New project;plenty of work required.

[Evilchicken0]

I just take the rubbers off the footpegs they look a lot better for it

[willandrip]

Got a small amount done over the weekend;

Whitewall tyres anyone ?



No sense masking off a tyre that is only to be binned when the stickies arrive !
I hate painting alloy wheels,whatever you do some contamination is always in the alloy,but powdercoat is out of the budget on this project.

Headers cleaned up nicely,studs and nuts fitted and exup valve was stripped and copperslip greased.(only one previously snapped cap screw which drilled out and retapped easily).New plugs were fitted and cooling system replaced.
Presenty awaiting new supplies of fasteners.(before someone quips up about exposed overlength bolts.)





Tidied up clutch casing center, where paint was lifting, in situ (gasket is nearly £10),but am not really happy with the finish.It may get stripped off and polished instead.



After Boris' reply to an earlier post I utilised his idea and cut the tags off the shock remote res mount and relocated them.
This allowed tags to be fabbed and positioned to utilise the original hanger for the can .
The fixings are external to the seat unit but original hanger is so bulky I did not wish to notch the plastics in order to fit it internally.
The original coolant reservoir is now refitted in its proper location.



Instruments and controls now refitted after fork overhaul.
As per usual,this was the first time they had been apart in 25 plus years.
New oil and seals fitted,the stanchions were much better than anticipated as was the condition of the bushings.
Heavier springs and new spacers to be fitted when sourced.
The legs cleaned up ok but some "worm trails" still remain in the alloy finish.







Braided hose for clutch routes through the frame and the replacement magnesium sprocket cover was given the wire brush treatment rather than paint.
Sidestand was replaced at the same time with one I had puchased months ago simply to get an original spring for another project.
The stand and pin had worn so much on the original that it settled another 10 degrees which was disconcerting.Nobody likes to see their bike lying on its side.



Headlight units refitted in anticipation of new fairing.



Uprated caliper fitted.



Starting to look like someone cares about it once more.









Whoever built this originally had thought it through and did a good job on the fab work,just a pity he chopped up an SP to do it.I think it has lain abandoned until very recently judging by the surface corrosion.
Now with the carbs serviced,plugs replaced, airbox fitted properly and a decent can on ,it runs sweet as ...
The shake down run will be the decider if its to be a keeper or not.

Next weekend is the rear end overhaul, hopefully.

[Kayla850]

just a pity he chopped up an SP to do it.I think it has lain abandoned until very recently judging by the surface corrosion.

It's looking nicer already Bill and I love the whitewall- should've gone with red wheels and matt black paint on the body for the proper rat rod look-



Red tuck and roll vinyl for the seat too I reckon

[willandrip]

Here woman,you should be slaving over a hot lathe !
Got any more thoughts on what to do with the chassis you aquired.
Pity there was not any sprints or hillclimbs more local to us in order to get some competative use out of these old bikes.!
Presently this is just going to be yet another road bike in the stable; which is getting a bit boring.

[Kayla850]

Here woman,you should be slaving over a hot lathe !
Got any more thoughts on what to do with the chassis you aquired.
Pity there was not any sprints or hillclimbs more local to us in order to get some competative use out of these old bikes.!
Presently this is just going to be yet another road bike in the stable; which is getting a bit boring.

I shall be slaving away this week!

There are hillclimbs near Pickering and Kat (who runs the Teesside bike nights) is organising a Sprint

[willandrip]

Thats good news.
I'd be up for them; the're within travelling distance for the auld Landrover (now only about 18mpg) and my hotchpotch of a trailer.!

[willandrip]

New battery fitted on Fri. pm
Yzf relays clip to front of battery box;there is no room for them elsewhere using the YZF harness.
It is always a boost to get a project to run from its own battery; it usually means the build is coming towards the end.



Visit to Kayla at Projection Components on Sat. to collect the overlength gear change pedal rod that was required to mate the Fzr footrests to the Yzf engine.
The existing was a badly welded up job.



Whilst there picked up a Genesis rubber shroud that encloses the headlight wiring harness.
Although the wiring was tidy and compact,this item just finishes it off and they are getting scarce.



Mocking up of rear wheel swap out to a 5" unit (also from Kayla.)
This is going to need further work such as properly measured spacers and more importantly a disc and carrier and is put on temporary hold for the time being.
Will try the Supercorsa's on existing rims. and then re-evalulate.



Trimming up of modified footrest mount ;removed surplus material that was also interfering with the chain run.





Original Fzr 1000 5.5" wheel repainted and fitted.
Braided hose a touch too long really.







Shock and swinger was stripped out and cleaned up;all linkages re-greased,in surprisingly good condition to start with.
Swinger got bobbin spool mounts welded on ,again parts from Projection.





Have decided to use existing O ring chain and sprockets to prevent costs escalating .
I had new spares but the originals have loads of miles left in them;chain is nearly new and surface corrosion cleaned off when in the paraffin bath.
The 2 tk chainguard was de-rivited.plastic rear laquered to protect the original chain legend decal and the front metal part resprayed satin black (too much silver on this project) and re-rivited.





Next weekend is tyre fitting and OW01 fairing mock up.

[willandrip]

Sticky tyres fitted today;



That decal looks a bit gawdy,even on the paddock stand.
It was lying about in the decal box for want of something to stick it on ; but I think,on hindsight, the bin may have been a better home for it .

Front cannot be balanced yet,it will need some roadwork to remove the shed material that has stuck to it when coming into the pits from its last outing .Amazing; this rubber has bouced back off underside of mudguard and re- adhered to surface of the tyre as it was coming in from sighting laps.There seems to be no way to remove except a very hot knife/wire or a bit wear on the road (will be rough though)
This just shows what a top class Supersport rider can do to a new tyre in 6 laps at a BSB meeting.



Attempt to show profile of 160 tyre on 5.5" rim against a 160 on a 5" rim (on right).



The loss of profile is less than 10% and its still more pronounced than the 180/55 on the same sized rim.(FZR 1000R)





Fairing mock-up;








Change of plan here also,was going to use a new OW01 road unit but had a spare nosecone from a 1000 that requires a little work,a new screen ,paint and a tidying of the running light,(actually have a N.O.S.item from stock,bought last year for 99p.



Flush fitting indicators will accompany this,I bought 2 sets from Germany last year for projects but when they arrived 4 sets had been sent.Not as good quality as original but the drilling is minimal to fit and easy to trim to fit the fairing contours.



The Genesis/SP 2TK birdcage/instrument mount frame will not match the 1000 nosecone and the mirror mount holes differ.





I will use the most of the original (it has been altered to fit the YZF instruments) and cut/shut the mirror mount arms from a scrap 3EN2 birdcage I replaced from my first build on this forum last August.



Thats it for this weekend;I'm out to ride one tommorow instead of sweating in the shed !

[willandrip]

Update;

Right then; after waiting for the new screen to be delivered and being told enchanting fairy stories as to why the bellypan had not been despatched we finally got round to paint and applying a few decals that were leftovers.
The last of the tomato red vinyl was hand cut (as you can tell) for the nosecone.
The tank and seat unit got a quick rub over and all paintwork was laquered,which put a lttle shine back on the original finish.
The mounting brackets were flat alloy bar and easily formed.
Old and damaged air pipe trims for the nosecone ,rejects from another bike,were cut down to fit the modified screen mounting frame.
The 1000R nosecone is a lttle large for the 400 frame scaling but it is perhaps not too bad !
Redundant scruffy white "Mickey Mouse" mirrors were repainted and fitted.
The new fixings tidy up the mounting of these.
Road test on Saturday,time and weather permitting.
Final costing and impressions to follow.

Here it is finished then;

[mattUKNC]

That looks great! Has a touch of 'mean' about it.
Nice work.