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Discussion Starter · #2 ·
Paid $1500 for the bike originally. So far to date I've only spent $31 out of my pocket other than the initial price. Sold the stock sporty take off parts to get me to this point. Most the other bits were just sitting around the shop collecting dust

Cost list as of today
Bike $1500
Front motor mounts $28
1.250 tube caps $10
04 gsxr1000 rear caliper $28
04 gsx750f rear rim $50
gsxf cush drive $15
TL1000s top triple $20
Fox MTB shock $80
 

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Discussion Starter · #3 ·
Tires came in yesterday. Need to mount them still. Wound up going with the Battlax. Never ran em so we'll see how they go



And started on making the handle bar. Piece of 1" tube I threw some knurl on real quick. Need to throw some bends in it and then step it down still

 

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Discussion Starter · #5 ·
Been working on the handlebar this week, bit by bit. Threw a couple degrees bend in each side



Then started working on the ends. Needed to step down from the 1" to .875". Turned a piece up tube down to fit the main bar and cut plugs for the ends



Plugs welded in and cleaned up, drilled for bar end mirrors ( need to tap ) and switch housing location holes drilled



 

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Discussion Starter · #6 ·
Fitted the bar ends with some switches, Busa masters and CRG levers




And threw them in the main bar on the bike




Gotta sort some angles so I can final weld the bars into 1 unit. Wires will be run thru the bar eventually and down thru the stem for a mostly hidden look. At least that's the plan at the moment.

Set of TL calipers up front also. Going to need to order some brake lines

 

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Discussion Starter · #7 ·
Been needing to sort the rear axle adjustment out. Lots of things needing to be done out back but cant because this bits not done. Racked my brain for a nifty idea and scoured the net for pics. In the end I decided to go simple and just use a bolt with a threaded bung I'll weld to the side of the axle plate. Did spring a few coins though and got these instead of a plain bolt



One thing that I was dead set on for this bike was the ability to carry a passenger. Means I needed a fender of some sort so I ordered that while I was spending. Came from the same place and got me free shipping so why not. No where close to ready for it yet, but threw it up for ideas. I highly doubt I'll use the entire length of it as its a bit much. May chop some up and make a front fender also.





The curve of the fender is about spot on with this tire. I was really worried about that and measured a ton, but knew it would be closer than any attempt I would be able to make

 

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Discussion Starter · #10 ·
Originally I hoped on running the rear caliper somewhere like so with a couple solid mounts right off the tubes



The sportster rotor was quite large ( 11.5" diameter ) and it might have worked. But this rotor isn't and so its going to hang under something like so. Without the fancy yellow tape of course

 

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Discussion Starter · #11 ·
The laser is tied up at work for the next week or 3 with the holidays rolling in. I could draw this bracket up and wait but I dont much want to. Got a ton of other projects waiting to be done. So we'll go at it a different way and maybe get it done a bit faster



Layed out the 3 main points and a bunch of other lines eventually made this



Trying to decide how I'm going to keep the caliper from spinning now so I can finish carving the bracket. I could weld a small slotted bracket to the frame that the caliper bracket would bolt to. A short brake arm is also an option

 

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Discussion Starter · #12 ·
Finished cutting on the caliper bracket. Might come back at a later date and hog out the center of it and I may not. Also made the frame tab



There was about .750 space between the brackets. Made this threaded deal to fill the gap



And glued together on the axle spacer

 

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Discussion Starter · #13 ·
Calipers hung and frame tab is tacked on, chains on and wheels aligned to the backbone. I can happily say I now have a roller :party-smiley: I still need turn a .250" spacer to get the front sprocket in line with the rear though.



Threw the fender back on to start getting a game plan for it. I'm not sure but considering chopping it flush with the top tubes. Maybe thin the sides a bit so its not as beefy looking. There isnt enough room to run the fender all the way down without removing the side for chain clearance. Seems pointless at that point for the extra work



 

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Discussion Starter · #14 ·
Ordered a front sprocket Monday. Turns out there wasn't enough available splines to simply space the one I had out. It should be here by the weekend so I can get that on.

Haven't made up my mind about the fender length either. Actually haven't really thought to much about it to be honest. Busy with the holidays rolling in and all that fun. Length aside, I still needed a way to mount it. So that's what I've been working on here and there at work. This is going to be the frame mount right behind the rider seat. Bungs will be rotated down so they wont be seen







Here's the start of the bracket that will weld to the fender and bolt to the above tube.

 

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Discussion Starter · #16 ·
Over a month since last update and ......

I ordered a bolt


I have also done a ton of doodling trying to get the fender bracket idea from my head onto this bike. Luckily sharpies last a while and I have a good supply of paperboard because most ended up in the trash bin. These 3 though are the better of em







Last one is a little dark but it's the one closest to where I'm going. Brackets going to wrap up over the top of the fender and tie into the other side
 

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Discussion Starter · #17 ·
Got the mounts drawn up and had them burned out a couple days ago. Also have this seat pan though I'm not 100% sure I'm going to use it. Its a bit narrow I think, but will work good for mockup



Tapped the axle plates so the fender will bolt through from the inside hiding the bolt. I may have jumped the gun a bit today and went ahead and threw some roll in the brackets. Should have drilled the holes first but Im trying to get this fender done so I can put the bike back down on the ground. Hard to visualize much when you cant see the side profile of the bike



Starting chopping up some 1.750 stainless pie cuts for exhaust today also

 

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Discussion Starter · #18 ·
Woke up to a rainy sunday. Decided it would be the perfect day to get some shop time in since I was stuck indoors. Had a fender that needed to be mounted and a little 4wheeler project needing some attention, so it was perfect.

After a bit of thought I ditched the over the fender bracket idea and opted for a simpler smoother transition. A little cutting here





A little welding, heating, shaping, smoothing and the end result wasn't to bad. Actually quite pleased with it. The sides flow into the fender quite nicely.



But when I stepped back and tried looking at the entire bike as a whole, it didnt look quite right. Looks nothing like I seen in my mind. Its too bubbly and curvy. Doesn't match the rest of the bike and kinda makes the bike look soft. Even with speedholes drawn all over it doesn't change



Told myself I'd think about it before starting over. Thats a lot of time to scrap. Guess in the back of my mind I already decided though as I made a set of fender strut bungs today

 

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Discussion Starter · #19 ·
Version 2.0. Much happier with how this ones turned out even though its not far from what most already do. Sometimes simpler is better I guess and it's definitely strong enough for a rider to sit on if the situation ever rises. Tried to keep the welds as small as possible also so they weren't as noticeable.











 

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Discussion Starter · #20 ·
Been working on this bike a minute here and there when I can. Cant seem to find time to actually do any serious work except at work

Made some stainless spacers for the shock. The ones on there were a bit skinny for my liking





Picked up this little piece for the seat also. Couldn't find any scrap brass and by the time I bought the piece needed I'd have been in for almost the cost of this part, plus I would have to machine it still



Cope was a bit off but that was a simple fix



Couple quick tabs



and the seat pan now hinges



And mounted on the bike. I've played with a bunch of different seat angles and this is what I'm thinking. It's nice to be able to finally sit on the bike and see how it feels

 
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