that is 37mm.

This is the exhaust system routing. The pipes are finished but the compensation chamber are still incomplete. Below, on the right, the main cooler, made by the union of the two stock elements and mounted in front position to have more cooling effect. Above, always on right the additional cooler, made by the union of two scooter Honda coolers.

As you can see, this cooling system solution shows a problem, the main cooler low edges surely go to scratch at the first lean angle, so i studied another solution that show you later.

I've choosed to remove the oil cooler, instead i've installed the intercooler used on the CBR 900 (i don't remember the year, it seems the 93 but i can fail) To have more cooling effect, since the water have the additional charge to cool down the oil too, i tought to mount a supplementary water cooler in the same place where the oil cooler was placed.

This is a schematic compensation chamber description. This i the solution that i found to have all four pipes with same lenght and have one junction point. I respected the stock pipe leght (around 670 mm). The view point of this drawing is the "front wheel" point of view seeing to rear of the bike.

This is the main cooler, obtained by the union from the two stock coolers, here are just positioned...

..and here the final result once completed. This in theory why, as you seen this cooler is too height, so i tought an alternative solution that is

...this. This is just an example, created with Photoshop. The final cooler anyway will be very similar. Conceptually i will use one stock cooler and one that is again the Honda scooter part, united with alluminium sheet formed. Once created and mounted i will post pictures.

This is the sequence followed to obtain the supplementary water cooler. Two scooter Honda coolers with removed all fixing points, hose joints and the two central "shoulders".

The final step. Red line shows the welding to unite it. After, in the low side, cooler was be holed to apply the joints for the hoses to connect it to main cooler.

That's all, for the moment.

Ciao, Luigi.

Hi to all.

Please, is there someone that can post some pictures (or link) of the new VFR 800 without fairing?

I need to see the new location of the water coolers. I have an idea to copy this mounting solution on a 5th generation, but i need some images to have a starting point for the work.

Thanks to all.

Luigi.

If you've made a change, would you be so kind as to tell me what the change was, and how you feel about the results. I'm hoping to be able to do a simple conversion...

Hi to all.

For what can worth my experience, in these days i'm in progress with the substitution of my 1998 VFR 800 front fork with parts coming from a 1995 CBR 600.

Is a simple work why is possible the tubes substitution only, maintaining the original VFR external case, that means no CBS brake system modification.

With just same kind of work required for the fork seals substitution, installing the CBR tubes you will have the useful compression setting on the fork taps and a longer spring setting.

The mod will be completed by a linear spring rate kit instead the progressive OEM equipment.

All parts dimensions are parfectly the same except for the tubes lenght (CBR's are bit longer than VFR's), but this just means a different ledge from the upper triple.

This is an entry-level conversion kind; obviously a front end swap with an upside-down fork can be much performing, but much more expensive, because if your idea is an USD fork, is better to choose a full setting model and not a simple "inverted" fork with no possibilities of settings.

Ciao, Luigi.

Great job Veefer! Really, really nice idea and crafting.

Luigi.

I would put money on it being almost exactly half the weight of the VFR piece.

I think It would be a great result!

Good to see the project moving along Luigi...

Thank you.

..hope you're doing well physically?

Sorry Phantom but i can't traslate well. What do you mean? Maybe about my crash?

I have a 600 f4 unit that I just weighted. This was with the axle, spindle, brake caliper and mount , chain adjusters and a little dirt. 16 lbs.

16 lbs, hence little bit more than 7 kg.

Thank you.

Hi - This has been a fun thread to watch. Good luck Luigi. :fing02:

Thank You! :biggrin:

...how much does the 900RR swingarm weigh?

Hello.

I not weightned swingarm yet since i'm late with work and i prefer finish the bike for the season, so i can't answer you

Keep in count that with this mod i can eliminate the heavy steel rear axle that alone weight not less than 700/800 grams (1.5 / 1.7 lbs, if i correctly converted) and all other swingarm parts.

More don't forget that the VFR swingarm are almost completely made with cast fusion with thick walls, consistently heaviest than the CBR, made in alloy sheet and profiles welded. Handling it i can feel a great difference but at this moment i can't tell you a number. When i did the mod i'll post all weights for sure.

Weight reduction is not the only goal. I'll have a consistently wheelbase reduction wheter CBR swingarm is shorter, than to install it i 'll made a C-style cut in the pivot spindle passage to adapt it to the VFR cranckcase.

Maybe this can be a source of handling problems, 'cause this means a whole bike weight balancing upsettings, but i'll work to solve it.

Like you understand, this bike will never ends (i live near Milano and here a work of this kind can be designated like "it will never end like Milano Dome"), but i have great fun anyway...

ciao, Luigi.

Hi to all.

Slower than the expectations but work are in progress.

Last works to finish:

- wiring harness simplified

- rear brake lever modification

- new exhaust

- rev counter and water temperature better positioned

- fairing and rear tail

Once the bike have made first laps on track new modifications are in project:

- complete 2009 Suzuki 750 GSXR front end with upside down forks, radial brake calipers and radial master cylinder.

- 2000 CBR 600 F4 front wheel with 1999 CBR 1100XX brake discs (310mm diameter)

- 1993 CBR 900 rear swingarm (much lighter than VFR stock) with 2000 CBR 600 F4 rear wheel.

- an engine modification that i talk you about later (when i'll be sure that is possible)


Ciao, Luigi.

is what steering stem is used on the conversions. I saw that the SP1 stem works, but is that the only option? Are there any others that can be considered from others'...

Hello.

I can tell you that many Honda stems are the same which VFR uses, perfectly the same.

On my "track use VFR" that now fits a GSX-R 1100 conventional forks i have used a stem coming from a 1987 CBR 600 (in USA called Hurricane) inserted in the Suzuki lower clamp.

The only modification required is welding a "lip" in the lower edge of the stem to lock the two parts once everything in assembled.

Like the VFR this stem are in one-block with the lower clamp too , but it's enough remove the welding joint with a lathe to have a stem that can be used on great number of lower clamp.

Here' the pictures:

1987 CBR 600 Stock clamp - Bottom Welding.jpg

This is the bottom of the 1987 CBR 600 lower clamp. Pencil shows the welding.

1987 CBR 600 Stock Clamp - Welding Removed.jpg

This is the stem after the welding removed. To extract it i've used a common workshop hydraulic press.

CBR 600 - VFR 800 Stem comparison.jpg

The CBR stem compared with a 5th gen VFR 800 lower clamp. Absolutely the same.

Note at the CBR lower edge the "lip" welded to assure the complete fixing once the stem are inserted in Suzuki lower clamp that i've used.

11th March 2009

Here the GSXR 1100 front fork installed.

Ciao, Luigi.

Post is below

Each of the four plastic tubes are connect to the vacuum lines from each cylinder. Each cylinder will exert a force on the oil in each tube. Essentially, the cylinders are playing a game of tug-o-war. Whichever cylinder is creating the most pressure will "win" and pull the oil in it's tube higher than the other cylinders. Our goal is to balance the starter valves so each cylinder is exerting the same amount of force, and therefore getting the oil level in each tube to be the same.

Thank You! :fing02:

I'm going to bulid a 4-column mercury vacuum meter and last doubt about was " i need a direct communication with open air or not, more than the four connections to the throttle body ?".

Your project answered to this question.

Ciao, Luigi.

Thanks Luigi! Now I need to go measure my CBR600RR swingarm again to see how far off it is!

OK.Good Job!

No worries, Timmy's a great Guy and Good Cop with a great sense of humor! :fing02:

:beer: OK. One beer of penalty for all the forum members :beer:

Timmy is both kind and nasty police! :laughing6-hehe:

oops, er.., ehm, :goofy:...what we was talking about? What's the weather in Carolina? :blush:

typical roads in carolina...

I just can dream this kind of roads, here where i live. :blush:

Myabe around the region of Trentino, but not so wide and lonely.

For the common italian sport riding style you rode too much road behind the pick-up.

This why you are gentle and kind rider or because police is nasty? :laughing6-hehe:

Ciao, Luigi.

Nicely done. I've always thought that if I ever got into riding on the track, I'd like to do it on a VFR - as the skills and bike characteristics would be able to transfer to the racetacks of North Carolina, I mean the roads of NC......

:fing02:

Thank you.

I need to know as soon as possible the VFR potential on track against the newest HyperSportster.

I'm sure that if i find the right suspensions (not the OEM, obviously), with a correct setup i will not eat so much of their dust...

Anyway, i don't know the North Carolina roads, but knowin mine roads i prefer to wait the end of the work to test this capability....

ciao, Luigi.

i love it. more please.

Just some weeks of wait and i will post picture of the bike completed. Without fairing, but complete and maybe with a .mp3 with exhaust sound...

Thanks to all, Luigi.