New project... 86 GSXR 1100

[svbmx]

Picked myself up a new project a few days after xmas.

An 86 GSXR 1100 rolling chassis with 91 gsxr1100 swingarm, srad750 forks and bandit1200 wheels. A good starting point.

Started on the tank/tail design...

https://i.imgur.com/7nn9dw0h.jpg

https://i.imgur.com/OL1lKN5h.jpg

https://i.imgur.com/BYSaXaVh.jpg

[andrewsmith]

Subscribed
Watching with interest

Sent from my D2303 using Tapatalk

[Stilo]

Could be interesting. I like the inventive use of a car tyre & pieces of wood. The mother of invention etc!

[maviczap]

I like it already, don't do any more ;)

[squirrel_hunter]

You set the bar high with your last build, so I'm looking forward to this one!

[Geodude]

*Excited girly scream* ;)

[garynortheast]

This looks good, I'll be following this with interest!

[andy650]

Can I see a hint of Guys monster bike in there?

https://cdn.rideapart.com/wp-content/uploads/2014/07/2014-Pike-Peak-International-Hill-Climb-Guy-Martin-01.jpg

[L3nny]

Yep, that's begging for a tubo'd 'Busa engine to be dropped in it :D

[svbmx]

Could be interesting. I like the inventive use of a car tyre & pieces of wood. The mother of invention etc!

Yup, whatever works right?!

Can I see a hint of Guys monster bike in there?

I hadn't thought about it but yeah i guess so. That's certainly a rad looking bike.

Yep, that's begging for a tubo'd 'Busa engine to be dropped in it :D

I'm thinking a 1260 kit with a nice set of carbs. Keep it N/A. Should be enough power for me!

The tank/tail unit will be ali with a very minimal subframe, just enough to support the butt region. The monocoque design should give ample support to the rest of the tail. Unsure whether or not to house the battery in the tail or use some of the tank space to keep the weight central. With the build being more track focused, fuel capacity isn't as much of a priority.

Anyway, I had a bit of time this weekend to do abit more on tank/tail mock-up...

https://i.imgur.com/jLVQAVAh.jpg

https://i.imgur.com/dCWZCxVh.jpg

[Fen Tiger]

Cool

[andy650]

Not that we want to lose you, but this forum would love to see the build as well

http://www.gixxer.com/forums/15-oil-cooled-gixxers/

[svbmx]

Not that we want to lose you, but this forum would love to see the build as well

http://www.gixxer.com/forums/15-oil-cooled-gixxers/

I actually signed up on that forum a couple weeks back thinking it might be useful during this build.

That's a good shout, I'll start a thread on there too

[svbmx]

I’ve been slacking with the build lately but finally got crackin with the mono tank/tail at the weekend.

Firstly, I dismantled and measured my cardboard mock-up to then recreate the parts in Solidworks. I then flattened and exported the parts into our (work) sheet metal software, where i then programmed the parts to be cut out of a sheet of 18 gauge stainless steel. I was originally going to use 2mm aluminium but the steel was half the price, our machinery at work is limited on the tooling i can use to punch 2mm ALI so I’d have had to cut all the parts manually! Plus I’m much better at welding steel :P

The design below also shows the battery location based on a 12-cell anti gravity unit and a channel to hide the wiring. What it doesn’t show are the tank baffles, which will be added later.

https://i.imgur.com/WNsQ1g6h.png

Below shows the freshly punched sheet

https://i.imgur.com/5szPci4h.jpg

Next I went about bending the metal. The zero radius bends i put on using the bending machines at work, but unfortunately work didn’t have the tooling to bend the larger radius bends i needed so i had to improvise at home! Fortunately a had a couple of used disposable argon bottles that worked a treat :)

https://i.imgur.com/BNwBBZxh.jpg

https://i.imgur.com/e3DlT2oh.jpg

https://i.imgur.com/xe5sqToh.jpg

Unfortunately I only got as far as tacking one side of the tank before i ran out of Argon but am pretty pleased with how it looks so far...

https://i.imgur.com/RdbQXSbh.jpg

https://i.imgur.com/4QBycsoh.jpg

[maviczap]

Bloody cool!

[shiftin_gear98]

Looking good, nice skills innit.

[yorkie_chris]

Mate I like your work

If you ever want any bits laser scanning and a model doing out of them then give me a shout, all the gear is in Bacup.

We have a romer CMM arm and a perceptron scanner for doing reverse engineering work

[yorkie_chris]

p.s all that gear and skill and you're using disposable bottles! ffs!

[svbmx]

p.s all that gear and skill and you're using disposable bottles! ffs!

I only bought the welder a few months back and ordered a few disposables with it at the time because I hadn’t sorted a larger bottle yet. Will be getting sorted soon enough!

[Geodude]

Very nice :)

[svbmx]

Little update. Welded and cleaned one side...

https://i.imgur.com/NvHEks9h.jpg

https://i.imgur.com/aeqhT9uh.jpg

https://i.imgur.com/cwiz1B1h.jpg

Got a bandit 1200 motor. Needs a good scrub but should clean up nicely.

https://i.imgur.com/L1aSOV9h.jpg

And a lovely set of custom rearsets from http://grumpy1260suzukispares.co.uk

https://i.imgur.com/ANwG2BBh.jpg

[svbmx]

UPDATE... (It’s been awhile!)


I’ve cleaned the engine up abit (but not alot!) and have it in place so i can make the mounts.

The rear shock relocation is now complete, along with some additional bracing. Super happy with it.

https://i.imgur.com/nzwWQVph.jpg

I’ve had to have the sprocket carrier machined so the wheel can sit central.

https://i.imgur.com/ljXNJjSh.jpg

I finished off the tank/tail shell and have also made the subframe. The 2 pieces are now connected via a hinge and supported by 2 mini gas struts. These will lift the shell from 45 degrees to vertical but are mainly in place just to keep the shell safely in its vertical position whilst access is required.

https://i.imgur.com/AvLgC3Nh.jpg

https://i.imgur.com/OE9H0jxh.jpg

Im also playing around with ideas for holding down the front of the shell. Quite liking this style of latch either side, bit of a feature. Thoughts?

https://i.imgur.com/3PxzL10h.jpg

I’ve also made the fuel cell, well, almost... i ran out of gas! This has a channel for wiring and a flush fitting fuel cap. Once welded, Il be filling it with foam baffle cubes. The tank will hold approx. 13 litres.

https://i.imgur.com/cleWlSDh.jpg

https://i.imgur.com/A53hpxdh.jpg

https://i.imgur.com/GiQF6crh.jpg

https://i.imgur.com/9XiF6eXh.jpg

https://i.imgur.com/0BSQtakh.jpg

https://i.imgur.com/sRLepngh.jpg

Ideally i would have liked to make the shell from either carbon fibre or aluminium, and the subframe + fuel cell from aluminium too. But as i can only weld steel and wanting to do as much of the build myself, i opted for what i can weld. Perhaps once the build is complete il learn to weld aluminium and remake the parts.

Anyway, still lots to do but its definitely starting to take shape :)

[Geodude]

Nice work as usual, thanks for the update :)

[Bibio]

looking good.

[squirrel_hunter]

Good progress.

The latches to hold the shell down are different, depends on the overall look that you are going for...

As for the tank or fuel cell, why fill it with foam and whats the detail here? What are you going to do to ensure that the tank is fuel tight? Also are you planning to treat the inside of the tank at all?

[svbmx]

Thanks all :)


As for the tank or fuel cell, why fill it with foam and whats the detail here? What are you going to do to ensure that the tank is fuel tight? Also are you planning to treat the inside of the tank at all?

Thanks. Once fully welded, I'll be treating the inside of the tank with some tank sealer. I might see if i can use the leak tester at work too. And the foam baffle cubes will prevent the fuel from sloshing about.

[svbmx]

These...

https://www.merlinmotorsport.co.uk/p/safecrest-1v-fuel-tank-foam-single-cube-tank-foam

[squirrel_hunter]

As you're making the tank yourself why not add some baffles into it as opposed to the foam? Also do you know how much foam is required and how long it lasts?

[svbmx]

Bit more done to the slabby.

Fuel tank done except the breather (waiting on some stainless pipe), engine mounts made, just need to radius the corners. Seat base ready for upholstery. Next the exhaust...

https://i.imgur.com/omrk1pLh.jpg

https://i.imgur.com/EYA7YL7h.jpg

https://i.imgur.com/TM49ssnh.jpg

https://i.imgur.com/4gNxLVYh.jpg

https://i.imgur.com/POVOL3hh.jpg

https://i.imgur.com/duq1o0Bh.jpg

https://i.imgur.com/JFZKQe6h.jpg

[Bibio]

some very tidy work going on there :-)

[Gordon13]

Awesome

[mister c]

Shows how long I've been away. Nice project., I'll be following this from now on.

[svbmx]

Hi Guys, Hope all is well :)

I’ve been struggling to find time to work on my build as of late, but managed to get on in a bit more over the last couple of weeks.


I found myself a rear brake caliper and had some custom spacers made up to make the B12 wheel fit.


https://i.imgur.com/qjQGSdoh.jpg

https://i.imgur.com/l3EcJrOh.jpg

https://i.imgur.com/4K4BVsgh.jpg

https://i.imgur.com/PoUPo74h.jpg


And I got going on the exhaust too. I decided against making the full system, figured the headers would be too much work for my amateur welding skills! So I purchased some Black Widow race headers, which are very nice indeed. Then proceeded to make the exhaust back from that. I purchased some 304 tubing and some pre-bent mandrels to suit. The mufflers however, I made and rolled myself from flat sheet 304. They were a b***h! But overall happy with what I’ve achieved so far.

https://i.imgur.com/dyb9C9rh.jpg

https://i.imgur.com/hXkMmo9h.jpg

https://i.imgur.com/W7siBhUh.jpg

https://i.imgur.com/fvjAavqh.jpg

https://i.imgur.com/dhzRYXwh.jpg

https://i.imgur.com/WWypgCGh.jpg

https://i.imgur.com/8jjVyhqh.jpg

https://i.imgur.com/avAWnRFh.jpg

[maviczap]

Looking better and better

[mister c]

Nice!

[squirrel_hunter]

Thats some lovely work.

Out of interest are the spacers ally or stainless?

[svbmx]

Thats some lovely work.

Out of interest are the spacers ally or stainless?

Thanks. The spacers are ally.

[svbmx]

Welding complete :) Just need to make the baffle inserts next.

https://i.imgur.com/y4vB1oIh.jpg

https://i.imgur.com/t2xMyVGh.jpg

https://i.imgur.com/d1w7oXTh.jpg

https://i.imgur.com/EM06RVHh.jpg

https://i.imgur.com/ttr6s1Sh.jpg

[Othen]

You are so patient in making the exhaust system almost from scratch #svbmx, I’d never have seen that through. I’d probably have found a system (or two) that was more or less right and done a cut and weld. You have done a really nice job though, well done.

I like projects that I can complete in a month or two, how long do you think this one will take you? I’m really impressed with your determination.

Alan


Sent from my iPad using Tapatalk

[Othen]

... I’ve just read the whole thread. I’m really impressed with the tank/seat unit as well - and continue to be amazed at your patience - in that respect you are a better man than I am Gunga Din.

Alan


Sent from my iPad using Tapatalk

[svbmx]

So, since finishing the exhaust I’ve done very little else! It’s been a hectic last few months and a pricey one too!

As funds are still too short to purchase any of the more important components (carbs, electronics, ignition etc) I thought I’d get a bit of paint on it. Wheels, bodywork and headlight/gauge housing. I also added some fork guards that I had originally made for the sv, look alright I think.

And I made a mounting bracket and some end caps for the Mocal oil cooler I has previously purchased. Really happy with how that turned out.

https://i.imgur.com/646QbNKh.jpg

https://i.imgur.com/9dWjnO2h.jpg

https://i.imgur.com/4UQOPRXh.jpg

https://i.imgur.com/29F6agIh.jpg

https://i.imgur.com/rBnWrqvh.jpg

https://i.imgur.com/EH3fl0ch.jpg

https://i.imgur.com/i6gjMCBh.jpg

https://i.imgur.com/s31exOrh.jpg

https://i.imgur.com/CMYaylih.jpg

[maviczap]

Taking shape nicely!

[mister c]

Looking good. I wish that I had the engineering prowess you have, it's outstanding

[Geodude]

Nice to see you have nearly finished my gixxer :D :joker: ;) Looking good.