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Discussion Starter · #1 ·
Yet another imaginatively titled build.

Plans for this year consist of:
More aggressive styling - new headlight, subframe, tail unit. I'm thinking something pointy-ish;
full bare frame rebuild - bit more comprehensive than last year;
paint and powdercoat everything (no more primer and boat paint!);
modified swing arm and Fireblade rear wheel.

So this summer ended with the bike sitting as such:


I rode the tits off it all summer and loved it. Such a fun bike, even if the rear shock is seized up and transmits every impact directly up your asshole.

In the week or two prior to the build-off start date I'd started stripping the bike down completely.



Proof of date/starting condition:
 

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Discussion Starter · #2 ·
So after spreading the whole bike over half the garage and a few close calls i decided to tidy up a bit.


I'm going to get the frame and swingarm sandblasted at my work so that I can work from bare metal. Plus I'll see how bad the foosty bits of rust are. I made up a couple of blanks for the steering stem on the lathe in the tool room at work.


That's right, I'm now a pro latheologist. Hit me up if you need poorly-finished cylindrical objects made out of scrap aluminium!

Tonight I'll strip the swing arm. The idea is to get a wee bit done in the garage every day even if it's something totally minor.
 

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Discussion Starter · #3 ·
So the frame and swing arm were dropped at work for sandblasting on Friday. Should pick them up on Wednesday when I'm back at work. In other news, that's my apprenticeship over, so I'm now a qualified maintenance engineer. Yass!

After spending Friday night and much of Saturday half-crippled from the start of a big back tattoo, I pottered about a bit. My new bar switches arrived:

Along with some METALLLL!


On Sunday I started cleaning up the engine for painting. I won't be painting it for ages yet but thought I'd clean it well in advance and give myself something to do. Had a couple of goes with pound shop oven cleaner. Here's the before and after:



Better than I expected but still some stank on there.
I've never painted an engine so any tips? I'm not sure if there's clear coat on the block and head or not so should I fire in about it with paint stripper as well? Do i actually have to use VHT paint and primer?
 

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Discussion Starter · #4 ·
The engine is coming along alrighty, one of those jobs you regret starting immediately but it'll pay for itself:


And the new tail section finally arrived. And it's too big :oops: love the shape though:



I was already leaning towards making a girder style subframe with lots of box section but figured I'd take a chance on the KTM replica tail. Unfortunately it's too wide and it would be too much work for me to cut, narrow and shut so I'll go back to Plan A! At least that way it's ALL home made :D I'll try to put in a bit more effort into the tail cover this time around though.
 

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Discussion Starter · #5 ·
Well, that tail unit sold pretty quickly. Sorry guys :D I'm going to make a start on the new subframe tomorrow, weather permitting.

This one is sure to split the room..(in a rather one-sided fashion):


Building it up...


The rear height is all to fuck now but ta-daaa


I know it's pretty much nobody's cup of tea these days but I think they look cool. It's just the look I'm going for. Apart from the whole six foot high ass...I've ordered an R6 shock and suspension lowering link to try to bring it back into shape.

Edit: this is solely for mock-up purposes. The swing arm still needs de-tabbed and the caliper bracket-bracket cut and moved back.
 

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Discussion Starter · #6 ·
Put the new headlight on. It's only on using the rubber straps it came with but they'll do for mocking it up until I find some kind of nice brackets for them.


Next to my other long-suffering project!


And here's the profile shot:

I'm super happy with the stance. Once I lower the rear and if my plan for the new subframe works out it'll look super badass.
Spent a lot of the afternoon filling in the plugs on the swing arm:

Although my cack-handedness with the flap wheel ended up making them worse! I'm not sure even powdercoat would cover up the unevenness:
 

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Discussion Starter · #7 ·
The R6 shock arrived nice and quick. Went out to the batcave to offer it up and it only needs minor work doing for it to work. I need to take 1mm off this sleeve for the mounting eye at one end:


And make up a couple of little spacers for the bottom mount. I'll also need to file a little bit out of the shock/swing arm/dogbone linkage. No more reservoir cable tied to the frame!


(I've mounted it upside down for reservoir clearance reasons)
 

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Discussion Starter · #8 ·
Turned up a couple of spacers for the bottom shock mount. Also took 1mm off the upper shock mounting sleeve for it to fit the CBR frame. I'm telling you, all this machining work has me fending off bitches with a shitty stick!


I'm going to try designing a subframe end of this week. I'm thinking box section with lots of bracing, looking industrial as fook. Tough to get started when it's dark and cold by the time you get home from work though.


On the plus side, new contract at work comes with an almost 50% pay increase. Yass! More bike goodies :rock:
 

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Discussion Starter · #9 ·
Can't upload photos to imgur on my phone, but little update - the body of the R6 shock is fouling on the cylindrical part of the swing arm linkage (probably naming it wrong - I mean the bit that mounts on the swing arm and connects the dogbone and shock mount). I took notches out the sides but the base of the shock still fouls so I'm not sure what to do...might just use it to make templates and have one custom made to suit. Pictures to follow later to clarify my gibberish :D
 

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Discussion Starter · #10 ·
My lowering link arrived from the States. Despite shock clearance issues I half-assed everything together loose to see how it would sit.


I adjusted it so it was 1.5" longer than the standard dogbone as a starting point.


That's more like it! will probably sit a tad low once the engine is in though. That's the swing arm just about finished now too by the way.

One thing I noticed with that adjustable suspension link - it comes with sleeves to put inside the ball joints for the mounting bolts to fit through, and, well...


That's not a clearance fit - that's what I like to call an 'apprentice electrician clearance hole," for reasons I won't go into :D
I'll get new ones made up soon.

Also:

Box section subframe? Yay or nay? It's my current plan, although admittedly only for aesthetic reasons :speechless:
 

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Discussion Starter · #12 ·
Well, it's not the most elegant solution, but hopefully after a bit of filing and re-shaping it'll look standard:


Seems to be sitting nicely now, feels comfortable when sitting on it. Plus it looks pretty badass if I say so myself:



I'm tempted to start painting bits as I go, but I know that'll just mean it'll never get powdercoated or done properly like last time.
Got a long weekend so going to chop the subframe and start goofing about with box section today :rock:
 

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Discussion Starter · #13 ·
Choppy choppy!



Debating going with something simple for the subframe. Might look neat with something quite minimalist with the stretched swingarm. Maybe use some curved steel sheet to box in the joins and blend the legs in?


Got my lengths of box section cut and ready but it's dark and cold as balls so I'll get tacking tomorrow. Glad to get some stuff done today though.
 

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Discussion Starter · #14 ·
Got a decent bit done today.
Here's my daft-looking clamp setup to tack in the top frame rails in line:

If it looks stupid, but it works, it ain't stupid :D

Taped up the bottom supports to see how they lined up, then tacked them in:



I also managed to weld in the rear tank support from the original subframe. That bracket has seen some shit!
Slapped some matte black on to cover it with something, then back into the light:



Now to mess around with tail ideas. Had a few thoughts but nothing really jumps at me. I'm going to trawl the forum for some inspiration.

 

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Discussion Starter · #15 ·
I made up a pair of templates using aerospace grade cardboard that I absolutely didn't loot out of the bin:


And chopped up a 90 degree bend I had in square tube to make a pointy thang:


Tacked it up and stuck a template undertray on:



So the stubby pointy tail won't have room for my battery any more, which is completely intentional and not at all because I forgot to take sizes properly. But it might work to my advantage, 'cause the battery can go where the ICU sat previously:

And I can have a wee fuse panel and the ICU sitting inside the tail under a removable cover. I'll try to come up with some kind of battery tray/clamp for under the tank to protect it from road shite and keep it secure.
 

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Discussion Starter · #16 ·
Was out late the other night tacking in the seat backing. Spent about four hours with a hacksaw and files trying to get the angles right!

Slapped on some yoga mat foam I had lying from making the last seat:

It's a neat fit - I'll need to lay off the pizza for when it's done! Also, I think I need to angle the new bit back so it doesn't cut me a new arsehole!

Stripped it down to the frame so I can take it to my mate's place to get the subframe fully welded up with the TIG plant. Hopefully I can smooth the welds and plate up the lower legs for a smooth joint with the top rails.
 

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Discussion Starter · #17 ·
Splurged on eBay - relays, fuse panel, etch primer and engine enamel. The enamel arrived next day and I can't wait to try it. Hopefully I can prep the engine well enough for it to look alright once I figure out a way to suspend it.

Some sick Honda-on-Honda action:


The frame all welded up, ready to sand down some of the welds tomorrow:



I'm making plans to buy a TIG welder now that I'm on a new contract and rolling in the benjamins.
I also got new sleeves and spacers machined for the rear shock (out of steel, to replace my shady aluminium ones).

So I was looking at my bar switches and tried doing a little diagram - does this seem right? I've never really used automotive relays before. I'll hopefully have the fuses AND relays in the tail so I'd like to keep the wiring from front-to-rear of the bike to a minimum. Excuse my cramped writing:
 

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Discussion Starter · #18 ·
Been working on the back of the tail all weekend. Think it's pretty much done apart from mounting holes for the seat and tail light mounting, if I can ever actually find one...


If someone goes into the back of the bike, they're losing an eye :D

Stuck a couple of bars on it to bolt the seat pan through once it's made:



Thought I was done until I remembered I needed a base inside the tail for my electronic gubbins:




Ta-daa:



I still can't decide on a colour scheme either. So much to do!
 

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Discussion Starter · #19 ·
Roughed out a seat pan:

Got my new spacers and sleeves in. I love getting new bits made. The old shitey ones are next to the new items for comparison:

Seat pan still needs finishing at the front before I start laying foam on it. Like the stance though:


Having a night off tomorrow. Might try to finish the wiring setup I'm testing on the bench just to get my head round it before I start wiring the bike.
 

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Discussion Starter · #20 ·
Haven't done a great deal lately on the bike. Been letting new tattoos heal, doing some christmas shopping and ordering more stuff for the bike - got seat foam and vinyl coming so hopefully will have a crack at that soon. Going to dig out the old fibreglass kit and have a go at making the tail cover next week at some point as well.

Here's the bench testing of my mini switch setup to go on the clip ons. I just had to make sure the switches wouldn't burn out or anything.

By the way, that horn sounds fucking hilarious :D I need to find out where I can mount it on the bike.
I also made a dual element circuit so I could use a wee LED truck marker light for a brake & tail light. Here's the mockup:

Started making a bracket for them too:

Ended up fucking it by breaking my only 3mm drill bit after it wandered, so I'll make one at work tomorrow.
Here's what you end up with when you don't have photoshop :D

I'm not sure what colour to do the valve cover and casings though. Thoughts?
 
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