Following the demise of the old forum, I have had a few requests to try and rebuild the build thread I had over on the old .org
The loss of that forum, and the subsequent demise of Photobucket means that this is going to be a mammoth task. I'm not going to write in present tense, as it would have been, but rather write it as simply a commentary of a photo album. I will use Imgur to hold the images, and this is what will take the most time, finding the pics and uploading them.
Here goes.
The bike as I bought it in June 2010. Two previous owners, and having only covered 4750miles:-
(https://i.imgur.com/1SNj8oO.jpg)
That was a Friday afternoon, come Saturday morning I was making stuff for it. First up was a couple of titanium brackets, the first for the Power commander, the second to hold the front brake hoses securely.
PC3 bracket:-
(https://i.imgur.com/sfUYi1H.jpg)
(https://i.imgur.com/fF9392E.jpg)
(https://i.imgur.com/y6LuURM.jpg)
(https://i.imgur.com/2a4AznW.jpg)
Brake hose guide:-
(https://i.imgur.com/t5IU3zX.jpg)
(https://i.imgur.com/deZvQpx.jpg)
Ill add to this thread as I find the time. I hope it is enjoyed by both those who remember it, and inspires those who are new to it.
fantastic :onya:
Much appreciated. Looking forward to the pics with your commentaries :onya:
:clapping: :clapping: love to see this thread again
Do you have the specs for the PC and the brake bracket - cheers Del
Thanks guys.
First round of upgrades consisted of a PC3, and Hel brake lines. These were all purchased with discount codes offered by the old .org, I removed the calipers and gave them a thorough clean while I was fitting the hoses.
(https://i.imgur.com/kIg934Y.jpg)
(https://i.imgur.com/LIS3Oga.jpg)
(https://i.imgur.com/lZ5hqMY.jpg)
(https://i.imgur.com/HANdoDb.jpg)
Then a few weeks later I started to add a couple of bits of bling. First was a set of rather naff CRG copy levers. I used to think these were ace, but now I realise they're just a bit crap.
(https://i.imgur.com/5wHeSF7.jpg)
Then out with the Bike-It tax holder and in with the Fiber-Lyte one.
(https://i.imgur.com/P8kLyFH.jpg)
(https://i.imgur.com/5sSn1Hy.jpg)
(https://i.imgur.com/ogd9UpS.jpg)
It wouldn't be long before that nasty anodised exhaust would go too. You get the idea from these pics at just how clean the bike was. It really was in excellent condition.
Quote from: Del on Friday, 19 January 2018, 07:04 AM
:clapping: :clapping: love to see this thread again
Do you have the specs for the PC and the brake bracket - cheers Del
Specs? I think I still have the brake bracket somewhere, and I continued to produce the PC3 brackets in alloy. I might have one of those ready to go. PM me if you're interested.
Couple of weeks later I rode over to Probolt in Tewkesbury and bought some fasteners.
(https://i.imgur.com/uMUVTa8.jpg)
(https://i.imgur.com/KQ4yuYT.jpg)
Also my boss bought me the Akrapovic system.
(https://i.imgur.com/pycTViM.jpg)
(https://i.imgur.com/3hSbrsp.jpg)
This then led to me needing a lighter hanger rather than the pillion footpegs. So I storated by making a jig to get the dimensions perfect.
(https://i.imgur.com/CwJF3ju.jpg)
(https://i.imgur.com/f5uRaqo.jpg)
(https://i.imgur.com/1ejt0RL.jpg)
(https://i.imgur.com/71mX54i.jpg)
(https://i.imgur.com/t7m6rAg.jpg)
(https://i.imgur.com/BZSwsgQ.jpg)
That would later get anodised black.
Around the same time I discovered that the Gilles tooling chain adjuster for the GSXR models would fit, so I bought a set of them with the paddock stand lifters.
(https://i.imgur.com/FsQWMdP.jpg)
This would lead to a whole other side project, the paddock stand. You'll see that later in the build thread, it get used a LOT! The bike spends 95% of its life parked on it. It started out as just a piece of bent pipe from the scrap bin. I was trying out a borrowed pipe bender, just to get a feel for it, and this pipe was left over.
Started by welding it to a couple of pieces of box section to make a frame. With this frame I could beat some sheet aluminium over to to form the two halves of each upright.
(https://i.imgur.com/Pxx71qi.jpg)
(https://i.imgur.com/wosDr9V.jpg)
(https://i.imgur.com/ggUJSAk.jpg)
(https://i.imgur.com/k92R87L.jpg)
This then left me with forms, that could be tacked together to form the monocoque:-
(https://i.imgur.com/8ygkleO.jpg)
(https://i.imgur.com/6R1dhgA.jpg)
(https://i.imgur.com/8aOYmdm.jpg)
And welded.
(https://i.imgur.com/ojAG9ed.jpg)
(https://i.imgur.com/krOCAga.jpg)
Roller blade wheels added.
(https://i.imgur.com/C4o7eFK.jpg)
(https://i.imgur.com/bf5SHxu.jpg)
(https://i.imgur.com/2HYJH9e.jpg)
A friend of mine made the cnc bobbin mounts:-
(https://i.imgur.com/OyPWkMc.jpg)
(https://i.imgur.com/gZZcUWt.jpg)
At first it had rubber feet at the rear, but these were later changed for aluminium. its easier to slide the bike back and forth in the workshop with the aluminium feet.
(https://i.imgur.com/f00lfao.jpg)
And in use:-
(https://i.imgur.com/bENrS8t.jpg)
(https://i.imgur.com/KZIe7eG.jpg)
This was powder coated satin matt black.
(https://i.imgur.com/TVOvegt.jpg)
(https://i.imgur.com/TKfh8bb.jpg)
I added some nylon guides behind the bobbins. Makes it easier to guide the stand under the swingarm.
(https://i.imgur.com/bMAwd7R.jpg)
And in use
(https://i.imgur.com/gIGibqb.jpg)
(https://i.imgur.com/nBLQuej.jpg)
Starting to look like my bike.
Later that summer, I bought a few relatively expensive items. For both the yokes and headlight mounts I was inspired by another forum members bikes, that belonging to Des Sharp. His bike had both billet yokes and billet headlight mounts. I loved both items, and ordered the yokes from Roy Martin and the mounts from Just Bandits. The bar clamps/risers came from Moorespeed.
(https://i.imgur.com/JbRPBUt.jpg)
(https://i.imgur.com/cuUlyYy.jpg)
The yokes were very nice, but upon trial fitting them it was apparent that the k5 model was different from the point of view of the key transponder reader.
(https://i.imgur.com/oGDD3Fs.jpg)
A few emails to and from Roy saw them modified to fit the later bikes.
(https://i.imgur.com/Bcw3qkj.jpg)
I'm not a fan of polished shit, so all of these items went off to be anodised.
(https://i.imgur.com/lVYITID.jpg)
(https://i.imgur.com/rEjs8cR.jpg)
(https://i.imgur.com/PnOdLTh.jpg)
The same time I fitted some Renthal ultra lows, they don't look very low, but they are.
(https://i.imgur.com/g5NHVAY.jpg)
(https://i.imgur.com/qH4jZWB.jpg)
Had a friend machine me some pairs blanking plates, those also got anodised black.
(https://i.imgur.com/HjZtM3k.jpg)
(https://i.imgur.com/hrTLOVT.jpg)
Banking off and removing some of the pairs pipes caused a headache with the plumbing. Two different size pipes needed to be blocked off. This was resolved by making a double ended bung, that basically goes between the airbox and the throttle bodies.
(https://i.imgur.com/OU6Sw55.jpg)
(https://i.imgur.com/5CLseEx.jpg)
And made some bar end weights as the standard Suzuki ones wouldn't fit the Renthal bars.
(https://i.imgur.com/zi2zsLS.jpg)
After 'polishing' with 240 grit paper in the lathe.
(https://i.imgur.com/WFnZ14T.jpg)
This led me onto the undertray. Undertrays were available and I thought they were a great idea, however that was before i would out you had to cut away a fair chunk of the sandwich box under the seat.
(https://i.imgur.com/3FqiKus.jpg)
By that point I had already resolved to ditch the snow shovel, so just set about chopping that off and leaving a tidy standard undertray.
(https://i.imgur.com/Ahu9S2G.jpg)
(https://i.imgur.com/kdIvrKD.jpg)
(https://i.imgur.com/UryEJtJ.jpg)
(https://i.imgur.com/A95Vpzi.jpg)
(https://i.imgur.com/dFYz439.jpg)
This left with with a dilemma, where am I gonna put the number plate?
As I had also ditched the fold out luggage hooks, I was left with two perfectly good mounting points for a tail tidy.
Tacked:-
(https://i.imgur.com/7dSYNAr.jpg)
(https://i.imgur.com/9Gf5JTR.jpg)
Welded:-
(https://i.imgur.com/53oeDTA.jpg)
Powder coated:-
(https://i.imgur.com/Uf8pvTR.jpg)
(https://i.imgur.com/Xqx9xqV.jpg)
So this was coming to the end of the 2010 riding season, and the last bits I got for it were the Coerce rearsets and the clutch slave bracket.
The clutch slave came first, ordered from Japan to see if they were any good, which they were. Very. Then a week later the rearsets.
Love Japanese packaging.
(https://i.imgur.com/urRjgpv.jpg)
(https://i.imgur.com/SRDckvm.jpg)
(https://i.imgur.com/3xnjPT5.jpg)
(https://i.imgur.com/3xnjPT5.jpg)
(https://i.imgur.com/tSMGHwc.jpg)
The rearsets made a huge difference to the feel of the bike. It helped stop it feeling mushy, and you felt far more connected to the bike.
I picked up and R1 throttle tube too, its very similar in shape to the GSX but has a shorter stroke.
(https://i.imgur.com/6Rl9f0W.jpg)
It makes the bike feel sharper. I'm totally used to it now, but I remember it being a 99p eBay game changer.
(https://i.imgur.com/ZrooekR.jpg)
(https://i.imgur.com/1Iq0MDw.jpg)
This was annoying. It was a friend who thought it would be funny to get back at me for a practical joke by peeling a sticker off my bike. I forgave him. We have since pretty much stopped talking, but because of something else entirely.
The winter of 2010 would be the first strip down. Primarily to clean the bike in all the hard to reach areas, but also to do a few mods that couldn't be done easily with the bike in one piece.
I'd need to extract the engine, and I had worked out that it couldn't easily be done without help. So I made an engine stand that would allow me to drop the engine through the side of the frame. It would allow the engine to rest on nylon stops and the front and rear could be independently tipped to clear the frame.
(https://i.imgur.com/Z8BiiiT.jpg)
(https://i.imgur.com/uMx6Kzz.jpg)
(https://i.imgur.com/0ib0kCQ.jpg)
It would use a pair of cheap Halfords scissor jacks to get the engine up and down in and out of the frame.
(https://i.imgur.com/Qj3bVia.jpg)
(https://i.imgur.com/5hML1zh.jpg)
(https://i.imgur.com/Joxxlrq.jpg)
Looks much neater in black.
(https://i.imgur.com/ckvlVGe.jpg)
Aluminium rear subframe. The following fotos will make it look like an afternoons work, but it took about eight weeks. this was because I had to out source the machining and try to get planets to align...
First I took lots of measurement. Lots. And started cutting, first the sandwich box, then the frame.
(https://i.imgur.com/0Vt2VRB.jpg)
(https://i.imgur.com/0I5ucsO.jpg)
I had some mounting bosses made, half in steel to match the frame, and half in aluminium to match the subframe.
(https://i.imgur.com/i3inYJv.jpg)
When I had the parts together, I hacked off the rear part of the frame.
(https://i.imgur.com/Gg6sRgY.jpg)
Tacked together.
(https://i.imgur.com/HTUchoP.jpg)
The half finished thing.
(https://i.imgur.com/xVz7zmt.jpg)
(https://i.imgur.com/5xTS8yQ.jpg)
I just found These pics on the computer. I dont think I posted them before.
(https://i.imgur.com/j2kKuqA.jpg)
(https://i.imgur.com/WaQjCix.jpg)
(https://i.imgur.com/pvSDuUX.jpg)
(https://i.imgur.com/yyF6rrU.jpg)
There were other little adaptions to the frame, mostly to shed some weight. I got rid of the centre stand, and added some hose guides to allow me to add braided hoses for the oil cooler I'd make a little later.
(https://i.imgur.com/iuRRAno.jpg)
(https://i.imgur.com/wJWXgtt.jpg)
(https://i.imgur.com/8ytDoUz.jpg)
(https://i.imgur.com/8N0rQz6.jpg)
(https://i.imgur.com/0yzGE0V.jpg)
The hose guides, originally designed for brake hoses on a mountain bike.
(https://i.imgur.com/PJH4zrI.jpg)
Ditched the horn brackets.
(https://i.imgur.com/a7e4ZP4.jpg)
Most of the frame furniture that came off.
(https://i.imgur.com/By1y77W.jpg)
Quote from: kanerdog1X1 on Friday, 19 January 2018, 08:47 AM
(https://i.imgur.com/ZrooekR.jpg)
(https://i.imgur.com/1Iq0MDw.jpg)
This was annoying. It was a friend who thought it would be funny to get back at me for a practical joke by peeling a sticker off my bike. I forgave him. We have since pretty much stopped talking, but because of something else entirely.
He's not a mate if he thinks that was ok to do. Think I would of killed him.
Great work on the bike & thread BTW. :onya:
Thanks for reposting your modifications :notworthy:
Awesome stuff :clapping:
Top job :notworthy:
And one question. End of the frame is modify (made from aluminium) just because of lose weight?
Hey, no problem guys. It's gonna take a while. There's something like 45 pages of info to upload. I'll do it as I find the time.
Quote from: kanerdog1X1 on Friday, 19 January 2018, 11:32 PM
Hey, no problem guys. It's gonna take a while. There's something like 45 pages of info to upload. I'll do it as I find the time.
So much appreciated Matt, some awesome work (and works of art) which we can enjoy again. :clapping: :notworthy:
Quote from: V_i_c_i on Friday, 19 January 2018, 11:31 PM
Top job :notworthy:
And one question. End of the frame is modify (made from aluminium) just because of lose weight?
Hey vici, yes to lose weight. And to look good.
Before the rebuild could start, I had been cleaning and boxing stuff up.
(https://i.imgur.com/OICUlsO.jpg)
(https://i.imgur.com/nJ86fFJ.jpg)
(https://i.imgur.com/eAHJRVP.jpg)
(https://i.imgur.com/fhd6Y4p.jpg)
The frame went across the road to be powder coated in January '11, initially I was struggling to find someone in 'the circle' to strip the old paint off. A mate of mine Dean came up trumps.
(https://i.imgur.com/Fn0i9IW.jpg)
A teaser of the finished frame. I was elated at this time.
(https://i.imgur.com/3tAdjSC.jpg)
The build proper started that weekend. Various stages through the weekend:-
(https://i.imgur.com/UMdhXY9.jpg)
(https://i.imgur.com/MW4fPSa.jpg)
(https://i.imgur.com/S4YPqk0.jpg)
(https://i.imgur.com/syZslTu.jpg)
(https://i.imgur.com/5Qf91QF.jpg)
(https://i.imgur.com/QofXmGF.jpg)
The eagle eyed will spot the rear sprocket. Another sub project right there...
The sprocket carrier was fun. I noticed that the studs holding the sprocket on were threaded more into the carrier, and that would allow me to spin them around and machine a grooved to fit lockwire to retain the nuts. Here you can see the difference, and the groove:-
(https://i.imgur.com/1ENM16H.jpg)
Having had all of the studs re plated and the new titanium nuts:-
(https://i.imgur.com/nI2rAPr.jpg)
(https://i.imgur.com/sxJLlX2.jpg)
The sprocket carrier was next, bead blasted to get it clean, and masked. then powder coated satin matt black like the frame.
(https://i.imgur.com/1qoWoDr.jpg)
(https://i.imgur.com/EH2SOpn.jpg)
Then reassembled with a new supersprox sprocket. Not a fan of these, they are very heavy and don't last too long.
(https://i.imgur.com/4mrzAZq.jpg)
(https://i.imgur.com/1zGMgTq.jpg)
Another little project was the coil mounting brackets, in titanium, naturally.
(https://i.imgur.com/ea3rwQ3.jpg)
(https://i.imgur.com/CEJG4EY.jpg)
Next up was suspension. This also took about eight weeks to complete as I had to get things blasted, painted, plated, ordered... but it will also look like an afternoons work.
The dampers came from another mate who has his own suspension tuning shop, Kevin Bancroft. At the time ohlins dampers were not impossible to get, but certainly they were not available in the U.K. These came direct through Kenth in Sweden.
(https://i.imgur.com/ODvUzHT.jpg)
(https://i.imgur.com/UM01Hdn.jpg)
(https://i.imgur.com/gmOrLr7.jpg)
Stripped the forks down to component pieces, so I could get the various parts colour anodised. I had little dimples machined in the top caps also.
(https://i.imgur.com/SKzZ5yO.jpg)
The lowers I bead blasted and had powder coated silver. Here you can see the bungs used to keep the grit out:-
(https://i.imgur.com/BRSjU0W.jpg)
(https://i.imgur.com/hkdHKJj.jpg)
(https://i.imgur.com/q7dfJEM.jpg)
The various parts back from the finishers so reassembly can start. The tubes back from being coated. I originally wanted them black, but they were too long to fit in the machine!
(https://i.imgur.com/UimeaKS.jpg)
(https://i.imgur.com/LNqTVgd.jpg)
(https://i.imgur.com/UrcZheH.jpg)
(https://i.imgur.com/7ogmIUr.jpg)
I made a little tell tale for one of the fork legs, much neater than a cable tie.
(https://i.imgur.com/RIsUjFD.jpg)
And also a tool to set the oil height.
(https://i.imgur.com/Lqwvuqb.jpg)
And the finished legs:-
(https://i.imgur.com/62GxpZM.jpg)
Fitted:-
(https://i.imgur.com/APQZXiE.jpg)
Right around this time the bike was featured in Performance Bike Magazine, in the readers rides section
(https://i.imgur.com/HPmxd62.jpg)
Next on the list was an oil cooler. This is my day job, so wasn't a problem per se, but I knew it had to be good because people were judging me on it.
The core was specially made for this application.
(https://i.imgur.com/sWuMtab.jpg)
At this time I got the fittings that attach to the sump from HEL.
(https://i.imgur.com/SLAUeIl.jpg)
First job was to curve the core slightly.
(https://i.imgur.com/gKTiIXp.jpg)
And make the end tanks
(https://i.imgur.com/LrwaJnj.jpg)
Once that was welded, I moved onto mounting it.
(https://i.imgur.com/FMnCFPn.jpg)
(https://i.imgur.com/vU4LNkZ.jpg)
(https://i.imgur.com/pS1PD2n.jpg)
(https://i.imgur.com/kKJw9ll.jpg)
The sun was starting to come out
(https://i.imgur.com/YkSXgjd.jpg)
Ha! In that last pic you can see the cable ties on the paddock stand, it was already annoying me, the rubber feet stopping it sliding freely on the workshop floor.
Other jobs around that time included getting the tired looking side cases painted.
(https://i.imgur.com/kXUc0Z0.jpg)
Again, bead blast and mask.
(https://i.imgur.com/lNXVW0T.jpg)
(https://i.imgur.com/5kDODIT.jpg)
Eagle eyed amongst you will have noticed that i removed the pillion mounts. this meant I couldn't run that exhaust hanger. I had seen this style of hanger on lots of Japanese bikes.
(https://i.imgur.com/LKpBtx2.jpg)
(https://i.imgur.com/fvZVSvx.jpg)
Again, I have a jig for this if anyone wants one like it.
And a wire for the oil filler cap. Titanium hoop, stainless r clip made from a mountain bike spoke, and stainless brake cable all silver soldered together.
(https://i.imgur.com/BswfTNb.jpg)
(https://i.imgur.com/G2Pqvmr.jpg)
And finally a little spring platform to replace the nasty zinc plated metal one on the Coerce rearsets.
(https://i.imgur.com/4stsA89.jpg)
(https://i.imgur.com/7Gq8PNP.jpg)
Ok, very nearly riding season. March is looking good, so I'm against the clock now to get it ready.
Oil line components and oil arrived, filter from the LBS:-
(https://i.imgur.com/fNF8QfE.jpg)
I had the oil lines custom picked. They are usually blue&red or plain black, but I wanted red&black. At the time this was unheard of, and the supplier was super helpful in arranging it.
(https://i.imgur.com/3BZdoCw.jpg)
As it turns out, I'm now really good friends with Alex, and he's asked all the time now for non standard combinations, but he won't do it any more as it leaves him with half eaten parts...
(https://i.imgur.com/UWHlUqY.jpg)
Having the frame powder coated left me without the VIN decal. I decided to make a replacement. I trimmed some aluminium plates to size, and had them anodised. On their return I took them to the trophy engravers with a photo of the old decal and had them etch the details into the plate.
(https://i.imgur.com/GiEBmpB.jpg)
This I then beat around a tube to shape it to that of the frame.
(https://i.imgur.com/Wkj9WSm.jpg)
And fitted.
(https://i.imgur.com/z1Eglj8.jpg)
This was April, and the sun was out. I took a long ish ride around the outskirts of the city in case there was a problem and I needed to be rescued.
(https://i.imgur.com/rQhBcTF.jpg)
All good.
Another trip to probolt:-
(https://i.imgur.com/plMeRNs.jpg)
(https://i.imgur.com/b7QKKWg.jpg)
And to prove it gets used.
(https://i.imgur.com/JssKXf4.jpg)
(https://i.imgur.com/HdaY5Rb.jpg)
(https://i.imgur.com/8NJbniT.jpg)
(https://i.imgur.com/SPc28ms.jpg)
Ok, more oil lines. This time for the rear of the engine.
(https://i.imgur.com/LRMNHiu.jpg)
(https://i.imgur.com/exnJuW0.jpg)
(https://i.imgur.com/TVFlvyo.jpg)
BSB scrubs. This is pretty much what Ive done ever since. A set of tyres from the BSB is about £50-65, and I generally get the season out of them.
(https://i.imgur.com/d5sdpLn.jpg)
Later in the year I did a track day at Silverstone. Temp before:-
(https://i.imgur.com/hKuJ7Eo.jpg)
(https://i.imgur.com/ryKcy98.jpg)
(https://i.imgur.com/UvfOJWV.jpg)
(https://i.imgur.com/nQMDOVV.jpg)
(https://i.imgur.com/EU393Et.jpg)
Temp after:-
(https://i.imgur.com/5Ub80pG.jpg)
Was a great day. Wasn't much that could keep up until I was on a straight, then the litre bikes would sail past you.
Randoms from through the year.
(https://i.imgur.com/gZKHAbQ.jpg)
(https://i.imgur.com/NobOZ6g.jpg)
(https://i.imgur.com/qbNwTJo.jpg)
The estate we are on is a mixture of first and second world war munitions factory buildings. Slowly they are being replaced by more modern structures, and the unit directly across form us was being demolished the next day. While the doors were off we decided to do an impromptu photo shoot. I asked permission to borrow the boss's camera kit and we took it over with a portable generator. The generator was a fail as it couldn't supply the juice the flash guns needed, so I collected together all of the extension cords in work and daisy chained them the hundred meters across the yard.
(https://i.imgur.com/exqWd01.jpg)
(https://i.imgur.com/WbkhITt.jpg)
(https://i.imgur.com/skNyEEy.jpg)
(https://i.imgur.com/8AABDow.jpg)
Some of these pics are ok, but you must understand I was still learning how to use a camera, someone elses camera at that.
(https://i.imgur.com/3yaUCcP.jpg)
(https://i.imgur.com/Btcecvs.jpg)
(https://i.imgur.com/t7HV5XV.jpg)
(https://i.imgur.com/KfbOYO3.jpg)
And to prove how good nice kit can make your bike look, heres how grubby it was:-
(https://i.imgur.com/SUH5ksw.jpg)
With the riding season at an end, the next big strip down was due.
Brakes were next on the agenda, first up I bought the Brembo rcs master cylinders for the brake and clutch.
(https://i.imgur.com/4JPAyLP.jpg)
This meant I needed a reservoir for the fluid.
(https://i.imgur.com/jW506pQ.jpg)
I like these little 30cc ones as they have no mounting. This allows me to fabricated some little titanium widgets.
(https://i.imgur.com/N5imeaS.jpg)
(https://i.imgur.com/oPDtQyJ.jpg)
(https://i.imgur.com/kNYk4jx.jpg)
(https://i.imgur.com/ieH82WC.jpg)
Next up, the brake lines. I made up some kit so that I could plan the hose layout, and send this off as a pattern to be made up.
(https://i.imgur.com/FMuwUi4.jpg)
(https://i.imgur.com/ZnYkQ1d.jpg)
And the supplied parts from HEL.
(https://i.imgur.com/kdebJpU.jpg)
(https://i.imgur.com/gjRAShe.jpg)
Which led to more titanium brackets.
(https://i.imgur.com/ow7Fat6.jpg)
(https://i.imgur.com/HGRmRpO.jpg)
A couple of little frame alterations. More of those cable guides, they are very neat.
(https://i.imgur.com/XpyJ6gX.jpg)
(https://i.imgur.com/6eiq55I.jpg)
(https://i.imgur.com/IMLP6fY.jpg)
A small adjustment to the Ohlins to give a better window of preload adjustment.
(https://i.imgur.com/Y2sUcYy.jpg)
(https://i.imgur.com/nhIgfNb.jpg)
And a waisted titanium clutch push rod to replace the stainless one I made earlier in the year.
(https://i.imgur.com/YFEcs9y.jpg)
Just found some head on pics. I love the symmetry of the brake hoses done this way.
(https://i.imgur.com/rOOpyde.jpg)
(https://i.imgur.com/1vj8hwE.jpg)
:onya:
The steering stem on the billet yokes was steel, I was never really happy with it. I made one in aluminium over the xmas holiday, and sent it off with the rear caliper halves to be hard anodised.
(https://i.imgur.com/hzSCoTz.jpg)
(https://i.imgur.com/WzMOwMY.jpg)
The caliper halves looked ace:-
(https://i.imgur.com/gmfj18D.jpg)
(https://i.imgur.com/ReHe28s.jpg)
Then I got some dry breaks for the brake hoses, and had HEL splice them in.
(https://i.imgur.com/sgZHX8W.jpg)
(https://i.imgur.com/8wd2626.jpg)
(https://i.imgur.com/QHRKkZN.jpg)
Reassembly would start again shortly after I got the frame back again from paint.
(https://i.imgur.com/kyCQVm7.jpg)
(https://i.imgur.com/xjk81cj.jpg)
(https://i.imgur.com/ArwCJ8Y.jpg)
(https://i.imgur.com/7gY2rDy.jpg)
(https://i.imgur.com/Nno2DE4.jpg)
(https://i.imgur.com/a8iniuT.jpg)
I started using 'special projects' cable ties, from Panduit.
(https://i.imgur.com/y7hL8sv.jpg)
(https://i.imgur.com/QCAprOy.jpg)
Some supplies for the rebuild.
(https://i.imgur.com/Am8Df82.jpg)
(https://i.imgur.com/lwOpEbB.jpg)
The loom I recovered in polyester braid. I did the switch gear also.
(https://i.imgur.com/DPeQMnG.jpg)
(https://i.imgur.com/h0aDmWz.jpg)
(https://i.imgur.com/KQJ5NPE.jpg)
I made some cups for the axles, later these would be anodised.
(https://i.imgur.com/lz8k3MY.jpg)
(https://i.imgur.com/jcl49gr.jpg)
(https://i.imgur.com/vmZrYTR.jpg)
(https://i.imgur.com/8pycCH0.jpg)
(https://i.imgur.com/n52eGAg.jpg)
(https://i.imgur.com/j4qdRsp.jpg)
(https://i.imgur.com/WXWSQkR.jpg)
And back together for '12.
(https://i.imgur.com/jKVE9h3.jpg)
(https://i.imgur.com/MYlvH85.jpg)
(https://i.imgur.com/65yrpLm.jpg)
First ride out
(https://i.imgur.com/WcKfCIK.jpg)
(https://i.imgur.com/vjhAz0O.jpg)
(https://i.imgur.com/rvVrBai.jpg)
After the success of the rear brake caliper being hard anodised I send the fronts off to be done.
I found a pair of GSXR k1 calipers on ebay, they are subtly different than the gsx1400 calipers. they are a yellower shade of gold, but importantly have aluminium pistons so weigh less. They cleaned up perfectly, the pistons were spotless.
(https://i.imgur.com/is4pmZj.jpg)
(https://i.imgur.com/loLkwPo.jpg)
(https://i.imgur.com/nf5DabS.jpg)
Before they went, I had a local machinist remove the 'TOKICO' branding, and recess it into the caliper instead.
(https://i.imgur.com/e2S6039.jpg)
When they arrived back from the anodisers I was heartbroken, as they were a odd shade of green. It is just luck of the draw, the colour is a product of the metallurgy rather then the process, but they were what I expected. I decided to try to dye them black, and this was a success.
(https://i.imgur.com/WsB0WOS.jpg)
When they were all done, I added paint into the tokico logo, and waxed the halves to seal in the finish.
(https://i.imgur.com/zGRgDmG.jpg)
(https://i.imgur.com/DmSg1RP.jpg)
Also,
(https://i.imgur.com/dwXUQ4c.jpg)
Been looking forward to your oil cooler mod.
I see that you made a somewhat normal sized cooler at first and will wait patiently for the next installment :)
i think that 1st cooler is the one i got from matt and on my b/w bike
:cheers:
Dymag wheels. I saved up for ages for those. Lucky I bough them at that time, for two reasons. Firstly, they were on offer. Which was because of the second reason, that they were about to change the design. Mine are 'UP7' rims, the later rims are the 'UP7X', which has a hole drilled in each spoke, which I think looks weird. Anyway, you can't get the UP7 anymore, so I'm glad I got them when I did. They feature captive spacers which is lovely.
I had some 90deg valves fitted, they are from a triumph I think.
(https://i.imgur.com/2cwgvFS.jpg)
(https://i.imgur.com/rWHatNt.jpg)
(https://i.imgur.com/zH3Ve50.jpg)
(https://i.imgur.com/xhJeHUv.jpg)
(https://i.imgur.com/b6rxgM5.jpg)
(https://i.imgur.com/xAUDCR1.jpg)
I also bought some brembo discs for the front, and titanium bolts from probolt.
(https://i.imgur.com/rPKQshk.jpg)
(https://i.imgur.com/N0ogHtg.jpg)
Quote from: seth on Sunday, 21 January 2018, 04:41 AM
i think that 1st cooler is the one i got from matt and on my b/w bike
:cheers:
Yes mate, I'm pretty sure its the same one.
I was worried about the oil cooler getting damaged from stones, But possibly wanted a neater solution to the guard. To this day I'm still searching to improve the design.
(https://i.imgur.com/bLqZaEB.jpg)
(https://i.imgur.com/F1rR9Ua.jpg)
(https://i.imgur.com/mZu0FOo.jpg)
The bike was featured in Performance bikes magazine, here is Gary Inman road testing it earlier in the year.
(https://i.imgur.com/IYfmF0l.jpg)
(https://i.imgur.com/ufoWSYj.jpg)
(https://i.imgur.com/lTlSYDB.jpg)
(https://i.imgur.com/wLRb4Fu.jpg)
(https://i.imgur.com/aoHJuo1.jpg)
(https://i.imgur.com/lTKx0Di.jpg)
So this was towards the end of '12. I had fancied making a side paddock stand so I could work on the front end of the bike freely. I knew I could make a tube fit between the frame and the engine, but that would be a complete strip down task. I started with the tube for the bike.
(https://i.imgur.com/I0nQSR5.jpg)
(https://i.imgur.com/9iBZQYg.jpg)
Then moved on to designing a paddock stand.
(https://i.imgur.com/SrBaGo3.jpg)
(https://i.imgur.com/8KkVnlK.jpg)
(https://i.imgur.com/1zAHA6Y.jpg)
Once I could get the bike apart I could start fitting the tube to the frame.
(https://i.imgur.com/6ioWpMV.jpg)
(https://i.imgur.com/qrJYu0X.jpg)
(https://i.imgur.com/gOAK8Cz.jpg)
(https://i.imgur.com/NXT68j9.jpg)
(https://i.imgur.com/YELmMoJ.jpg)
The oil pipes would be for the second generation oil cooler I was planning...
The second special core, as I arrived. I ordered it with bigger tube plates so I had some material to play with.
(https://i.imgur.com/ASfc4Ko.jpg)
Started by making a former for the end tanks.
(https://i.imgur.com/2TtlvQQ.jpg)
(https://i.imgur.com/b4VnB4O.jpg)
Then made the tanks and curved the core.
(https://i.imgur.com/0HfR2XK.jpg)
(https://i.imgur.com/l6z6yEQ.jpg)
Welded up.
(https://i.imgur.com/FWZnRWJ.jpg)
I felt this needed more titanium porn, so I made a fan bracket too.
(https://i.imgur.com/QqpmRmK.jpg)
(https://i.imgur.com/AlUJY4i.jpg)
(https://i.imgur.com/dSqqBpq.jpg)
(https://i.imgur.com/7BYAgAe.jpg)
While the frame was apart I needed to do a couple of other things to it, minor things. I needed to move the location keys for the tank mounts slightly, to allow more clearance for the wiring loom.
(https://i.imgur.com/fRhi9H7.jpg)
(https://i.imgur.com/aSl3vDd.jpg)
Also I had a plan to change the air filter later, so I wanted to be able to remove the air box without dropping the engine. The only real problem is the cam chain tensioner, and the side panel brackets. So I made a jig so I could make removable brackets.
(https://i.imgur.com/WggtCNb.jpg)
(https://i.imgur.com/2ICVNaY.jpg)
(https://i.imgur.com/g8XPoxw.jpg)
(https://i.imgur.com/WUnnfMf.jpg)
(https://i.imgur.com/FeIYwf7.jpg)
Also during 2012 I had the plan to look at the fuel system. I wanted to add a few things, dry break filler, fuel rail with AN hose and a dry break on the tank so it was try quick release. It took almost 6 months to complete this.
The ATL dry breaks. Very expensive, but very exclusive. During repositioning of the logo.
(https://i.imgur.com/77lQFa2.jpg)
(https://i.imgur.com/79ng4eZ.jpg)
(https://i.imgur.com/dSg4Qko.jpg)
(https://i.imgur.com/t7Dfe7S.jpg)
(https://i.imgur.com/5xOetxv.jpg)
(https://i.imgur.com/pwAJ7fJ.jpg)
The foam in the fuel tank.
(https://i.imgur.com/czlkbgi.jpg)
(https://i.imgur.com/9P4FuzO.jpg)
This needed the fuel sender to be partitioned/baffled away from the foam. Behind the baffle:-
(https://i.imgur.com/tWetxkO.jpg)
And the baffle.
(https://i.imgur.com/ddWT0f8.jpg)
(https://i.imgur.com/AXy60aQ.jpg)
And the titanium quick release bracket.
(https://i.imgur.com/AQPW5Vw.jpg)
(https://i.imgur.com/MLGTp9k.jpg)
(https://i.imgur.com/EAQjEoG.jpg)
You can also see a third side panel mount I did to test the strength. I took some breaking...
The tank was adapted to allow quick release with a DZUS fastener.
(https://i.imgur.com/Q4Ou5KA.jpg)
(https://i.imgur.com/dMruP2N.jpg)
Next was trusting someone to paint it. A friend of a friend was recommended, and while he did a good job I was really expecting better.
Testing before it went away.
(https://i.imgur.com/clg6wGs.jpg)
Ready to be collected. He took my old tank as a pattern.
(https://i.imgur.com/cpHQwXF.jpg)
Updates sent to me through the weeks.
(https://i.imgur.com/imPJkJ0.jpg)
(https://i.imgur.com/W5WipQC.jpg)
(https://i.imgur.com/9avNZQR.jpg)
(https://i.imgur.com/hRbPUeO.jpg)
(https://i.imgur.com/JLTjQED.jpg)
(https://i.imgur.com/bw3sjNF.jpg)
(https://i.imgur.com/UosG2cY.jpg)
You can see here the broken decal.
(https://i.imgur.com/CPypqF8.jpg)
He also did my front mudguard.
(https://i.imgur.com/w1AZnjA.jpg)
And fitted.
(https://i.imgur.com/NCcbZhH.jpg)
The fuel rail and pump.
Here's the fuel rail I made.
(https://i.imgur.com/cOmMGCj.jpg)
(https://i.imgur.com/ab1F5eu.jpg)
Pressure testing.
(https://i.imgur.com/0KW3rgp.jpg)
(https://i.imgur.com/ab1F5eu.jpg)
And back from anodising along with some other bits.
(https://i.imgur.com/NHCVEVz.jpg)
And reassembled onto the throttle bodies.
(https://i.imgur.com/ybfnZNw.jpg)
Also the fuel pump. I used a GSXR 750 pump as the donor, as it did or didn't have something, and I can't remember for the life of me what that reason was.....
First attempt:-
(https://i.imgur.com/PWs20DR.jpg)
Third, forth or fifth attempt, and I got it right. It's tight under the tank.
(https://i.imgur.com/QdxGm8B.jpg)
Back from the platers. looks brand new.
(https://i.imgur.com/7shJeIo.jpg)
Re tested
(https://i.imgur.com/Y5hTWki.jpg)
Some supplies for the project.
(https://i.imgur.com/3qeo50n.jpg)
(https://i.imgur.com/appfV3L.jpg)
And built up.
(https://i.imgur.com/DfEG7BU.jpg)
I needed a way to get electric back into the tank, but keep the petrol in. The standard bike has a riveted arrangement, but I wanted something serviceable. This is what I came up with, teflon insulators and stainless hardware. Still working 5 years on.
(https://i.imgur.com/TfKRA9q.jpg)
(https://i.imgur.com/sZfnfs5.jpg)
In between all of that being done, I was cleaning up the other parts ready for the rebuild.
(https://i.imgur.com/P18Vnhd.jpg)
(https://i.imgur.com/gXQYmkf.jpg)
The rear caliper has steel pistons standard, and my bandit had aluminium, I took the opportunity to swap them over. the standard steel pistons weigh 162g a pair, the aluminium ones 64g a pair.
(https://i.imgur.com/RJsvPlv.jpg)
(https://i.imgur.com/E9F1dsO.jpg)
Also had the side cases re done. They take a battering from stone chips combined with the heat.
(https://i.imgur.com/cyxOWY7.jpg)
Rather then get the frame re powder coated, I simply dusted over the bare sections with rattle can.
(https://i.imgur.com/rApJKuE.jpg)
Then the rebuild could start.
(https://i.imgur.com/erSS7iB.jpg)
New shorter hoses.
(https://i.imgur.com/ru16nSD.jpg)
(https://i.imgur.com/FhnBwfE.jpg)
(https://i.imgur.com/DaSpu0X.jpg)
(https://i.imgur.com/AUecITt.jpg)
(https://i.imgur.com/9nPeNsC.jpg)
(https://i.imgur.com/RmfMWY2.jpg)
(https://i.imgur.com/ngu0vx5.jpg)
(https://i.imgur.com/oTtJdBC.jpg)
(https://i.imgur.com/tGyMm91.jpg)
(https://i.imgur.com/mD5Lkqk.jpg)
At this point I was just waiting for the tank. Waiting. Waiting.
The tank!
(https://i.imgur.com/7PHjGSG.jpg)
(https://i.imgur.com/RCy2xL0.jpg)
It needed a little plumbing for the breather.
(https://i.imgur.com/RKxMtKu.jpg)
(https://i.imgur.com/ic3U7sz.jpg)
Later I added a quick release fitting. I got this idea after meeting another rider and seeing it on his bike.
(https://i.imgur.com/mWYSiZr.jpg)
(https://i.imgur.com/zC77KSX.jpg)
This is the key ring I use to fill up.
(https://i.imgur.com/mdJejuF.jpg)
To make servicing the tank easier, I made this frame to hold it steady.
(https://i.imgur.com/COpmnpd.jpg)
(https://i.imgur.com/XKqrf4z.jpg)
(https://i.imgur.com/SECIcNy.jpg)
So this was summer 2013.
(https://i.imgur.com/bMPxBb5.jpg)
The breather box plate lets a lot of light through under the airbox, this I like.
I found a new use for the filler.
(https://i.imgur.com/Bn3ikcQ.jpg)
Eagle eyed viewers may have noticed the air filter mock up in some of the previous pictures. I made a template from aluminium, did a couple of drawings and sent them to fiber lyte to be cut in carbon. The pattern is made from Kingspan.
(https://i.imgur.com/DKiJMzK.jpg)
(https://i.imgur.com/aWfn9iN.jpg)
(https://i.imgur.com/zWBZM58.jpg)
(https://i.imgur.com/dKwLp4q.jpg)
Once this was done I could send part of the assembly to ITG to have a filter bonded on.
(https://i.imgur.com/7GHbofZ.jpg)
More supplies
(https://i.imgur.com/Xy9vnJy.jpg)
(https://i.imgur.com/LSVmQ3i.jpg)
(https://i.imgur.com/wmmAK4G.jpg)
(https://i.imgur.com/hARnTiH.jpg)
(https://i.imgur.com/fnCgE1b.jpg)
And fitted.
(https://i.imgur.com/L4uFLa9.jpg)
(https://i.imgur.com/N0cY8nu.jpg)
(https://i.imgur.com/b3ZivQU.jpg)
(https://i.imgur.com/LkmpxyH.jpg)
Simple tool to help with assembly/adjustment.
(https://i.imgur.com/clFxfzz.jpg)
(https://i.imgur.com/azkUEJM.jpg)
New oil cooling delivery pipe for the head.
(https://i.imgur.com/Pcl5hLL.jpg)
(https://i.imgur.com/jUeATL7.jpg)
Lambda bung in the exhaust.
(https://i.imgur.com/yM8zZw0.jpg)
PC5 with data screen thing. Theres no replacement for good mapping on a dyno.
(https://i.imgur.com/viMN2Mw.jpg)
Some artistic shots. I was getting more confident with taking good pictures.
(https://i.imgur.com/2VfCfoW.jpg)
(https://i.imgur.com/b3ZivQU.jpg)
(https://i.imgur.com/LkmpxyH.jpg)
(https://i.imgur.com/gIZVXDy.jpg)
(https://i.imgur.com/xXbm3cD.jpg)
(https://i.imgur.com/NGSX8fn.jpg)
(https://i.imgur.com/nGRcPsk.jpg)
And another little photoshoot in a disused great war building.
While exploring part of the trading estate that has been out of bounds for years, I rediscovered a building that we used to play in as a child. I had assumed that the building was torn down, as the surrounding area has been levelled for redevelopment. This is one of the only buildings left standing, and is hidden from view by this thinnest line of trees. I spotted it yesterday afternoon, and took the opportunity of the nice weather today to use it before it is no doubt destroyed.
The building, this is roughly half of its interior:-
(https://i.imgur.com/OiKoRoH.jpg)
Rotherwas, and formerly ROF Hereford, was a munitions factory during both world wars. the site is pretty big, and most of the original buildings are demolished, some still stand derelict but a handful are still in use, as industrial units. This particular building is I think the biggest, and it has a huge amount of RSJ suspended from the roof, suggesting it housed a production line. At one end, there are huge doors and a dropped floor, I am pretty sure this was a platform for a railway line.
(https://i.imgur.com/CPhoyPT.jpg)
(https://i.imgur.com/HHHmU4C.jpg)
(https://i.imgur.com/W9fRo2x.jpg)
(https://i.imgur.com/Punm3mo.jpg)
(https://i.imgur.com/kCJxsou.jpg)
(https://i.imgur.com/NcI0mkt.jpg)
(https://i.imgur.com/VJVqV5g.jpg)
And my favourite shot.
(https://i.imgur.com/5r683EY.jpg)
Some more pics from the magazine shoot.
(https://i.imgur.com/UUqLmgA.jpg)
(https://i.imgur.com/A7g0Vc8.jpg)
The strip down at the end of 2013 was merely to clean and address a couple of snags.
The fuel pipe appeared to be perishing. At that point it was 10 years old.
(https://i.imgur.com/LFjrjev.jpg)
The damper was touching the frame on one side. I simply tickled away the metal with the grinder and sander. Again I just rattle canned the bare areas.
(https://i.imgur.com/dKVtQuZ.jpg)
(https://i.imgur.com/WCXBYsS.jpg)
(https://i.imgur.com/s9Kz0fU.jpg)
The brakes and clutch master/slave were given a thorough clean and inspection.
(https://i.imgur.com/3U2YKMN.jpg)
The rear master was showing a little corrosion that cleaned up perfectly.
(https://i.imgur.com/WhiwWfx.jpg)
(https://i.imgur.com/rFS16ax.jpg)
Made some tools to pull the pistons from the calipers.
(https://i.imgur.com/emoihQk.jpg)
Some were worried that the foam would block the filter, it was not the case.
(https://i.imgur.com/TEeiEPe.jpg)
(https://i.imgur.com/2wBwv3O.jpg)
Also went from red&blue unions back to bland&red.
(https://i.imgur.com/b0PQKxa.jpg)
(https://i.imgur.com/2QLaZlG.jpg)
(https://i.imgur.com/UkOWbuN.jpg)
After a long break I reassembled the bike in April 2014, primarily because it was so cold in the new unit. Warmer weather gave me the drive to put it back together. I used an engine hoist to get the engine up so I could give it a proper clean.
(https://i.imgur.com/VoNEqyP.jpg)
(https://i.imgur.com/YkHHZhd.jpg)
(https://i.imgur.com/nBKOtfO.jpg)
(https://i.imgur.com/4pnO7NK.jpg)
(https://i.imgur.com/YwZsNk3.jpg)
Also fitted a new PC5, and made a new bracket for it.
(https://i.imgur.com/jba3HZ7.jpg)
(https://i.imgur.com/gq5SKex.jpg)
(https://i.imgur.com/DH75Vmg.jpg)
new chain and sprockets.
(https://i.imgur.com/P6vLIQW.jpg)
(https://i.imgur.com/0unKPtl.jpg)
(https://i.imgur.com/9DG2M6r.jpg)
(https://i.imgur.com/2VUpEYy.jpg)
(https://i.imgur.com/jNg3FPU.jpg)
(https://i.imgur.com/ipPDYlO.jpg)
Ready to go!
First ride out, got a puncture!
(https://i.imgur.com/CcwbXmp.jpg)
(https://i.imgur.com/NJwMuO9.jpg)
So, the work at the end of 2014 didn't really consist of a strip down, just a once over. The brakes came off to service:-
(https://i.imgur.com/6BYK94S.jpg)
Good job, the rear pads were shot.
(https://i.imgur.com/XripAeq.jpg)
The dampers cleaned. Gunk I used in the tyre when I had the puncture was hard to get off!
(https://i.imgur.com/nP01SyK.jpg)
Rebuilt the master cylinders with these straight adapter from accosssato.
(https://i.imgur.com/H2RQ1mz.jpg)
(https://i.imgur.com/L054pv6.jpg)
Then I started on the big oil cooler.
Big cores as they arrived.
(https://i.imgur.com/LsKr8vW.jpg)
(https://i.imgur.com/vVgNH6q.jpg)
Gently curved.
(https://i.imgur.com/jMkxomI.jpg)
Clearance to the front wheel.
(https://i.imgur.com/aenf7zT.jpg)
(https://i.imgur.com/znaqK8G.jpg)
(https://i.imgur.com/iIjc7FS.jpg)
(https://i.imgur.com/FXVI1Zl.jpg)
Making the formers from inch thick aluminium.
(https://i.imgur.com/fHTxmlE.jpg)
(https://i.imgur.com/erRvlKy.jpg)
(https://i.imgur.com/gWF1E8v.jpg)
(https://i.imgur.com/YClepP0.jpg)
(https://i.imgur.com/aivwCUe.jpg)
I wanted quite sharp definition lines and really flat sides so had to be careful how I worked the material.
(https://i.imgur.com/PLuzC7A.jpg)
Started to form the tanks.
(https://i.imgur.com/qYAu71w.jpg)
(https://i.imgur.com/DjwLPAs.jpg)
(https://i.imgur.com/ibWEmk1.jpg)
The two sides of the tank fitted together.
(https://i.imgur.com/aXPFhMd.jpg)
(https://i.imgur.com/Llv9M2X.jpg)
The opposite tank.
(https://i.imgur.com/8Ehu1fa.jpg)
(https://i.imgur.com/keRaRKp.jpg)
(https://i.imgur.com/RKIMkg8.jpg)
This was the second attempt as the first wasn't quite up to scratch.
And the lower and upper sections welded together. Its quite involving, and I didn't stop to take many photos during this process.
(https://i.imgur.com/RHugUkV.jpg)
(https://i.imgur.com/G9uTPWU.jpg)
Then there was a bit of a tight bend needed, certainly tighter than I can bend with tools. so I formed it around a smaller buck made from solid.
(https://i.imgur.com/mqwgMIY.jpg)
(https://i.imgur.com/ThgoU0o.jpg)
Those wiggins connectors :smitten:
(https://i.imgur.com/j0FoJ0n.jpg)
Wire frame pattern for the lower pipes.
(https://i.imgur.com/vY9OW08.jpg)
(https://i.imgur.com/7QgzpwI.jpg)
Wasn't sure if this new material would bend...
(https://i.imgur.com/XzehgIj.jpg)
Annealing it lets you bend it.
(https://i.imgur.com/qqxIEPW.jpg)
(https://i.imgur.com/ch0hywJ.jpg)
Pretty happy with the fit:-
(https://i.imgur.com/WtUQulQ.jpg)
(https://i.imgur.com/ymsMeqQ.jpg)
(https://i.imgur.com/god5bpD.jpg)
(https://i.imgur.com/qIaWHSE.jpg)
So then my mate decided he needed his bike setup on a dyno, and so did I. So i hurried to get it to a state where it could be run, old oil cooler on and ready to go.
(https://i.imgur.com/UUDJDo8.jpg)
(https://i.imgur.com/xtRFumu.jpg)
Still grubby
(https://i.imgur.com/SMZciSV.jpg)
JHS near bristol did the mapping.
(https://i.imgur.com/yh1yA4c.jpg)
I felt shit that day, proper man-flu.
That was in january, and I didn't do much to the bike after that until march, when I simply reassembled it for the summer.
(https://i.imgur.com/SIEJQXS.jpg)
Couple of things happened during 2015, I added gold reflective tape to the rear of the air filter, old:-
(https://i.imgur.com/bTuSjxw.jpg)
New:-
(https://i.imgur.com/CKwndNC.jpg)
(https://i.imgur.com/63JHSJj.jpg)
And the fork seals went. I replaced them with the recommended Kawasaki ones.
Made a tool to help.
(https://i.imgur.com/1z1KplO.jpg)
(https://i.imgur.com/KSuHkMu.jpg)
(https://i.imgur.com/R7CfzaQ.jpg)
Then the rear tyre gave up. Found a rear on its own, but ended up replacing both.
(https://i.imgur.com/3gQBMER.jpg)
Then there were some bad vibes at work, and I had to get my bike out of there. I put it into storage, and didn't do anything with it for almost a year, but in 2016 I was given a key so I could get at it whenever I needed to, so as it didn't have an M.O.T., the rush was on!
Took the battery off to charge.
(https://i.imgur.com/AWKUxX5.jpg)
The battery was shot tho, had to get a new one. Bike passed the mot, but still had a slightly weepy seal on the forks. These are the kawasaki seals I had:-
(https://i.imgur.com/2nB611W.jpg)
(https://i.imgur.com/wP192ru.jpg)
I had been talking to Alex at Torques about designing a better dry break for a while, since I got the previous set. He had some samples made earlier in aluminium but we still needed to improve upon the design, and the final items arrived in July 2016. Here's the last drawing:-
(https://i.imgur.com/qACGmHg.jpg)
Here are the variations he caries now
(https://i.imgur.com/y9BJPii.jpg)
(https://i.imgur.com/cM8MCc8.jpg)
And yes, the banjos are titanium. :)
I had HEL make me up some revised brake hoses, this was all they needed:-
(https://i.imgur.com/HzoTvtr.jpg)
(https://i.imgur.com/Y1sHWGA.jpg)
As the hoses arrived
(https://i.imgur.com/hnnsiUL.jpg)
(https://i.imgur.com/Xdw6j2c.jpg)
And fitted up
(https://i.imgur.com/eFdtIcq.jpg)
(https://i.imgur.com/GYO6GtV.jpg)
Redid the fork seals and used SKF seals. Had to machine my tool slightly as the SKF seal is a different profile.
(https://i.imgur.com/HFAM0ZZ.jpg)
(https://i.imgur.com/rPvaU4G.jpg)
(https://i.imgur.com/lsBCSTz.jpg)
Its a little bit mickey mouse but i got a koso temp gauge so i can keep an eye on the temps.
(https://i.imgur.com/l3b3Oqq.jpg)
plumbed in to the oil gallery
(https://i.imgur.com/FEtHG8L.jpg)
Again, naff all happened over the winter, and I only got the urge to ride when the sun came out this year. First ride was in march.
(https://i.imgur.com/dHtwOcK.jpg)
I did however have a new oil cooler to fit.
(https://i.imgur.com/mHyWBbp.jpg)
(https://i.imgur.com/hNx0S8d.jpg)
(https://i.imgur.com/L1XSJgg.jpg)
It needed a mesh cover, so i trimmed one out.
(https://i.imgur.com/y3huSeE.jpg)
(https://i.imgur.com/0NBLNgd.jpg)
(https://i.imgur.com/N6QoKLv.jpg)
(https://i.imgur.com/ylmvlwN.jpg)
(https://i.imgur.com/IuzdIZK.jpg)
(https://i.imgur.com/Wb0Cit9.jpg)
From a suggestion from a couple of other high end interweb users, I managed to source some of the very desireable 1/4 x1/4 welded stainless mesh.
(https://i.imgur.com/pJuYqCn.jpg)
From this i was planning to make a silver soldered assembly, but it didn't go completely to plan.
First attempt:-
(https://i.imgur.com/FeL5xrP.jpg)
(https://i.imgur.com/qbsTvKo.jpg)
All good so far. Then some practice joins
(https://i.imgur.com/CYcq8zL.jpg)
Still all good. I'm quite happy at this point.
(https://i.imgur.com/dUuLKW2.jpg)
Disaster. too hot. Gonna have to rethink this.
Second try. Same wire frame to begin with.
(https://i.imgur.com/51JKLoE.jpg)
But lock wire on instead of soldered.
(https://i.imgur.com/51JKLoE.jpg)
(https://i.imgur.com/PgsZH8p.jpg)
(https://i.imgur.com/xC2G9dy.jpg)
Perfect! And still clearance.
(https://i.imgur.com/s8p0mNr.jpg)
And the very last thing I did was to fit the new brake levers I had.
(https://i.imgur.com/9sfe9tF.jpg)
They had been lurking in the tool box since 2012, but I never got around to getting them painted satin, like the rest of the lever.
So, this is it. Possibly time to let go.
What a fantastic job, when I first saw it advertised for £8k I thought you were having a laugh, but now I think it's a fair price. Whoever buys it will be getting a very special bike, brilliant.
some top quality work and parts :onya:
best ad ever to show everything done to this bike.
good luck matt and remember you don't have to leave the org when you sell the bike I'm sure there will be folk asking your advice for a long time to come .
:hat: :salute:
ive seen a lot of mods/restores. yours is by far the best. your talent and thinking just enormous. no praise high enough. incredible.
Incredible.
Too incredible.
My thoughts of my being good doing my own servicing and gentle mechanics are blown apart.
After this thread I am developing an inferiority complex.
It's lunchtime here in France, where's the wine.....
:bugga:
What a steal @ 8k :onya:
The fabrication is amazing but it's the welding that tops it off for me. It's beautiful.
G'day Matt. Having had some involvement with championship winning bikes and racecars, I see race engineering as art. You are certainly an artist.
Thanks for detailing the work you have done on your bike for us all to see. :onya:
Truly awe inspiring mate. Thank you for recreating the thread for us here - a lot of work I know:)
Quote from: lil4399 on Sunday, 21 January 2018, 08:56 PM
It's lunchtime here in France, where's the wine.....
Sorry I always finish the wine at breakfast time.
For reference - muesli is best matched by a sweet white, but not a dessert wine (that's an amateur mistake ) :lol:
Following The Troubles, things have almost gone full circle. I not do the odd day in AH to help out, two days this week. I mentioned yesterday to one of the lads that works there today that I was missing a load of items after the move. Most of the parts I couldn't care less about, special funnels for filling gearbox oil, an 11L(good for 10L fuel and a dash of 2stroke oil) Gerry can, watering can etc. I can make anything like that again, as it's the items that have gone rather than the skill. One item tho that I couldn't find after the move was the original PC3 bracket way back from page one. It was titanium, and was one of the first things I made, and I was quite attached to it. I think it was in my big tool box, as I was planning to pick the neoprene off, vapour blast it and apply a new rubber band and neoprene.
Couldn't find it. Anywhere. Looked more than twice.
Eyes lit up when I described it, and out came the step ladder. He'd seen it, it had been tossed up above the false roof area on top of the toilet! I'm so happy.
(https://imgur.com/gallery/BP97q2l)
I'll be able to finish picking off the neoprene now.
I remember that, I bought one of your titanium headlight adjuster brackets back then........wow where did the time go mate 👍
Iv noticed there's an actual 'readers bikes' type section in general, would this thread be better placed there? I wonder if admin could move it for me.
Ta.
Quote from: kanerdog1X1 on Friday, 03 August 2018, 04:59 AM
Iv noticed there's an actual 'readers bikes' type section in general, would this thread be better placed there? I wonder if admin could move it for me.
Ta.
No problem - done :onya:
Perfect, thankyou.
Stunning bike, beautifull parts and excellent craftmanship 👌🏻👌🏻. Enjoyed the whole story.
Thanks guys.
Made a start on an odd project at work this last week, and the wobbler came in handy. We have a rolling road at work, and a particular customer wants to be able to run bikes on it, so I set about making a frame so we can run bikes. Its adjustable, so different bikes can sit on it, and Ive run the 14 on it very briefly and all seems well. I only took one pic, right at the start of the project.
(https://i.imgur.com/z5hYyRd.jpg)
If anyone needs a bike, or 2wd car for that matter setting up on the rolling road, we are ready for you.
Bike is now sold, so this will be the end of my contribution to this bike. The new owner may be in here, I'm sure you will make him welcome.
Good and sad news as I for one will miss your updates on the bike.
I know that needs must and life moves on .
Please don't be a stranger here .
Good luck buddy :cheers:
this is amazing work, thanks for posting! :)
Just found this from a link on Facebook by the new owner.
Just speechless. The Raquel Welch of 14s.
I raise mine hat thee of ranker worth than I.
Spoke to the new owner this morning. Glad he is Dutch, can finally sit it with my own eyes.....can't wait. New owner is org member so think he will post some pictures when he has some.
Quote from: BbigMmac on Wednesday, 30 September 2020, 06:43 PM
Spoke to the new owner this morning. Glad he is Dutch, can finally sit it with my own eyes.....can't wait. New owner is org member so think he will post some pictures when he has some.
https://gsx1400owners.org/forum/index.php?topic=4316.0
:grin: