Big Heavy Wobbler

[kanerdog1X1]

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.

[kanerdog1X1]

The bike was featured in Performance bikes magazine, here is Gary Inman road testing it earlier in the year.

[kanerdog1X1]

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.





Then moved on to designing a paddock stand.







Once I could get the bike apart I could start fitting the tube to the frame.











The oil pipes would be for the second generation oil cooler I was planning...

[kanerdog1X1]

The second special core, as I arrived. I ordered it with bigger tube plates so I had some material to play with.



Started by making a former for the end tanks.





Then made the tanks and curved the core.





Welded up.

[kanerdog1X1]

I felt this needed more titanium porn, so I made a fan bracket too.

[kanerdog1X1]

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.





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.

[kanerdog1X1]

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.













The foam in the fuel tank.





This needed the fuel sender to be partitioned/baffled away from the foam. Behind the baffle:-



And the baffle.





And the titanium quick release bracket.







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.

[kanerdog1X1]

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.



Ready to be collected. He took my old tank as a pattern.



Updates sent to me through the weeks.















You can see here the broken decal.



He also did my front mudguard.



And fitted.

[kanerdog1X1]

The fuel rail and pump.

Here's the fuel rail I made.





Pressure testing.





And back from anodising along with some other bits.



And reassembled onto the throttle bodies.

[kanerdog1X1]

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:-



Third, forth or fifth attempt, and I got it right. It's tight under the tank.



Back from the platers. looks brand new.



Re tested



Some supplies for the project.





And built up.



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.

[kanerdog1X1]

In between all of that being done, I was cleaning up the other parts ready for the rebuild.





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.





Also had the side cases re done. They take a battering from stone chips combined with the heat.



Rather then get the frame re powder coated, I simply dusted over the bare sections with rattle can.



Then the rebuild could start.

[kanerdog1X1]

New shorter hoses.





















At this point I was just waiting for the tank. Waiting. Waiting.

[kanerdog1X1]

The tank!





It needed a little plumbing for the breather.





Later I added a quick release fitting. I got this idea after meeting another rider and seeing it on his bike.





This is the key ring I use to fill up.



To make servicing the tank easier, I made this frame to hold it steady.

[kanerdog1X1]

So this was summer 2013.



The breather box plate lets a lot of light through under the airbox, this I like.

I found a new use for the filler.

[kanerdog1X1]

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.









Once this was done I could send part of the assembly to ITG to have a filter bonded on.



More supplies