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ZUK ATTaCK
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2,957 Posts
Discussion Starter · #1 ·
Here we go fellas -

Inspirational quote I found that I dug to get it rolling...

"This man beside us also has a hard fight with an unfavouring world, with strong temptations, with doubts and fears, with wounds of the past which have skinned over, but which smart when they are touched. It is a fact, however surprising. And when this occurs to us we are moved to deal kindly with him, to bid him be of good cheer, to let him understand that we are also fighting a battle; we are bound not to irritate him, nor press hardly upon him nor help his lower self." - John Watson


Plans -
Alum Tank/tail/shroud/fender
r1 rear and front suspension - 5 spoke wheels
1127 kat motor - velocity stacks(if I can tune em) with gsxr cam(s) and custom muffler
billet triples/risers
Old ass headlight with HID set up
Braced frame
Alum subby
Dirty bars
Aftermarket oil cooler with AN - fittings
Prolly other stuff as I go

Pics:

How she sits today -


The frame has been drilled to accept the r1 swing arm pivot bolt. And I chopped off the old subframe/suspension mounts prior to today.



Motor -




r1 pivot bolt, rethreaded and cut off with new SS nut machined out of 303 stainless.



Random bits -



So there it is, wish me luck figuring out how to bang this alum out.

Nate
 

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ZUK ATTaCK
Joined
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2,957 Posts
Discussion Starter · #2 ·
Threw the motor in. Seriously easiest motor swap ever.

Swingarm on too to check how much work there would be to get the sprockets and wheel to line up. Pretty close on first try. Might need a small spacer for the front.

Looks nice and meaty in the slabby frame -





Nate
 

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ZUK ATTaCK
Joined
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2,957 Posts
Discussion Starter · #3 ·
Gonna need an offset front sprocket - anybody have a source for them for 1127's? Lemme know in the discussion or pm!

Well upon some research, looks like the output shaft splines are all the same for the old oiler's to the newer stuff? So I should be able to pick up a 1/4" offset sprocket for a 1000 or busa and it would work?

Nate
 

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ZUK ATTaCK
Joined
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2,957 Posts
Discussion Starter · #4 ·
Boring update but with pictures -

Making a bowl in a stump for metal work -



Wood slapper w/o leather yet -



First try after some annealing, some hammering, some planishing, a little wood slapper-ing and some sanding. Just a test piece to see if we can get the polish nice without an e-wheel. And some patterns for frame bracing/boxing.



Oh and thanks to Piester for figuring out the sprocket situation, should be pretty easy.

Nate
 

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ZUK ATTaCK
Joined
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2,957 Posts
Discussion Starter · #5 ·
Got to work on the subframe mounts -

cut some alum out of the chunk.


Faced and layed out




More metal working tools -


Piester sent me a 520 offset front sprocket for shipping costs - what a fella!


set of headers from escort1991 -


So still some designing to do on the subframe mounts. Waiting on my triples to get finished to settle the rear wheel/swingarm in the frame and then I need to make mounts for the rear suspension. Then make a spacer for the swinger. Then it'll be a roller and can work on aesthetic stuff. I want to use square tubing(i think it'd go better with the boxy tubing used on the frame/swinger) for the subframe but it might prove to be more trouble than it's worth. Waiting on a paycheck to buy more alum to use for boxing the frame in. Thanks for looking!

Nate
 

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ZUK ATTaCK
Joined
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2,957 Posts
Discussion Starter · #6 ·
6 hrs later and I've got one mount finished?! Or close to finished. Here are some pics -









I'll prolly break the corner a little to flow better. Going to make a boss to weld the subframe too that will have the bolt head buried in it. Turned out pretty well for my first machining attempt.

Here is the test piece after more and softer planishing for the tank/body work alum.



Looks much better now and I may be able to get the finish I want.

Thanks for looking!

Nate
 

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ZUK ATTaCK
Joined
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2,957 Posts
Discussion Starter · #7 ·
"Finished" the subframe mounts. Prolly gonna knock off that top corner.





Rough cut out pieces for boxing the frame in.


Swinger set at 12 degrees when the frame is level.


Waiting on the triples to be finished to get the wheels/swinger in the frame finally. Tons to do but waiting on some money to come in to buy supplies. Made a stand for the engines too...not pictured.

Nate
 

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ZUK ATTaCK
Joined
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2,957 Posts
Discussion Starter · #8 ·
Kinda ghey update. Birthday dinner tonight, family bought me a new lens for the camera.

Nifty 50mm for the cannons. Super pumped about it. One of those things you always wanted but never had the spare cash to buy.

Pic of the new box with the old lens -



1/35 shutter sitting on a chair.

New lens, sitting in my hands at 1/500, shit light of the cheesecake my bro made for my b-day lol, serious -



Gotta buy some filters before I use it in the shop.

Nate
 

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ZUK ATTaCK
Joined
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2,957 Posts
Discussion Starter · #10 ·
Started work on the clutch cover bits -










and got some metal in for the subframe/bracing -



I also ordered the left over stuff to get the swinger/rear wheel set for sure. Triples are supposed to be done soon too.

Nate
 

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ZUK ATTaCK
Joined
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2,957 Posts
Discussion Starter · #11 ·
Welder is bollox'd. Dropped it off at the place we got it from gonna be two weeks to see if the board is messed up or not - might be expensive to fix. We'll see.

Nate
 

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ZUK ATTaCK
Joined
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2,957 Posts
Discussion Starter · #12 ·
Got some bits in the mail, trying to wait for the triples to be finished, but not yet.

HID Headlight bits from theretrofitsource.com - Top notch blokes over there. Seriously nice set-up and easy to wire up. We'll see if I can fit it in a housing.



Then I got the bottom shock mount "done" - Gonna round out the end of it for ground clearance. Let me know if it looks bollox'd or if it should work.





Nate
 

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ZUK ATTaCK
Joined
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2,957 Posts
Discussion Starter · #13 ·
Welder is back. Got the old man to tack some "frame boxing" pieces in. He's got the touch for it, I'll weld some on the body work, but the structural stuff is all him.











Welded a machined plate to accept the bottom shock mount and brace that crossmember as well.




Crossmember at the top of the frame, then there will be one connecting the two for the top shock mount.



Then started machining the top shock mount. Hoping to get the frame finished in a couple weeks here, still need rearset mounts and oil cooler mounts.




I've got the wheel centered in the frame using a center finder on the neck, then connected to a straight edge that is centered on the wheel. It's within 1/64th of an inch at the rear wheel. Is this close enough to run straight? or should it be dead nutz straight? Thoughts?

Nate
 

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ZUK ATTaCK
Joined
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2,957 Posts
Discussion Starter · #14 ·
Got some shit done.

About 40 hrs of mill work lol. Noobie-time.



That look ok? Seems good, but no weight on it yet.





Tried to make the filler plates for the neck piece out of 1/8". But, it turned out to be too stiff to fit it in there right. Used the sheet 3003 alum and that worked out much better.





I think I'm gonna cut some out of this upper shock mount, maybe put a hole through the top and some design cuts on the sides before its welded.





Thanks for looking, input welcome.

Nate
 

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ZUK ATTaCK
Joined
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2,957 Posts
Discussion Starter · #15 ·
Got the bitch welded up. Had to pre-heat the shit out of it. Nice work - big thanks Dad! - since we have a bit of too small of a welder/shop wiring to weld something this big.

The headlight I'm gonna use and my new oil cooler came in the mail too(not pictured).

Still need mounts for the subframe, oil cooler and rearsets to be finished/made/welded. Gonna put the motor and swinger/suspension on tomorrow to make sure everything still fits - *crosses fingers*. Triples should be done next week, but it needs a longer stem since they are larger(top is) so it'll be an extra week yet. Then I can start banging out alum.

Pics:











Comparison shot for the whole thing -



Pic of that top mount with some cosmetic mill work -



Sorry for the wobbly shot there.

Nate
 

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ZUK ATTaCK
Joined
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2,957 Posts
Discussion Starter · #16 ·
Got something done today too! lol -

Just piecing together the muffler




Then put the motor/swinger/rear suspension in. Everything still fits. Woot. Gonna start doing electrical or finalizing the sprocket/chain situation.



Nate
 

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ZUK ATTaCK
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2,957 Posts
Discussion Starter · #18 ·
Working on wiring. Gonna get it to cranking or running? in its current state, then chop up the wiring and repeat. Waiting on some switches and wires/shrink tube to start chopping up the harness.



Oil cooler(ebay), 60's zuk headlight(ebay), and MOTY battery(dafizuck). Prolly only gonna end up using only the bezel and make the rest of the housing, but I liked the shape and old-ness of the headlight lol.



Nate
 

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ZUK ATTaCK
Joined
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2,957 Posts
Discussion Starter · #19 ·
Pulled some covers, and put one on. Then !FINISHED! the swing arm pivot bolt!!!! 03 r1 swing arm bolt, chopped up, then we made a nut for one end(re-threaded the bolt and internal threaded the new nut). Then made one of the same look on the other side and welded it to the bolt. made them out of easy-to-machine stainless round stock. Gonna make a tool to be able to torque the bolt correctly.







The ignition sensor cover looks kinda lame on the inside, and the starter gear covers aren't that exciting either, so I think I'm just gonna do a clear cover on the clutch. Can you powder coat that pressure plate thing w/o problems once installed?



Think I got all the wiring sorted, so gonna start chopping it up. Hopefully the triples will be done within the next week.5?!

Thanks for looking!

Nate
 

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ZUK ATTaCK
Joined
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2,957 Posts
Discussion Starter · #20 ·
Muffler "baffles" welded in -



Gonna prolly wrap the tubes with some fiberglass or whatever that stuff is before welding it up.

Welded the clutch cover. Going to do black motor with blue valve cover/clutch ring blah blah.




Got the AN lines/fittings ordered and my gauge set up. ALSO! got all the lights working and had it turn over WITH spark. So the wiring is good on the new motor, now I just gotta hack it up and make it fit in the frame.

Nate
 
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