Project Budget Turbo Dragqueen

[Jon]

Make yerself a cup of tea, its a long few posts for yer all to catch up. Copy n pasted these forum build diaries from few other uk forums. If yer bored at work have a read, if not scroll n look at pics n figure out what Ive been up to. Lol. Enjoy…….



My latest project I got few weeks ago. Wasnt planning another project, but it just kinda happened. Got garage full as is with my VW trike, Harris, n Ninja fighter, but hey ho. Was at the right price and just round corner from me.

http://i61.photobucket.com/albums/h63/pitstop-paint/bandit%20project%20tiny%20pics/SN853876.jpg

Had been sat outside n well weathered. Everything either rust or brush painted hammerite. Nice. Been sat for a year as had an electrical problem. Him n his mates couldnt sort it so gave up and it just sat in corner of shed in bits and several boxes. Tank got damaged from kicking about on floor. Few dents n a big ass dent underneath n tap snapped off. Why do I buy these things? Well its a 2004 bike and it was only £400, round corner and still had T&T on it and a few nice bits like braided hoses, renthals, high level race pipe, brand new discs F/R, Chain n sprockets, n stack of spares like brake pads another chain, etc, etc.

Original plan was to break it, or just get it running n flog on for small profit as a tatty winter hack for someone. Got it running within an hour n phoned him and left a message on his machine of it revving away quite happily. He wasnt too chuffed, but hey ho Im good at electrics too.

Anyway one thing led to another and decided to keep it n build a drag style bike out of it like this:-

http://streetfightercafe.com/images/6-17-2007.jpg

A style I havent done before. Always built streetfighters to handle n thought it would be something different. Completely pointless given I live on a remote scottish island with next to no straights, but miles n miles of twisty empty mountain roads with no traffic lights/junctions/cameras, etc. But hey got other bikes sitting there for the twisties, might as well build something different n silly. Show up local chavs imprezas n knee slider brigade up Stornoway who just ride round n round n round town centre all day............... when its sunny of course.

Right quick catch up via pics, cos cant be arsed typing every stage of it so far.

Stripped it down using a grinder as all bolts rusted solid! :-

http://i61.photobucket.com/albums/h63/pitstop-paint/bandit%20project%20tiny%20pics/SN853903.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/bandit%20project%20tiny%20pics/SN853941.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/bandit%20project%20tiny%20pics/SN853886.jpg

Found some of the exhaust studs were welded onto collars as were snapped. Bodgetastic!:-

http://i61.photobucket.com/albums/h63/pitstop-paint/bandit%20project%20tiny%20pics/SN853899.jpg

Sorted out loom properly as it was nothing but loose wires n selotape when got it as owner n mate had been attempting to `fix` it:-

http://i61.photobucket.com/albums/h63/pitstop-paint/bandit%20project%20tiny%20pics/SN853886.jpg

Me mate Yantosh cut out damaged section on underneath of tank, built it back up n put on a new boss for the tap, which I got out of my mates junk pile:-

http://i61.photobucket.com/albums/h63/pitstop-paint/bandit%20project%20tiny%20pics/SN853931.jpg

While it was there some mods for fuel return were done to allow fuel to be pumped back into tank above fuel level through one of original breather tubes underneath. Reason to be explained later in pics. lol. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/bandit%20project%20tiny%20pics/SN853929.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/bandit%20project%20tiny%20pics/SN853930.jpg

Got this fresh GSXR750M motor (last of oil cooled models) offf a mate in exchange for a cut price lid paintjob for his girlfreind:-

http://i61.photobucket.com/albums/h63/pitstop-paint/bandit%20project%20tiny%20pics/SN853927.jpg

Came with big 36/38mm slingshot carbs too, and matching CDI pack:-

http://i61.photobucket.com/albums/h63/pitstop-paint/bandit%20project%20tiny%20pics/SN853928.jpg

Straight out of running healthy bike as he upgraded to 12 lump. 102 rwbhp stock n good 110-115 with some jetting n fiddling. Good strong lump n in good nick. So good in fact I sort of got carried away n bought this for £49 delivered:-

http://i61.photobucket.com/albums/h63/pitstop-paint/bandit%20project%20tiny%20pics/SaabT25Turbo.jpg

Bargain and in full working order with no play or owt. Correct airflow CFM and A?R ratio, etc to match engine characteristics. All turbo specs required off FastByMe who certainly knows his stuff. On standard motor at low boost to keep it reliable will give bout 150-160 rwbhp n vertical torque curve. Keeping it geared down to 150 flat out in 6th gear too, so will be damn quick acceleration. Yantosh is making my plenum and exhaust headers in exchange for paint too. Keeping costs down. lol.

Got a drag spec bandit 12 swingarm coming from Yantosh in exchange for some airbrushing on the SF mag project SV650. Underbraced and some one-off 6-8" extentions to keep front end down.......... hopefully. Might stick on some wheelie bars too. If yer gonna be silly, might as well be properly silly.


Continued……


Nother wee bitty after finished off comission lid today.

Cleaned up mastercylinder mounted onto bars with rest of refurbed bits n bobs.

http://i61.photobucket.com/albums/h63/pitstop-paint/SN854529.jpg

Couldnt get clock dials off n didnt want to bugger clocks so carefully masked em n voila:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN854512.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN854517.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN854518.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN854522.jpg

Not clear coated other bits yet, but clear coating comission lid tomorrow so see whats left in gun each coat. Lol


Continued……


Genny back together:-

http://i61.photobucket.com/albums/h63/pitstop-paint/Engine9.jpg

Starter motor:-

http://i61.photobucket.com/albums/h63/pitstop-paint/Engine8-1.jpg

Carbs cleaned out n back together (just need good outside of body scrub):-

http://i61.photobucket.com/albums/h63/pitstop-paint/Engine7.jpg

Engine all clearcoated n shiny again:-

http://i61.photobucket.com/albums/h63/pitstop-paint/Engine1.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/Engine2.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/Engine3.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/Engine4.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/Engine6.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/Engine5.jpg

Started stripping off casings for polishing:-

http://i61.photobucket.com/albums/h63/pitstop-paint/Engine10.jpg

Dunno if polishing cam cover or spraying silver yet. Gonna be twat to polish. I`ll see. Casings got some serious scrapes n chips outta em. Gonna take flap disc on grinder n sander to em n see if can get rid of worst of em before polishing. Be a few days of looking like a black n white minstrel before updates folks. lol.

Where Im up to anyway (+ engine of course):-

http://i61.photobucket.com/albums/h63/pitstop-paint/Engine11.jpg

Want casings back on engine before go for engine into frame task without chipping paint. lol. I`ll leave off sprocket casing/genny/starter till engine in frame to maximise my clearance issues getting it in. Gonna go for old engine on its side wrapped in cloths n tape n lower frame over with help of a glamorous assistant (me gorgeous missus). lol.


Continued…….



Got a photo today of last nights bitty.

Casings well scabby n scored/chipped up under paint or what was left of it:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN854649.jpg

Took sander to worst of scrapes n got carried away n sanded off lettering and rounded all edges, etc. Got rid of 99% of marks tho. Couple of tiny marks that are too deep to sand out, but only tiny. Couple hours last night with wet n dry n bitta polish. Need a proper buff with drill but my polishing mops dead so will have to wait till get a new one to finish them off properly. Looks ok tho:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN854657.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN854662.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN854661.jpg

Think smoothy look works quite well against complexity of airbrushing. Nother buff up with a new polishing mop n shuld look ok. ;D

Start sanding another cover back tonight. Not my favourite part of a build.


Continued……



I am still workin on this project dont worry. Took a step back from it recently as personal problems overwhelmed any inclination to work on it or generally do owt. :hrm

Back on with it again now tho. :upup

Clutch and other crank casing sanded smooth/polished and back on. Starter too! Looks fab. Not sticking altenator on till in frame tho to maximise clearance.

http://i61.photobucket.com/albums/h63/pitstop-paint/SN854670.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN854707.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN854711.jpg

Oil filler plug was `slightly` tight! Dont know my own strength. lol.

http://i61.photobucket.com/albums/h63/pitstop-paint/SN854673.jpg

In process of stripping cam cover just now. Not sure whether to attempt to polish it or paint it silver as would be a bastard to do and keep shiny under tank. :hrm All the fins, etc. I`ll fink of what options n make a choice.

Not far off engine in frame stage anyway. :wink: Under cam cover spotless like rest of engine.

http://i61.photobucket.com/albums/h63/pitstop-paint/SN854701.jpg

Valve clearances fine, cam chain looks very new as do guides. Think I got lucky with this engine big time. :coolg

Once cam cover done engines on its way back into frame.



Coninued…….



Still coughing my guts up ere with the flu, but had a spell this afternoon of couple hours where felt able to be upright so got wee bitty done.

Frame n engine reunited n altenator back on:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN854750.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN854740.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN854754.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN854756.jpg

Me gorgeous missus Linz gave me a hand line em up, etc. Couple tiny scratches on frame in unseen areas, but nowt I cant touch up so alls good.

Just rear engine bolts in at mo as not cleaned others up yet, or ground down more of my stainless fastners for removeable frame section. Needing new flap discs for grinder, but up town wednseday so I`ll grab some then n get em made up n everything bolted in tight.

Chopped down my scrap workbench a foot or so to easier height now. Turned it round so got access to both sides for assembly as clean bits up. My wife also gave me a hand lift the frame/engine back up onto it again. Garage tip of the day:- `marry a yorkshire lass`. lol.

http://i61.photobucket.com/albums/h63/pitstop-paint/SN854757.jpg

Cam covers not done yet, decided it would be a nice touch to grind/sand off all the fins and casting marks for a smooth look like rest of engine casings. Needless to say its a lotta work. Should look cool smooth n polished up tho like rest. Wasnt wanting to let the cover hold me back tho so went for engine in anyway. lol.

Grab some more flap discs mid week as said n get rest of frame fixings made/cleaned up n that bolted together properly. Get the cam cover done n back on, and then probably move on to front forks since have top yoke/bars, etc already done n sitting waiting.

Liking look so far tho, n mega cheapola. lol.


Continued……



Not got hell of a lot done. Works manic. Been working last couple weekends and evenings too to try catch up with comission work. Still not a bad complaint. Gotta grab the work when its there n not keep folk waiting.

Sanded back sprocket cover over last few eveings removing worst of scrapes. Got to last bit under normal clutch actuator housing n found a fucking crack. Flexed my moobs to see how bad it was and snapped the casing in half. DOH! Was going to fling it off nearest wall then realised I dont need most of cover anyway as on my motor the clutch actuator is on the clutch cover side.

Attacked what was left with grinder/sander, etc, and ended up with this. Does the job n dont look too bad I reckon. Saves cost of another cover too. lol.

http://i61.photobucket.com/albums/h63/pitstop-paint/SN854796.jpg

Bit of grinding n fiddling with spacers got bandit leccy speedo sensor mounted to gixer 750 output shaft:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN854813.jpg

Carbs remounted with some new hoses n bodies scrubbed up, etc:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN854808.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN854809.jpg

Took completed handlebars oota downstairs toilet wedged em on roughly in place to get em out of my way in house. Be getting bolted up soon anyway. Clock inserts look cool in situ. Nice cow horn bars. lol. Mooooooooo!

http://i61.photobucket.com/albums/h63/pitstop-paint/SN854811.jpg

Still fighting with cam cover, but times against me till work dies down a bit. Still Im in no rush. It`ll be done when its done.


Continued……



Nother bitty today. Got cam cover done n on. Not perfect but best I can do with basic hand tools n graft. Any imperfections wont be seen once coil leads, hoses, bodywork, turbo pipework, etc, etc on. Dont look too bad tho n summit different for nowt outlay.

http://i61.photobucket.com/albums/h63/pitstop-paint/SN854839.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN854843.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN854846.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN854855.jpg

Ground down some more stainless bolts and got removeable frame section bolted up properly:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN854847.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN8548473.jpg

Breather cover to clean up, couple frame touchups from getting engine in, and then onto front end next methinks.


Continued……



Not a lot to report progress wise as not had much free time with work n guff. Cheers for good comments so far tho folks. Keeping me chipping away at it. 8-)

Cleaning up wee random bits n bobs in spare time tho n sticking em on. Coils took about 2 hours to clean up!

Some eeejit had colour coded them to match rest of bike in 4" brush and red smoothrite. Duh! Scrubbed up ok eventually tho. Found Taylor leads beneath the smeg too which was cool.

Cleaning up odd`s n sods so post a proper update somepoint once got something substantial to show. lol. Works just too busy to get anything substantial done so picking away at wee odds n sods. Folk from states posting lids over to get sprayed n all sorts. Good tho. 8-)

On side note tho PandKG (Pinstriping and Kustom Graphics) magazine are wanting to run a bi-monthly feature on the build focussing on the artwork obviously. Good advertising for business tho as that mag has a feckin HUGE readership worldwide. Got in touch with em about running a small cheap advert n ended up doing editorial. Lol


Continued…..


Have been chipping away at this honest! ;D

Coils, tank rubbers, loadsa misc bits, etc cleaned up n on:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN854979.jpg

Rearsets looking bit better than smoothrite n rust originals:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN854984.jpg

Some matching flames/bio-mech airbrushing on wee bits like shifter arm:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN854980.jpg

Sidestand:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN854981.jpg

Shift rod:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN854982.jpg

Footrest brackets:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN854983.jpg

Polished up footrests n removed those horrible 1/2 ton lead weight things on bottom.

Tother side:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN854987.jpg

Cleaned up n painted wee bits like frame brace, relay mount bracket, etc:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN854985.jpg

Stripped seat release mechanism as rusted solid:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN854986.jpg

Where Im up to:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN854989.jpg

In middle of chopping undertray up with grinder n smoothing it off to sleeken up rear end. Hate those original snow-plough extensions, lol:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN854990.jpg

Polishing up exhaust can n bracket at mo too:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN854994.jpg

Decided to use some of old exhaust system. Dont really need can on it with turbo as cops/mot guys up here really layed back on loud pipes. Wanna run it tho as a race can so not too quiet, plus turbo will suck up lot of exhaust noise. At least I can go touring 2-up and down south n stuff without getting too much police hassle. Got a Db kliller insert with the bike so can stuff that in for longer trips to keep the plod happy. lol. Nice high level setup too, but can mount it anywhere really so options are open.

Box of bike bits I got with it looking sparce:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN854991.jpg

New brake pads x3, 2x new chains, wheel spindles, n brake parts really. Couple indicators, tax disc holder. Not a lot left really to go on.

Got rear wheel and front forks/wheel under desk so they`ll be dragged out before long as running out of small bits. lol.

Brand new Suzuki discs on both wheel I noticed too. Bonus.

Got new bit of lexan through from Yantosh. Cheers bud. Really need to fix borken clutch cover window on Harris somepoint too so can give it a good clean n thrash.

http://i61.photobucket.com/albums/h63/pitstop-paint/SN854995.jpg


Continued…..



Did these bits for a mate`s GSX 750 project to help pay for the gixer engine in the bike I got off him.

Transformed his old manky 80`s switchgear which had seen better days into this to match rest of his bike bits:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN854859.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN854860.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN854862.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN854866.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN854868.jpg

N a catch tank:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN854877.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN854881.jpg

Switchgear on my bandit cleaned up pristine and as new, but looking at how the above manky old switchgear came out with bit of TLC is making me think I should strip my own switchgear back off n airbrush it.



Continued……..



Not a lot today, but nother wee bitty.

Chopped the rear undertray standard snowplough extension off n smoothed out as much bits of it as possible. Looks pretty good.

http://i61.photobucket.com/albums/h63/pitstop-paint/SN855028.jpg

Got it mounted:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN855026.jpg

Looks nice n smooth fitment now:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN855024.jpg

Better side profile too. Much sleeker than crappy stock setup:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN855025.jpg

Dug out wiring loom and gixer CDI box so I`ll get that all back on the loom and connected next few days n see from there really.

Gave up on cleaning up exhaust can/pipes as not sure 100% where its going on bike yet as options are well open. Might cut it down 6 inch too so gonna have to wait till more bodywork bit on, etc and see how its looking and turbo pipework routing, etc.

Nowt left in bits box except brakes n few random suspension bits. Under table is front end and back wheel so looks like theyre next in line so have something to bolt brakes to.



Continued……..


Ok now Im stuck! Thought it was all going far too easily. lol.

Didnt get much chance to look at it today as airbrushing till late on. Went out to do a quick 1/2 hour of getting loom layout sitting right round frame tubes, connect few bits n bobs, etc. Basically make a start on getting electrics done.

Thought it would be a straightforwards job as loom mint after sorted it. Knew I was gonna have a few slight problems because of gixer engine. i.e. no carb position sensor/carb heaters. Just taping them up tho as not needed on loom now. Few engine connector blocks different too, but again no biggy to figure out. Plain sailing I thought as pretty good with electrics.

Went to swap over CDI packs to the gixer one to match the engine Im using, and the sodding pins/connectors are different. Probably down to the TPS system which alters timing to match throttle position, etc.

Gixer CDI on left, Bandit CDI on Right:-

http://i61.photobucket.com/albums/h63/pitstop-paint/cdi.jpg

Gixer CDI pack standard sized pins so can stick some individual connectors on easy enough, but bit stuck as to what to connect to what.

Got bandit and gixer manuals here, but doesnt show pin/colour wire sequence. Can get wire to pin sequence off bandit loom, by following wires, but dont have a gixer loom to see which wire goes to which pin! HELP! Can anyone draw me out a pin diagram of gixer cdi/loom connector showing pins and wire colours so can figure it all out??

If have both sets of info I can probably sit down with both wiring diagrams and figure out the right pin sequence. Bit of an unexpected bugger tho.


Continued…….



Got it done tonight! Woohoo. lol.

http://i61.photobucket.com/albums/h63/pitstop-paint/CDI-1.jpg

Took a bit of figuring out getting the 12 odd wires onto 6 cdi pins. Couple of wire splices, and taped off few now obselte wires (2 for TPS and 2 for netural switch engine limiter, etc).

Used standard shielded spade connectors which were a nice tight fit on pins. Taped it all up too, just in case. Pretty well protected behind undertray and seat unit plastics, but better safe than sorry.

I`ll get rest of loom on in next couple of evenings. Need to chop about couple of connectors onto engine which are different. No biggy to figure them ones out tho compared to cdi wiring. lol. Tape up a few obsolete connectors as go along too like carb heaters/TPS, etc. Worth taking time with wiring tho to avoid hassles later on. Get it fed round frame, etc nice n neat and everything soldered up, etc.


Continued……



Weeeellllllll. Did a bit of wiring in between clear coating this afternoon. Got everything chopped about engine connection wise, and clock wiring worked out, etc, etc.

Looking fairly neat:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN855040.jpg

Tucked front section of loom into headstock area to cut down on wires and connector blocks visable at front once get that together.

Took sidestand switch and neutral switch wires down under sprocket cover n up back of engine to neaten up whats on show. Some blue mini zip ties on starter wires, etc too.

http://i61.photobucket.com/albums/h63/pitstop-paint/SN855037.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN855038.jpg

Still need to solder/tape up a few wires, but got a problem!

Altenator wires! They dont match connector wise. No surprise as rest of engione connectors didnt match either. Chopped em off went connect up n wire colours are different. Checked manual and they dont even match wiring diagram colours, or give any explanation about what goes where in genny.

Heres gixer genny wires on left (one red, and one pinky/orange), and bandit wires on right (one black, and one black and brown).

http://i61.photobucket.com/albums/h63/pitstop-paint/SN855036.jpg

Checked in manual and bandit wire colours are red and black/brown. Hmmm. Looked at bandit lump to get an idea n totally different genny. Black wire went onto bolt originally (yellow circle), and brown/black wire went onto one of the pins (red circle) with the other pin left blank.

http://i61.photobucket.com/albums/h63/pitstop-paint/SN855034.jpg

Looking at wiring diagrams for both bikes, both genny outputs are live. One connects into wiring/fuse box, etc, and the other connects into lighting circuit. Presumably lighting one is at higher wattage that other.

Well stumped with this un. Cant think of way of figuring it out apart from leaving disconnected till up n running then measuring genny outputs to figure it out. Anyone know theyre gixer/bandit genny`s??


Continued……


After a fookin lovely day yesterday, today its pishin it doon up ere! River of water running down road. Grrrr. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN855042.jpg

Got Harris clutch cover back on tho after its slight bandit frame interface. lol. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN855045.jpg

Dragged both bikes out n stood in the rain giving them a damn good scrub up. After about 5 buckets of soapy water I finally found them underneath the grinding n wire brush bandit smeg. I know theyre technically kwaks but bandits my first Suzi n loving it. lol. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN855044.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN855043.jpg

Can sit in the garage to my hearts content in the evenings fettling n polishing them back up.

Anyway not much bandit related to speak of as concentrating on getting other 2 bikes cleaned up n running (harris). Trike just needed a wipe over which was cool.

With bikes out of garage got space to drag out bandit front end n look it over:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN855047.jpg

Looks like pile of crap same as rest of bits pre elbow grease. Deceptive tho. Brand new suzuki discs on front and back wheels. Only had bout 100 miles of use by previous owner before bike went off road:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN855049.jpg

Took wheel off n stuck to one side with back wheel. Do them after forks, etc together as will be airbrushing centres/polishing them as a pair anyway.

So these are the next bits in line to clean up in evenings:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN855050.jpg

Yoke manky but wire brush n paint can sort that. Forks well rusty up top end where they were hidden weathering behind those shitty original headlight brackets.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN855048.jpg

Removed n binned them as fooked n just plain ugly. I`ll `buy` (against the blood I know) some new light brackets for forks, or solid mount to 2 tags at bandit frame headstock when get to that stage.

Bottom halfs of fork stanchions mint tho n unpitted. I`m thinking along lines of shrouding top halfs of forks where bad in metal tubing between yokes to hide the rusty sections. Best option can think of really.

Sorry bout non interesting update, but hey ho every builds got boring bits. Lol


Continued……


Went out this afternoon n connected battery n battery charger to gimmie a bit of power, and................................nowt. Waaaaah. lol.

Cut open loom, quadruple checked cdi connections, checked clock/ign wiring. Couldn't find a problem. After about an hour of bridging wires straight to battery n sitting with voltmeter I swapped round starter relay connections n bingo!

Heard the swoosh of the clock dials n everything lit up ready to go-ish (well no oil/forks/wheels, etc, etc lol).

Shouted `Yeah Baby` very loudly and heard a couple of tourists walking by gasp n ask what was that. Oops. lol.

Everything working as far as can see anyway. Dash/clocks/starter/lights, etc. Just have to connect front/back lights and indicators/horn when get to that stage. Back to sanding n polishing/painting then. Lol


Continued…..


Sat with my wet n dry n autosol tonight n got one fork leg cleaned up:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN855062.jpg

Not perfect, but pretty good. Had a shitload of scrapes n hammer/tarmac dings like engine casings, etc, but most of em sanded/polished out eventually:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN855059.jpg

T`other one tomorrow night. I`ll slap some 2K black on lower yoke when get a chance too n can bolt em back up in next few days.


Continued…..


Bit slow with updates at mo. Made the stupid decision to not just paint bottom yoke, but dig out all the misc bits n bobs that were gonna need sprayed too n do em at same time while got paint gear out, etc.

Got sidetracked into brakes! Seemed like a good idea to strip em n paint em at same time as rest of wee bits n bobs.............

Could I fook get em apart! Lump hammer, centre punch, heat, WD40, vice grips, etc, etc. Those pad pins werent for budging! Ended up cutting pad retaining pins in half with grinder/hacksaw. Still couldnt get pads out as they were rusted solid to pins! To cut a long story short a couple of evenings were spent grinding n drilling pins out of caliper bodys. Weird thing was brake pistons were clean n free and bleed nipples undone no probs too.

Got em apart tho:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN855088.jpg

Pistons cleaned up perfect beneath smeg. In middle of spraying em at mo, but got new pads with bike so they`ll be going in all round:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN855090.jpg

Sprayed bottom yoke up.

http://i61.photobucket.com/albums/h63/pitstop-paint/SN855082.jpg

Gonna airbrush it up along with brake calipers n assorted little brackets next few evenings. Might as well detail the we bits too. lol.

1/2 way through polishing up other fork leg too so will have all front end bits n bobs ready to bolt together in next few days. Opted to do back caliper now too tho to get it out of way.

Scored this intercooler of egay for £10 delivered.

http://i61.photobucket.com/albums/h63/pitstop-paint/intercoolerfaeegay.jpg

Dont quite need it yet, but was going cheap n gonna be needed further down line. Good clean up n brackets, etc n should look fine.

Bout it for now really till get front end bits together. Did have a 2 minute play on paint tho to roughly test out few ideas. Rough n ready but no time to sit for days doing it properly:-

http://i61.photobucket.com/albums/h63/pitstop-paint/DragBanditmockup3.jpg

Yantosh`s long braced B12 swingarm. Helmet nose fairing at front with lights inside as mentioned previously. Scoops at side of bike cover:- on RHS the turbo side mounted on log manifold, and on LHS the intercooler mounted sideways n force fed airflow by scoop. Want smooth shrouded look overall and gives more bodywork for me to play with the airbrush on as got a `full on` mad idea for the bodywork. Muwahahahaha!!!! Little bellypan, n Hayabusa-esque swingarm spoiler scoop finishes things off. Sorta stealth bomber long n low menacing look Im after at end of it all. Subject to change along the way, but liking the rough concept at mo.


Continued…..


Sat this afternoon n put me front end bits back together.

Top yoke:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN855140.jpg

Forks n stuff:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN855144.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN855147.jpg

Front calipers all cleaned up, painted, greased n new pads in, etc:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN855137.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN855149.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN855139.jpg

Banjo bolts where rusty chrome so prepped n sprayed those too to cheers em up a bit.

Made new pad pins out of old imperial allen keys. Old trick Ive used for years on brakes. Hexagonal section doesnt seize in countersunk holes. Cut to length leaving a decent size bit sticking out to get hold of with vice grips, unlike originals! Notch with grinder/hacksaw for R-clip n bobs yer uncle. Free, not gonna seize in there, n good quality steel.

http://i61.photobucket.com/albums/h63/pitstop-paint/SN855138.jpg

Sprayed up the wee steel clips n mudguard brackets, etc while at it:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN855151.jpg

Some of yer might have noticed the black section on the fork photos above. Been looking about for offcuts of steel/plastic pipe to slip over pitted sections n cant find owt locally n not paying for it. lol.

Tried a bit of black gaffer tape on with join at rear edge n actually looks nice n tidy! Not gonna see much of it when nose fairing on anyway so might run with it to disguise pitted/rusty top sections. Nice textured gloss finish n hard wearing too.................. and free. lol.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN855157.jpg

Onto the back brake bits next as sprayed up caliper at same time as rest of bits, oh and the horn too as was rusty as hell. Not gonna be seen, but not having rust on the bike. lol.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN855152.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN855154.jpg

Give everything a good clean up n slap in new pad pins and pads, etc like front.

Oh yeah n bolt front end back on too of course. Doh! Lol


Continued……


Nother wee bitty today.

Back caliper hanging on bungee as nowhere to put it yet. Getting well excited about my new swingarm tho. Few feet of alloy to polish n fondle. Muwuhahahahaha............

http://i61.photobucket.com/albums/h63/pitstop-paint/SN855160.jpg

Put the piccy up tho to show I did actually airbrush the back of the caliper too cos will be visable through wheel from other side.

Back mastercylinder and reservoir cleaned up bolted back on:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN855166.jpg

Needs a new brake light switch, but I`ll get one somepoint when ordering other odds n sods.

Mounted the freshly painted horn under the tank as a handy spot out of sight and a nice convenient mounting there from original suzuki breather air valve thingy that I dumped when changed engine. lol.

http://i61.photobucket.com/albums/h63/pitstop-paint/SN855173.jpg

Front forks back on. Dropped em through the top yoke as far as could till hit the bars. Only bout an inch or so. Would have liked more, but back end will be slammed down so extra rake n stability in straight line aint a bad thing. Starting to look like more of a bike now:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN855179.jpg

Was happy with the look. till me gorgeous missus came out for a look n thought my gaffer tape on the fork tops looked shite............. so under order to re-do it better. lol.

Theres an exhaust place up town (45 miles away!) that stocks length of pipe. Nowt`s easy up here for parts! Couple of quid should net me some wee bits of tube to airbrush up and slide over fork legs to neaten em up. I`ll get some next time up there for shopping. Unbolt top yoke n slide em on so no biggy and will look better ultimately. Like the black look tho of the fork tops n hides the crappy pitted sections.

Looks like Im onto wheels next as next to no wee bits left to clean up. Wheels are gonna take some graft to get looking nice tho. Rough as fook, but no worse than rest was n think its coming along nice. Well I like it anyway. lol.



Continued…..



Nowhere to get alloy tube bud up ere. Steel tube from exhaust place up town is closest thing n 45 miles each way. ::) :-/ Makes life interesting tryna build stuff up ere. ;D Tank shouldnt hit horn, but can bend about/remake the bracket if needs be easy enuf. Was just a handy spot out of the way.

Fork tubes were annoying me tho so went back out to shed n came accross couple of dried up part tubes of silicone sealant. Been sat in wee shed since moved in couple years back n god know how many years before that. lol.

http://i61.photobucket.com/albums/h63/pitstop-paint/SN855187.jpg

Mixed with the old bandit headlight bracket rubbers:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN855188.jpg

Chop rubbers in half, cut off ends of silicone tubes, clean out dried up silicone/plunger, etc, simmer for 1/2 hour and serve:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN855197.jpg

Need about 4mm trimmed off n sanded/painted/airbrushed up.

http://i61.photobucket.com/albums/h63/pitstop-paint/SN855198.jpg

Sturdy enuf for covers tho and only bout 2mm bigger than fork legs internally so nice snug fit and most importantly........................FREE! lol.

Linz has started to call me Orinocho. Could be worse I suppose. Could be Uncle Bulgaria! lol.

No sign of my intercooler yet cos of post strikes. Hey ho. £265 spent all in so far tho when it turns up.


Continued…..


Got my fork covers done n on today. Turned out quite well for a freebie. :P:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN855209.jpg

As yer can see dropped forks through yokes nother couple of inches too. Want really slammed final look. Left enough fork leg below bottom yoke for fork action and thats about it. Should be fine on clearance as oil cooler not going in usual position anyway, but can slide about fork legs once have rolling chassis to work with.

http://i61.photobucket.com/albums/h63/pitstop-paint/SN855205.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN855212.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN855214.jpg

As a result bars wont fit back into top yoke cast-in risers. Sat with grinder today and an offcut of scrap alloy in pic below cutting some adaptors out to remount the bars to the risers on top yoke.

http://i61.photobucket.com/albums/h63/pitstop-paint/SN855204.jpg

Got em roughly hacked out with grinder n holes drilled, etc. I`ll get em tidied up with wet n dry,and bolt bars back on tomorrow, etc. I`ll get few pics up of course. lol. ;D

Dont expect amazing Yantosh levels of engineering as only got crappy drill/grinder combo. Should look ok tho.


Continued……


Sanded n polished up my adaptors last night. Not perfect, but best I can do with basic tools n scrap alloy. lol.

Went to bolt em on n couldnt find any decent looking bolts/washers for em. Cant even nip down local garage (8 miles away) to grab some stainless bolts/washers as its sunday and of course round here that means gods day off. lol. Washings hanging out n grinders chopping away in garage as normal tho. Muwahahaha.......

Loosely bolted in place with shitty fixings to get an idea how looks n sits, etc:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN855215.jpg

Because of clamp angle on yoke the bars havent actually been raised any and have only moved back an inch or so. Fine for my T-Rex short arms anyway. lol.

http://i61.photobucket.com/albums/h63/pitstop-paint/SN855216.jpg

Tank clearance looks ok. Up town tomorrow so will grab few stainless bolts/washers n bolt it all up properly n such. Bit neater than just now. Its all straight n strong tho. Dont think it looks too bad fixings aside.

Semi circle gaps left Im gonna feed wiring harnesses from switchgear through so can do away with zip ties on bars:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN855220.jpg

While looking for bolts came accross these riser blocks in a random box. Bolt holes even line up. Grrrrrrrrrrrrrr. lol.

http://i61.photobucket.com/albums/h63/pitstop-paint/risers.jpg

They would have saved me good days work making em, but not tall enuf on own so would have had to jack up inch n half at least with spacers to clear forks n dont really want bars any higher. Big cow horn renthals are tall enough as is.

I`ll get some bolts, etc n see how my setup looks n decide which to go for.

Box searching also came accross this old air guage off an old compressor:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN855222.jpg

Might do for a boost gauge. Screwed it into mirror boss to keep it out of harms way for now, but will probably end up mounting it on bracket in same place anyway. Got oil temp gauge on my Harris mounted same place and like it there.

Grab some stainless bolts up town tomorrow anyway. Seeing that mate about the gixer wheel too while up there. See what other bits he`s got lurking about too. Lol



Continued…..



Still not happy with riser setup, even with nice fixings. Just not neat enuf at 2nd look. Thinking of reverting back to normal n running ratchet lowering straps to lower front end few inches.

Know theyre not meant for street use, but not fussed about that up ere. lol. Can slacken em off for mot`s after all, or if rides like bag of shite giving me standard setup without any work or fuss. Loosen em for general riding n slam em for dragging n shows, etc. Would give me tidier top yoke, lowered suspension with less chance of bottoming out as will be lot firmer with the extra preload. Should allow me to run nice n low. Handling aint what this un`s about anyway. Got my Harris for the corners. Just want something to cruise on n leave black lines everywhere up town to wind the chavs up. lol.

Dont like comercial ones that loop over headstock. Cant be good that twisting about with steering. Gonna design my own setup that runs to bottom yoke so doesnt affect steering. I`ll give it some thought n see what I come up with. Shouldnt be too hard tho to fab.


Continued……..



Stuck the tank/seat on today to double check tank clearance n look of it all. Dunno, not happy with it. Looks a bit messy. Bars look waaay lower than thought too. :-/

http://i61.photobucket.com/albums/h63/pitstop-paint/SN855231.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN855228.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN855233.jpg

Could have just bolted on these riser blocks I found other day on spacers to sort it out. Long bolts, few 1" spacers, etc n these would do the job.

http://i61.photobucket.com/albums/h63/pitstop-paint/SN855234.jpg

Promised them to a mate tho. Doh! n double doh! ::)

Dunno giving it all thought as to straps, etc on front or raising bars up, etc, etc. Trial n error, but all good fun. Forks through top yoke looks alright with tank on as not sticking up in face. If bars where raised too then would look better n mask fork ends too.

Decisions, decisions........



Continued……..


Had another play about tonight. Stripped bars clean n tried a few things. Mounted em backwards and upside down. Think this is what gonna go for tbh. Clamped on loosly at mo as not got bolts long enuf yet. Few long bolts n spacer tube onto original yoke mounts n should look good n be solid. Im liking the look. Not any lower than clip-ons. Moves bars forward inch or so. Nice low look and makes fork legs look a lot better through yoke, etc.

http://i61.photobucket.com/albums/h63/pitstop-paint/SN855247.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN855246.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN855235.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN855241.jpg

Climbed up on table n sat on seat with my head between roofing beams. lol. Bars feel good height/reach n have same pullback, etc as normal cos just mirror image but upside down. Seem nice n comfy n not too much of a stretch. Wide, good comfy angle n just generally neat/low looking to the eye. Im liking it anyway.

http://i61.photobucket.com/albums/h63/pitstop-paint/SN855243.jpg

Bit cafe racer-ish. Remind me of the feel of my old Z`s ace bars. Makes me feel old remembering them. lol.


Continued…..



Not done a shitload in last week or so cos of buggered up arm n work being radio rental!

Caught up again tho n arm better so game on!

Handlebars all done up nice n tight n everything back on again:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN855281.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN855276.jpg

Mates got some dragbars I can have if dont like final look/feel.

Spent few evenings sanding back wheel rims. Pitting was worse than engine casings. Good couple mm in some places. Took sodding ages to sand out by hand. Got 99% of it tho n polished up pretty good:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN855365.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN855369.jpg

Did a bit of top secret airbrushing for Yantosh n got a gixer cooler he had in exchange. Cheers bud! Good clean n 2k black n looks like new:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN855379.jpg

Got my intercooler through post at last off egay. Not original one as little chav never sent it. Got my money back n got this one of a rs turbo tho for £5.99 delivered.

http://i61.photobucket.com/albums/h63/pitstop-paint/SN855377.jpg

Cost £5.85 to send according to label. lol.

Nice size, inlet/outlet perfect bore match to turbo n good positioning of tubes too for bike. I`ll spray it black tomorrow afternoon along with front wheel centre ready for airbrushing up.

Hoping to get the wheel airbrushed/cleared n back in this weekend.

Discs cleaned up like new so decided not to paint em. Only bout 100-odd miles on them from new so mint underneath dirt/rust. Gotta give em a proper clean up, but quick degrease removed most of it:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN855388.jpg

I`ll get wheel airbrushed up n in this weekend n post pics, etc



Continued………



Got wheel cleaned up n assembled today in living room while watching sunday telly with kids. lol. ;D

Wheel artwork, with flame licks coming off spokes onto rim to give impression of movement to wheel:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN855425.jpg

Discs cleaned up with brillo pad to remove rust n general smeg ::), n buttons painted blue:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN855424.jpg

All bolted up:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN855427.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN855429.jpg

Think it looks pretty cool. Not 100% perfect cos wheel was a right state, but aint far off. ;)

Was gonna bolt it back onto bike but a mate`s posting me up some bearings he has for it ;D so might as well replace em before sticking it back in.



Continued…..



Had to go up town today as Linz out of printer ink n orders to sort, etc. We decided to take car up n get bits of shopping, etc to make the 90-odd mile round trip worthwhile n stuff.

While had car up town with us (its a hearse so loadsa space, lol) popped in to see my mate Willie about that gixer 750 wheel.

Dragged it out only to find it was the same size rim as bandit one (4.5"). Waaaaaaaaaaaaaahhhhhhhh. Bollocks I thought. Spied a wider rim in corner, but he said it was for a project, but in end let me have it for bandit in echange for drawing him a caricature of his gixer as featured in 100% n SF mags recently.

http://i61.photobucket.com/albums/h63/pitstop-paint/Williesgixer.jpg

Result n keeps me budget down. lol. No cost to me other than good few hours drawing here n there in evenings to do piccy for him.

Was in a rush so scooped it up n flung it in the hearse. Had a proper look when got home n thought that does look feckin wide that. Its only a 6" gixer/busa rim! Wider than I could have even hoped for. Woohoo. ;D ;D ;D

http://i61.photobucket.com/albums/h63/pitstop-paint/SN855465.jpg

Came with good as new renthal 44 tooth sprocket:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN855464.jpg

Ideally suited to engine setup Im going for compared to bandit 47 tooth one. Not interchangable stud pattern anyway so gonna have to run 44 tooth one which as I say much better match for engine. Gonna knock speedo calibration out tho, but can always get a speedo healer black box to recalibrate things down the line.

Also got spindle n all spacers:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN855463.jpg

Think Im short of one outer spacer between wheel n swingarm, but sure can sort that out. Everything else there tho, just need to sort bearings for it. One in cushdrive there n mint, but other 2 missing. Not the end of the day tho. Chuffed as fook to get such a monster wheel for the project. Cheers Willie! 8-)

Me days haul!:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN855462.jpg



Continued……


Nipped out today in between things to chill out for 1/2 hour. Turned bike around on table other night which was a fair lift, but I managed.

Rear end felt pretty damn light so stuck a big trolley jack on back of frame to hold it down for now till get some back end bits in.

Got front wheel bolted in. Pitch black skies up ere n storms so took a mixture of daylight and flash switched on pics cos both looked wrong, so have to use yer imagination. lol.

http://i61.photobucket.com/albums/h63/pitstop-paint/SN855497.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN855498.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN855500.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN855499.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN855510.jpg

Check out deck height of lower frame rails. Gonna be nice n low!

http://i61.photobucket.com/albums/h63/pitstop-paint/SN855505.jpg

Liking look so far myself. Gonna be bloody wide once scoops on sides are on covering turbo/intercooler.

Linz up town today so grabbing some more paint stripper, so I`ll crack on n start cleaning up the busa back wheel. Bearings on way for it too.


Continued……



Finally got back wheel polished up. Thought it would be easy compared to weathered front wheel, but paint stripper revealed bout 20 coats of high build primer to hide the state of the severely pitted alloy underneath. Arrrrrrrrrrrgggh! :-/ >:( >:( >:(

Took me about 10 hours of sanding last few days or so in evenings to get rid of 99% of it same as front wheel.

Got it polished up tho n looks fab. Big bugger n looks nice polished. Was worth the hassle. 8-)

http://i61.photobucket.com/albums/h63/pitstop-paint/SN855604.jpg

I`ll get it sprayed black n fling some airbrushing on next few days to match front hoop.


Continued………..



Nother wee bitty this afternoon.

With the busa rear wheel polished up I masked up centre n sprayed it 2K primer n black gloss ready for airbrusing up:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN855649.jpg

While doing that decided to spray nother few random bits while everything set up, etc.

Got front lights apart with a grinder n drill as welded together with rust. lol. Poured the rust out of the shells so they dont rattle any more. Doh! lol.

http://i61.photobucket.com/albums/h63/pitstop-paint/SN855640.jpg

Gave the shells a quick spray up:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN855642.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN855645.jpg

Also did the rear brake disc centre:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN855643.jpg

Nowt fancy just clean n black n shiny. lol. All parts that are mostly gonna be shrouded, but want em neat anyway. lol.

Filed off all the buggered brackets on the egay rs turbo intercooler. Good degrease, etc n ends came up shiny black plastic so just masked off the alloy centre n gave that a tidy up. Also straightened up few dents n bends. lol :-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN855644.jpg

Had a quick slice with jigsaw at crash damaged helmet Im gonna use as nose fairing:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN855652.jpg

Dont look too bad lined up to bike n know dominator lights fit in behind visor. Cant get better idea of shape, etc till have the headlights solid mounted on some one-off brackets on front, but thats on the list to do soon.


Continued….


Sod all to report today really as finishing off comission helmet to post tomorrow. lol. Its a xmas present for someone so been full bore at it. Started it Monday with a blank lid n ready to post (thursday afternoon). Up to post office early in morning for me. Should get there in time tho.

Stripped tape off intercooler while munching lunch n cleaned up plastic end caps. Looks pretty good for something that`ll be hidden. lol.

http://i61.photobucket.com/albums/h63/pitstop-paint/lights.jpg

Sat this evening n cleaned up lights n got bits back together. Little clips drove me mad slightly more than usual. You`d need carnie hands to make that job easy. lol. Bulbs were blown, but had couple in shed which was handy.

Got in about lenses n reflectors with cotton buds n got the rust staining off from outside n inside edges as looked shit.

http://i61.photobucket.com/albums/h63/pitstop-paint/lights2.jpg

Not too bad n ready to bolt on when make brackets.


Continued………


Got wheel airbrushed up n clear coated today:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN855737.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN855729.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN855730.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN855736.jpg

I`ll get edges sliced clean with scalpel tomorrow once hardened a bit n get the tape off n rim re-polished, etc, etc.

Should look good tho with that fat polished alloy rim either side.

Need to scrub up disc/sprocket/carrier, etc too. Keep chipping away at it. Lol


Continued……..


Got all the back wheel bits cleaned up n assembled n guff. Looks well:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN855750.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN855758.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN855768.jpg

Next stage will be to get it down off my wonky table onto the ground n get back end blocked up to ride height n play about with wheel to get an accurate measurement of swingarm spindle to rear wheel spindle for Yantosh to work with for the swingarm.

Prob start making brackets for headlights/nose fairing after that.


Continued…………


Had a go at the seat unit tonight. Thought it was gonna need recovered as was splattered all over with paint and fibreglass resin by looks of it. Spent about 2 hours or so with the wd40 and picking away at it with my fingernails n came up like new:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN855772.jpg

Bit of a result n saves the expense of material, etc. Only a wee bit yeah, but theyre adding up slowly. Lol


Continued…..



Farting about in garage tonight tryna unwind as lotta crap on plate as per life.

Mounted headlights off frame tabs at headstock down to between dominator headlight units. Helmet cowl will bolt straight onto dominator light side mounts normally used for fork brackets. Nice n simple.

http://i61.photobucket.com/albums/h63/pitstop-paint/SN855776.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN855779.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN855786.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN855787.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN855783.jpg

Should look alright all sprayed up to match bodywork including visor insert as per my usual helmet paintwork.

On full fork lock the legs tuck inside back edge of helmet. Might have to trim lower edge as gonna sit close to front muddy. Easy enuf to do tho. Need to tidy up edges anyway somepoint.

http://i61.photobucket.com/albums/h63/pitstop-paint/SN855789.jpg

Might remake lower headlight bracket too as got bit of flex in it. Easy 20 minute job tho somepoint.


Continued………


Did another wee bitty this afternoon in between building snowmen with kids. lol.

Remade the lights bracket out of 6mm steel bar so no flex now. lol.

http://i61.photobucket.com/albums/h63/pitstop-paint/SN855802.jpg

Moved it all up few inches, trimmed down rough edges with flap disc on grinder,

http://i61.photobucket.com/albums/h63/pitstop-paint/SN855806.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN855808.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN855809.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN855812.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN855814.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN855823.jpg

On full steering lock the clocks and bottom yoke tuck inside but dont hit anything.

http://i61.photobucket.com/albums/h63/pitstop-paint/SN855824.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN855825.jpg

Just needs couple of holes drilled for fixing bolts to hold helmet fairing onto light units n job done I reckon.


Continued……..


Took grinder to lid again n took off bout an inch off back edges n added more curves, etc to make it look a lot less bulky. Then managed to mount it over an inch back on headlights for a more flush look. Also angled up chin slightly. Much happier with look now.

Managed to mount it to headlights using countersunk bolts which are covered up when visors down for a nice smooth no fixing mounting.

http://i61.photobucket.com/albums/h63/pitstop-paint/SN855830.jpg

Got some triangular motre indicators with bike. In good nick n working n nice clear lenses. Tried to find a place for em then noticed top vents on lid. Out with drill n file. Need a bit of tidying up prior to paint, but lenses sit almost flush n pretty neat once painted up I reckon. Wont stand out neither as helmet with have a bio-mech face airbrushed on it when do bodywork which will be prodominantly whites n greys so should blend in nice in end.

http://i61.photobucket.com/albums/h63/pitstop-paint/SN855829.jpg

Reckon its better:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN855834.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN855840.jpg


Continued……..


Was priming n 2K blacking comission tank today n thought well it would be rude not to do same to those bandit bits Ive been filling n sanding for last few evenings. lol. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN855850.jpg

Helmet fairing, visor n vents for same, side panels, frame infil panels, front muddy (god that was a state! - LOADSA FILLER).

Couple days off for xmas n I`ll start sanding em back n airbrushing em up ere n there when get time. Look miles better in black tho.


Continued………


Got my mate Rob up at mo visiting. Went out this afternoon n reorganised garage, lifted down bandit onto ground, n blocked up rear end n rear wheel etc at ride height. Taped on bits of bodywork roughly so we could bath stand back n partake in copious beard scratching. lol.

First time to see it on the ground in one peice and be able to stand back from it few feet. Eres the pics:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN855987.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN855999.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN855992.jpg

These are with wheelbase set at 1600mm. Got measurements for swingarm for Yantosh while at it. Swingarm pivot to rear wheel spindle distance 700-800mm slots bud. Pics are at smaller setting, but reckon looks spot on at this sorta length.

Should look good with fat 200 section tyre on there:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN855990.jpg

Rob giving me dosh for old wheel n bits which cleared a bit of space too. Reckon its looking cool tho n worth the £160 so far. Not too low or long to be unrideable or impractical. Not gonna be a show bike after all. Gonna see a shitload of tarmac. lol.

Some dodgy hairy fecker ran in n sat on it making `broom broom` noises. lol.

http://i61.photobucket.com/albums/h63/pitstop-paint/SN855996.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN855997.jpg

Got this standard bandit oil cooler off Rob as part of deal too. Gonna run 2 coolers so quick clean n paint n should do nicely:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN856002.jpg


Continued………


No time to do owt today as in middle of some full on bike artwork for a customer. Gonna try get nose fairing n few odds n sods airbrushed up this weekend tho.

My photoshop died so had to resort to paint to do a quick doodle. Enuf to see Im on track for look Im after tho which is cool:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN855987mockup-1.jpg

I`ll try get few bits painted up this weekend n stick up pics. Nose fairing n frame infil panels first as ready to mount.


Continued………


Been a busy bunny doing a few hours spraying this weekend when not in bed n could be arsed. lol.

Not clear coated yet which will really make it look nice n blend colours together more n give the black much more depth, etc, etc. Will look stack better than now basically.

These are before clear coat as not done that yet. lol. I`ll get it cleared n assembled n back on bike next few evenings or so n post pics. Quite happy with it tho. Based loosely on a slipknot mask n wanted to tie it in with bio-face frame side sections n plans for rest of bodywork.

http://i61.photobucket.com/albums/h63/pitstop-paint/SN856195.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN856197.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN856204.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN856208.jpg

Vi

[Gitzy]

Well that was alot to take in, good read..

[Fight_fan]

Awesome read mate! Gr8 way to waste my morning at work lol

[holyman_999]

Wow... I don't know where to start!
Fucking insane... Loving the build.
Just spent the better part of an hour checking it out...
Great job dude!!! [8D]

[Large]

I've spent 40 minutes in this thread and I'm only half way through.

Will return witha a cuppa and biccies to finish

[Gitzy]

I like that me and Lance got paid to read it. hehehe..

[Surt]

awesome paint job mate! more pics! :) i mean detailed pics coz its hard to see details in the mess (cell phone camera? :()

[Jon]

Cheers for compliments guys. Mucho appreciated. Im not worthy!:)

Yeah big ass post to take in. Few months to catch up on tho for you guys n I do waffle on just a bit. lol.:D

I`ll post updates as I go, but thats bang up to date to where I am with the build. Just battling with exhaust headers at mo.

[Jon]

quote:Originally posted by Surt

awesome paint job mate! more pics! :) i mean detailed pics coz its hard to see details in the mess (cell phone camera? :()


Pics do seem quite small n low res. Must be forum settings or my upload settings. Doh!

Most of pics are on my website though in bit higher size/res if wanting to nosey. Its www.pitstop-paint.co.uk , and pics are top of `Bikes` page on left hand menu. HTH.

[Gix11]

Wow - Epic! You sure know your way around an airbrush mate. I love the fact that this was a sideline project and you've done so much more work than I've seen in ages just on the paint!

[80s freak]

Great thread mate, top job!

[Surt]

quote:Originally posted by Jon

Cheers for compliments guys. Mucho appreciated. Im not worthy!:)



i daresay u r Jon... cept ur welding skills lol! i'd luv to take a few lessons in air brushing from u real awesome work! wat paint do u use hows it with the brake fluid?
coupla more questions: how do u fix the mesh to the i.c. trim? i was already thinking about, decided to make a double trimming with the mesh in between fixed with screws, wats urs?
nother question, where do u pick up vacuum/boost from carbs, pics please!
the last one by now:
quote:Originally posted by Jon

Just before pipe feeds in bottom/back of carbs to my pitot tube setup And then into a middle entrance in bottom of plenum chamber afraid i dont get it: the pitot tube is sposed to pressurise the float chambers from the compressors outlet as in ur pics, so how it can be connected 'then' to the plenum?
more close up pics on the matter! ;)

[Jon]

cept ur welding skills lol!

Using a MMA Arc stick welder bud and learning to weld too. Best it will do Im afraid. No dosh for Mig or Arc setup n got 2 MMA machines for nowt so make use of em. None of its seen anyway once bodywork on, so rather do it myself for free than pay out n blow my budget. Would cost me more than the £250 Ive spent on entire bike so far to get pro welding of plenum/headers.

luv to take a few lessons in air brushing from u real awesome work!

Many thanks bud. Reckon Im getting there. Only been airbrushing 3-4 years, but got background in artwork and design beforehand which helps. lol. Give it another few years n hopefully be up to standard Im aiming for near the top of my game. Aim high I say.


wat paint do u use hows it with the brake fluid?

2K clear everything bud. Doesnt get much better for wear n tear really. Dont know of any finishes really that will stand up to brake fluid tho. Wil eat through paint and powdercoating with ease that stuff.

coupla more questions: how do u fix the mesh to the i.c. trim? i was already thinking about, decided to make a double trimming with the mesh in between fixed with screws, wats urs?

Got it pop-rivetted to bracketry on inside bud so not seen. My intercooler and turbo are going to be shrouded in airbrushed scoops like bodywork once done tho so not going to be seen anyway. Going for smooth look to focus on paintwork as thats my business n its good advertising.

nother question, where do u pick up vacuum/boost from carbs, pics please!
the pitot tube is sposed to pressurise the float chambers from the compressors outlet as in ur pics, so how it can be connected 'then' to the plenum?

Sorry maybe my typing bud. Pitot tube is just before plenum inlet. Tube from pitot goes to carb float bowls via a t-peice. Boost guage take off, fuel pressure regulator feed, and blow off valve pressurisation all come off carb vacuum points so can see negative vacuum on boost guage also. Carb top vents on these model of carbs goes to plenum chamber. Hope this clears it up bud. There are pics of it all in thread somewhere if dig.

PM/email me if needing any turbo advice. No expert, but absorbed as much info from net/books as physically can over last 6 months of this build to learn as much as can.

[suacycle]

Awesome,good to see a real artist.

[Surt]

quote:Originally posted by Jon

cept ur welding skills lol!

Using a MMA Arc stick welder bud and learning to weld too. Best it will do Im afraid. No dosh for Mig or Arc setup n got 2 MMA machines for nowt so make use of em. None of its seen anyway once bodywork on, so rather do it myself for free than pay out n blow my budget. Would cost me more than the £250 Ive spent on entire bike so far to get pro welding of plenum/headers.

luv to take a few lessons in air brushing from u real awesome work!

Many thanks bud. Reckon Im getting there. Only been airbrushing 3-4 years, but got background in artwork and design beforehand which helps. lol. Give it another few years n hopefully be up to standard Im aiming for near the top of my game. Aim high I say.


wat paint do u use hows it with the brake fluid?

2K clear everything bud. Doesnt get much better for wear n tear really. Dont know of any finishes really that will stand up to brake fluid tho. Wil eat through paint and powdercoating with ease that stuff.

coupla more questions: how do u fix the mesh to the i.c. trim? i was already thinking about, decided to make a double trimming with the mesh in between fixed with screws, wats urs?

Got it pop-rivetted to bracketry on inside bud so not seen. My intercooler and turbo are going to be shrouded in airbrushed scoops like bodywork once done tho so not going to be seen anyway. Going for smooth look to focus on paintwork as thats my business n its good advertising.

nother question, where do u pick up vacuum/boost from carbs, pics please!
the pitot tube is sposed to pressurise the float chambers from the compressors outlet as in ur pics, so how it can be connected 'then' to the plenum?

Sorry maybe my typing bud. Pitot tube is just before plenum inlet. Tube from pitot goes to carb float bowls via a t-peice. Boost guage take off, fuel pressure regulator feed, and blow off valve pressurisation all come off carb vacuum points so can see negative vacuum on boost guage also. Carb top vents on these model of carbs goes to plenum chamber. Hope this clears it up bud. There are pics of it all in thread somewhere if dig.

PM/email me if needing any turbo advice. No expert, but absorbed as much info from net/books as physically can over last 6 months of this build to learn as much as can.


thanks bud just curious bout ur setup ;)

[Jon]

Some of my thread pics might be offline. Got an email from Photobucket saying my 10Gb monthly bandwidth limit had been exceeded! Guess a fecking lot of folk have been following this thred on different forums. lol.

Pics will come back on automatically soon tho if any missing. Can always check out most of pics on my website tho in meantime. On `gallery - bikes` page.

[Jon]

Got last pipe of my exhaust manifold made up tonight. Took it off welding jig and tried on engine. Tighter fit as my new outlet port sections are good 1mm+ wider than originals. Tighter n leak free the better tho. Quick slap of my hand on pipes n slotted into oulet ports fine which is a relief to say the least! Lol.

Number 3 cylinder sitting too close for comfort to frame downtube tho so gonna cut out few inches of pipe n rework bend to clear better. Not end of world tho. These things happen when building a 3D shape off the bike. Another bit of welding n fab n be ready for heat wrap. Ordered up heat wrap off egay. Got some graphite black 2” wrap and stainless ties for £9 delivered which is cool. Hopefully by next weekend or so I should have pipes done/wrapped n bolted onto engine. I`ll stick up pics when done as it’s a weird pipe setup obviously for side exit.

Been busy as hell work wise so my lovely wife suggested since extra cash been coming in could get bit for bike off my list. Biggest expense left to buy was back tyre (190-200mm). Been looking for one at sensible price for months, but going for silly money, plus of course everyone wants £20-30 extra courier delivery charges to get stuff up to my little island making it bloody costly! Saw a Dunlop D207 200/50-17 on egay for £80 brand new inc. delivery. Contacted seller to ask about delivery to up here n said he`d send it normal postal service parcelforce to me for free to avoid courier charges. Sweet. So that’s a big fat tyre on way for my busa back wheel.

Emoe a great guy sent me an gsxr Srad rear shock he had sitting around for free!:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN859235.jpg

Gonna do him a v.cheap caricature of his gsxr fighter tho in return. Lot beefier spring and fully adjustable compared to shitty bandit 600 one I had. Should be much more of a match to extra leverage of 9” over swingarm out back. Cleaned it up today and swapped lower linkage and my stainless spring cover over to srad shock. Added to parts pile again. Lol.

Picked up a little light up town for my number plate illumination. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN859238.jpg

Same units I`ve got on my trikes mudguards and a bargain at 80 pence. Lol. Going to paint top/sides/front of it and mount it to my number plate surround next few days. Also going to run wiring inside surround for neat look.

That’s about it for moment as all my free time (when I get any) has been thrown into making exhaust headers. Once theyre done tho can start mounting turbo itself and intercooler and pipework, etc, etc.

So with the fat tyre, exhaust wrap and number plate light that takes my budget up to huge £340 including bike. Need to buy oil lines/fittings, battery, brake light switches f/r, and a boost sensitive fuel pressure regulator so reckon will be on road for under £500 GBP when done which cant be bad. Lol.

[Jon]

Mr. Postman came today:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN859303.jpg

Never been into fat tyres as live on an island which makes TT course look tame roads wise. lol. Always been more of a bald edge of tyre kinda guy n corner addict. Fat tyre is gonna look real good tho on style of bike bandit is. Nice n fat! Mount it on wheel when get chance.

[Jon]

Got section of last cylinder of my exhaust header cut out. Cut out some new curves to re-route further out. Tacked together for now. I`ll get out next couple evenings n weld it up properly, etc. Not far off tho.

Nice evening so got out in sunshine with my tyre levers n soap n got tyre on busa rim. Looks good with polishing n airbrushing, etc.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN859363.jpg

I`ll tyre pen sidewall lettering sompoint when rubber dry again. Wedged it between lumps of alloy on bike bench. Sitting bang on measurements Yantosh has given me of swingarm at full stretch so gives me a better idea now with tyre on of final look. Me likey:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN859367.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN859372.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN859371.jpg

Back to fiddling about with headers again next few evenings, but hoping to have em wrapped n bolted on by weekend depending on free time I have.

[Jon]

Cleaned up my headers with wire brush on drill this afternoon, double checking for loose welding slag hiding any pinholes, etc, etc. Stuck wire brush up each pipe too to make sure nothing hiding inside pipes too. Good hose out n quick paint with high heat aerosol. Look like bag of shite due to my welders limitations, but not gonna be seen n have cost me nothing but time to make so not gonna complain. Lol.

My heat wrap for pipes showed up in this afternoons post along with stainless ties:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN859407.jpg

That’s my job for tomorrow evening if get a chance is to wrap em up. Did try headers on actual engine again earlier too. Good snug fit and new section of pipe clears frame by miles so all seems good. Just wrap n bolt on hopefully.

Stood back from bike n had good look over bike with copious beard scratching n sucking through teeth. Lol. Only bit I wasn’t happy with was the mirror I made before sticking up in air. Had it in my head for it being a low slung under bars german style mirror. Unbolted it in chucked most of it in bin. Lol.

Routed out some old carbon fibre number plate cut-offs from years ago. Made the circular headlight covers for my Harris with the middles of them years back. Lol. Bitta scrap alloy n a rough plan:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN859389.jpg

Bitta drilling n attacking with grinder later on. Quick spray of clearcoat on carbon bits to give em a shine too. Low slung n fully adjustable in every plane thanks to little swivel alloy block on bottom.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN859406.jpg

Plenty clearance on full steering lock:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN859403.jpg

Nice low side profile:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN859400.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN859397big.jpg

If find too low can move about till right. Worst case can swing round to above bars position again. Fullt adjustable as I say so can find something that works. Under bars looks better tho.

Hopefully next update will be headers in place on engine n can offer up turbo to see how sitting n get idea of just how stupidly wide bikes gonna be. Lol. That’s what I wanted tho long/low/wide so on track. Got me other toys for corner carving after all.

Had planned on rebuilding ninja next as got stack of ideas n some radical plans drawn out for it, but bikes just been taxed recently wheras Harris tax has just ran out. Might do Harris overhaul first then as next project. Nothing too radical planned tho as love it way it is tbh. Just damn good paint/polish/detail of everything to show standards really.

[Jon]

Got my pipes wrapped tonight. What a twat of a job getting routing of wrap right. Unwrapped it several times n tried different paths to get best coverage n look, etc. Think it was a pita cos of my compact weird header design really tbh. Very tight with hardly any gaps to wrap between.

Got there in end tho. Looks fairly neat n stainless ties, etc. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN859436.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN859430.jpg

Weird design I know but best I could come up with. Whole system had to fit into one pipes width in front of frame downtubes for front wheel clearance as front end sooo low. Got 3 pipes stacked to keep width down. Cylinders 2 & 3 merge into vertical 2-1 y-peice on top.

Cylinders 1 & 4 merge into horizontal y-peice underneath (see underside piccy below):-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN859427.jpg

Both Y-peices merge together into a venutri shaped collector and meet right at turbo inlet:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN859428.jpg

Had it slipped into engine ports before wrapping so know it fits. Turbo flange sits bout 7-8 cm proud of side of head and slight upwards angle to match cylinder head angle so exhaust pipe sits at right angle to everything else. Turbo slots onto header flange too, so hopefully just a case of bolting everything up.

Not mounting turbo though just yet till get my drilled/tapped camcap bolts for side of head back off Gixerjon so can make n mount a big billet alloy support bracket to take weight of turbo off headers. Smacked crap out of headers with large lump hammer n very strong if ugly arc welding, but rather turbo was supported instead of relying on pipes to hold its weight.

Was gonna bolt headers on tonight, but ended up lying under hearse in pissing rain using rest of exhaust wrap to quieten down a exhaust joint on it. Was soaked to skin (puddle in boxers!) n sliced my hands a good one on stainless cable ties, so called it a day n lay in bath instead. lol.

Get em bolted on next day or two anyway. JUST enough room to slip headers into engine past front wheel. etc on full steering lock so should be fiddly but straight forwards. Just gonna be a pain to get into exhaust bolts, but not end of world. Once theyre on, theyre on for a while.

[NoZ]

as always, sweet!

[Deano]

epic read. i think the flange on your headers needs to be thicker. bout 8mm minium. i am using 10mm stainless. also you will need to check it for straightness after welding as it will just piss out exhaust gas.

[Iceman]

Awesome work Jon, I can't wait to see the final result.

I'm with Deano on the flange thing though. I had the same problem with my first manifold.

[Jon]

I`ll check flange for flatness yeah. Material is about 5-6mm stainless sheet. Biggest I had. Cant nip to my local metal merchants up here cos there isnt any n live on a remote island.:D

Seen some t25 gaskets on egay that crush fit as you clamp turbo up. Might get one of them. Someone suggested car CV joint grease or something. Apparently it burns off n solidifies n leaves a good gasket??

[Jon]

Spraying all this weekend yet again, just like every weekend for months. Starting to grate a bit now. Lol. Getting irritable n dropping off edge of my ninjas back tyre on single track roads. Not a good idea when the side of road is a cliff face round here. Need to unwind methinks. Buried myself into spraying today n got ahead of where expected to be, so might take most of tomorrow off. Wahey! Should probably be starting something else, but going mad from lack of time off n need to refresh.

Went out tonight tho n bolted on headers. Couldn’t get cylinder 1 tightened up tho as bike against wall n cant move it at moment. Tried lying over top of bike, underneath, squashing down side, etc but was in danger of knocking bike over as Im not that skinny. Lol. Not worth destroying bike and my Harris as it landed on it too. Bolts in place finger tight. Just need tightened up once got back end together n can move it about. Not end of world.

As you can see tho the system is bloody compact n tight! Had to be really to maximize front wheel clearance. Can see below pipes sit about 10mm from frame downtubes and cam cover at front of engine. Close as you like.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN859450.jpg

3 pipes stacked keeps width down n space up for front wheel travel. Also no.2 cylinder stays inside frame downtubes and travels up before coming outwards to come round frame. Gives a bit more space also. Tried every trick I could to maximize the space I had available at front. Can try it once back ends on n on its wheels. If too close can raise front end slightly, but looks about right:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN859452.jpg

Turbo stuck in place roughly with one bolt. Need camcap bolts back so can make up a big chunky billet support for turbo to take bulk of its weight off headers to avoid stress cracks down the line. Holds it in place for now tho to get an idea. Took my Ninja n Harris out of garage so could get some decent pics with no other bikes in way. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN859454.jpg

Exhaust pipe on:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN859441.jpg

Angles back in towards bike:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN859465.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN859464.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN859472.jpg

Climbed up on bike n sat on it. Bars are comfy n my knee tucks in with few inches to spare and end can even though pointing in, because has turnout exits just past my knee.

Can looks a bit big tho so might knock up a simple exit pipe out of stainless instead. Also came across this old random piston I might lathe out innards of n polish up into a mini endcan for something a bit different.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN859459.jpg

Loud cans up here not a problem anyway and turbo will absorb most of exhaust noise. Can always slot on big can and Db killer insert for MOT`s or down south trips. Lol. I`ll give it some thought n see what I come up with out of scrap I have here.

Quick wedge of intercooler in place on other side and sitting on top of my lathe got a front on shot, hence pictures so bad cos a lathe aint comfy! Lol:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN859470.jpg

Wide look aint for everyone, but exactly what I planned from outset. Full-on cartoon look! Lol.

Think it looks lot wider than actually is in reality tho tbh. GSXR lump is really narrow. Took some measurements to get a more realistic idea for you guys:-

Height from ground to top of handlebars = 3` 3”

Width of turbo/intercooler + scoops still to go on = 2` 6”

Length of bike = 7`

By time scoops go on to cover turbo and intercooler yeah it`ll be wide, but measured against my Harris its only 6` wider than that bikes engine. Z engine measures 2` across! Low height of bike makes it look a lot wider though which is what I was after.

Scoops will go on over top like in original drawings back at start of project thread somewhere. They`ll have airbrushed chrome look terminator style mechanical 3D claw hands coming out of blue flamework reaching forwards to match helmet nose fairing paintwork as per original plan. Pretty mean kiddy scaring look. Quick mockup with hugger n paint.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN859478.jpg

Well all seems on track according to original doodles, etc at start of project. Not gonna be a style that appeals to everyone, but that’s what I wanted to build. Long, low and wide. Something attention grabbing n different from the norm. Got me other bikes for playing stupid buggers about the mountain roads on.

[Jon]

Deano/Iceman. Cheers for watching my back. Checked turbo flange on plate glass and with edge of steel rule. Cant see any deflection. Gonna order up one of those crush fit gaskets anyway to be sure, but hopefully should be ok. Failing that might get a bit of brass plate n make a gasket out of that to joing 2 peices together.

[Jon]

Quick play about with a cardboard box, knife n gaffer tape. Tryna get a rough idea of how its gonna work n look.

http://i61.photobucket.com/albums/h63/pitstop-paint/SN859482.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN859486.jpg

Front mesh (once find another fireguard in a skip, lol) with air filter poking through front:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN859487.jpg

Back open to allow for compressor outlet pipework:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN859480.jpg

Yup looks big n bulky, but thats what going for this build anyway. Still narrower than lotta production cruisers/tourers tho surprisingly. Think its just cos so low that looks overly wide.

[el sammo]

dude good work!! paint is amazing

[Jon]

Had a quick nosey about. Even thought bandit looks wide at 2` 6”, its still 7”+ narrower than a goldwing. Lol.

Also only less than an inch wider than a Busa. Lol.

[Jon]

Everything sorta on hold at minute tbh. Need spare dosh for oil fittings/lines, battery, boost sensitive fuel pressure regulator, n whatever else Ive forgotten about. Think thats mostly it tho tbh.

Cant get back end together obviously without swingarm, but thats just as of when Yantosh gets the spare time to finish it off. Busy man. Lol. No biggy tho as got most of bits there to put it together when comes.

Cant make up turbo support bracket n bolt turbo down properly till get drilled/tapped camcap bolts back off Gixerjon when he gets a chance. Once thats bolted up right can get intercooler bolted on n start fitting up ppework between the two, and connections to plenum, etc.

Still finding the odd bit to do here n there, but struggling a bit tbh. Managed to fix my knackered front brake light switch by cracking open casing n soldering in a new terminal, etc. Yeah theyre only £5-6 brand new off egay, but thats £5-6 towards something else instead of off my budget. lol.

Sprayed my reworked cardboard turbo cover with rattlecan black n stuck on a printout of rough image I intend to use for hands. Nice image as realy 3D play on perspective to it to emphasize the way scoops will be reaching outwards and forwards.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN859495.jpg

Gives a much better idea of look n gives me some idea of shape to transfer to templates and then ultimately alloy sheet for both sides. Standing back, yeah it does look a bit mad like its owner. lol:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN859494.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN859492.jpg

Well more updates as something arrives through post or happens. lol. MUST RESIST URGE NOT TO START ANOTHER PROJECT in meantime. lol. Got some radical plans for ninja kicking round my head.

[yantosh]

you made it Australia Jon , not been here for a while myself

[TheBogyman]

that thing mad mate,,totally mental,,well done,,,cant wait to see her finished, you on the west side or east side o jockland,,??

[dixiethedog]

Hmmmm..... i dont agree with comment about marrying a yorkshire lass. Geordie ones are much harder. I fell for mine when i saw the way she handled a wheel barrow,good strong back for lifting engine,i thought.

[Jon]

Yantosh back from TT n welded on end sections to arm in welding jig, so super accurate:-

http://i52.photobucket.com/albums/g25/yantosh/DSCF5268.jpg

Tubular underbrace to shape and add now, but not far off. End sections been reworked with a countersink for some trick flush fit smooth axle covers.

As for anything else its in Yan`s hands. He`s got artistic license.

Pictures wont disappear again. Had to splash out £15 on photobucket pro account for unlimited bandwidth as had used my 10Gb allowance in 10 days this time! Lol. Checked stats n hitting average 30-40,000 picture hits a day. Jeezus!

[Jon]

sensai
quote:Originally posted by TheBogyman

that thing mad mate,,totally mental,,well done,,,cant wait to see her finished, you on the west side or east side o jockland,,??


Waaaaaaaaaaaaaaaaaaaay north and west bud. Isle of Harris.;) Not found factory where my Harris was built tho yet. :D

[Jon]

l.
quote:Originally posted by dixiethedog

Hmmmm..... i dont agree with comment about marrying a yorkshire lass. Geordie ones are much harder. I fell for mine when i saw the way she handled a wheel barrow,good strong back for lifting engine,i thought.


:D:D:D

[Jon]

quote:Originally posted by yantosh

you made it Australia Jon , not been here for a while myself


Yup Im getting as bad a media whore as you sensai!:D

[Grouch]

The swinger looks awesome Jon!! Yans the man :O)

[Jon]

Should look good with brace n end covers on, etc n all polished up to mirror shine. :)

[Jon]

Wee bitty this afternoon. Cracked out some scrap cardboard n tape again. Came up with these little curved plates to tie side scoops back to frame so don’t look so separate from rest.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN859554.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN859553.jpg

Flattened out scoop onto biggest sheets of scrap steel I had and couldn’t believe it when they fitted plates exactly to edges!:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN859551.jpg

You couldn’t make that shit up. Lol. Exact size on 4 sides of sheet! Weird.

Chopped out bits with angle grinder, smoothed them off with flap disc then formed the curve round a telephone pole right outside my garage door. Lol:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN859556.jpg

I then welded on some tabs on inside to mount to any handy tabs, etc. Solid as hell once bolted up. Good 1”+ clearance from turbo housing too so hopefully keep temps down with airflow through scoops:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN859562.jpg

Exact copy of cardboard scoop so looks and sits exactly the same.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN859561.jpg

Just need to play about with cardboard template in picture then cut that out n tack onto back so welds hidden. Other end will bolt onto old oil cooler bolt under headstock.

Also came across another old scrap fireguard so that’s my mesh sorted for scoop fronts. Gotta be free! Lol.

[ALBI]

hmmm nice build mate just read in streetfighters mag no"195" aswell !
dont know about the position of turbo outlet tho??
would it be better if you laid the hairdryer flat so inlet was level with raod and you could then use "dare i say it " a screaming eagle cone airfilter" and have the exhuast outlet come out at 55 deg give or take down past engine cover with a balownie cut facing out at 45 deg to the rear or run it along the frame to the muff you have !!
only a sugestion mate !

[Jon]

Well not a shitload to report as up to eyeballs in paintwork so bandits taking back row for now. In middle of bodywork for a rather cool trick framed GSX1400 fighter you`ll be seeing in streetfighters mag soon Im sure. Really full on bike and paint and deffo worthy of centrespread which would be nice coverage for me. Meant to be 2 weeks airbrushing but having to do it all this week (stoooopid long hours!) as next week is ridiculous!

Kept it quiet as wasn’t 100% on it as pics/emails flying back n forth last few days n stuff needing approval by set directors/film directors, copyright clauses, etc, etc, etc. They paid n booked today tho. Got to do 5 matching skull n flame lids for a Bollywood bike action movie (apparently a first) being shot in London. 1 for main lead, 1 for his double, and 3 for the stunt riders! Only catch……….. all 5 helmets need to be done next week, from scratch to out the door! Do 2 lids a week normally and Im busy. Must be mad taking on 5 in a week, but they waved the cash, and what an opportunity tbh. Thought it was a wind-up by mates, but nope turned out to be genuine. Wont be sleeping next week at all I think, but chunk of cash towards bills n a good opportunity.

Don’t expect much to be done on bike in next week or so. Lol. Imagine I`ll be working 20 hours a day next week to get em done in time, but needs must n all that. I`ll be Mr. Grumpy by next weekend tho. Lol.

Heres where Im up to for now tho. Side scoop made and extention peice up to headstock. All brackets done n bolts in place fine clearing forks on full steering lock, etc. Some mesh added with a hole in it ready for air filter peeking through. Got trim organized n sitting ready for when airbrushed, etc, just getting time for it is gonna have to wait. Lol:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN859684.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN859686.jpg

£21 on egay inc. P&P got me both this nice filter (blue one in pic). Its about 180mm high inc clamp neck, n about 120mm wide at widest point so will peek out of scoop by bout ½ its length or so.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/filter.jpg

And this turbo gasket:-

http://i61.photobucket.com/albums/h63/pitstop-paint/gasket.jpg

That’s me budget up to £361GBP inc bike so far. I`ll get scoop filled/smoothed/painted/airbrushed when get some free time in evenings. As you can imagine tho that wont be next week. Those couple free hours a day will be spent sleeping/eating. lol

[Gix11]

Bollywood Bike Action Movie?! Mental. I bet it's still shits over that "Biker Boyz" Bollox:

http://www.youtube.com/watch?v=rUVfKb_emfk

Should have been called "Pole smokerz".

[Jon]

Torque was 10 times worse. lol

[latheboy]

quote:Originally posted by Jon

Deano/Iceman. Cheers for watching my back. Checked turbo flange on plate glass and with edge of steel rule. Cant see any deflection. Gonna order up one of those crush fit gaskets anyway to be sure, but hopefully should be ok. Failing that might get a bit of brass plate n make a gasket out of that to joing 2 peices together.


You'll want some copper gasket grease, its the shit.

I cant wait to hear about the first time you get a flame out the exhaust:D

[Jon]

Managed to get out to garage for 15 mins at oh 9pm after downed spraying tools. Lol.

Post came today n brought me air filter n gasket. Wanted to trial fit it before trimming n airbrushing cowl, etc, just in case. Lol.

Actuator hose wouldn’t clear air filter so fed it into air filter through hole in rubber clamp-on adaptor plate on filter. That’s me fat finger pointing to it. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN859770.jpg

Another wee hole through the rubber to get hose back out again n down to actuator. Keeps hose tidy too. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN859771.jpg

Quick bolt up of everything n seems fine fitment wise. Got some blue trim for scoop leading edges around inlet for once sprayed. And some carbon fibre trim for cut-out hole for filter too. Nope didn’t buy any, just chopped along length of pneumatic hose I had for instant edge trim. Lol.

Looks as thought tho. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN859772.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN859774.jpg

Well back to work, still got as few hours of sleep I can do without. Lol.

[Deano]

unfortunately the actuator hose has to be mounted after the impeller. having it in the filter will do nothing and you will have no boost limit at all. you can just mount it in the up pipe but it does need a boost signal and there isn't much boost in the air filter.

keep an eye on those cheap filters aswell. they tend to brake up and if that filter material comes apart. use quality filters like k and n and bmc etc.

[Jon]

Actuator getting fed from original outlet on compressor housing bud. Just routed hose through that way to get it to fit in space available.

[sharky]

quote:
keep an eye on those cheap filters aswell. they tend to brake up
I agree...had one of the cheap copies and it literally started to fall apart...bits breaking of...luckily didn't do any damage but imagine if your shiny turbo ate the gauze and mesh of the filter....ouch..
Play safe, buy a K&N....cheaper in the long run.

[Deano]

so it goes in one side and out the other?

coudn't just put a barb in the up pipe?

[Jon]

quote:Originally posted by Deano

so it goes in one side and out the other?

coudn't just put a barb in the up pipe?


Its the original setup bud with barb on compressor housing. Was just too close to outer diameter of inlet for filter so had to get creative with routing.

Yeah know what you guys are saying about cheap filter, but trying to get on road cheap as poss. Iron out flaws, get it to few shows, etc.

Once its done its job advertising my airbrushing for wee while the next stage is get hold of a 11/12 motor in exchange for paintwork, make a spacerplate and dialled cam sprockets, etc, bigger turbo, wideband A/F ratio guage, and go for 14 psi n bout 250bhp at wheel. Spend out on decent air filter then along with everything else. Reckon will take my build budget to £1000 GBP or so. Then can enjoy it myself and get it dirty.:D

[NoZ]

I'm conflicted on the cheap filter debate. I was told that unless you're racing and want to wash out your filters, there's no point in laying out for K&N's. One something sucking that much air though Jon (that is when you start having fun on it) I'd put a K&N one on. Got cheap pods on mine and so far, so good. Bloke in the dyno room agreed that the cheap pods are ok provided but K&Ns are a good investment.

[Jon]

Had a chance to do owt on bike for last few weeks. Airbrushing works through the roof! Not a bad complaint tho, just not much free time at all to do anything. Lol.

Done 100-120 hour weeks for last few weeks so bikes been on backburner priority wise.
Chipped away at side scoop re-shaping n filling into on smooth flowing shape. Got that prepped n basecoated a while ago, then put to one side.

Got a few hours this afternoon free-ish so whipped it out n made a start. Still at rough sketching stage, but gives an idea of where Im heading. Hand will be finished in stylized blue/brown chrome effect like headlight fairing pics. Still need to build up the layers of pipes/wires, etc and of course the intricate background too. It’s a start tho:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN850095.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN850099.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN850101.jpg

Try squeeze in doing a half hour here n there to get it done.

After that Im still in a standstill position really parts wise. Cant start plumbing things in and tightening parts up like turbo, or mount intercooler till get camcap bolts back so have something to bolt onto.

Swingarm isn’t far off now tho judging by latest pic off Yantosh.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/Swingarmupdate.jpg

Bit of adjustment n final welding to do yet, but getting there. He`s the same as me n crazy busy so doing wee bits here n there when gets time to spare at it. Flush fit covers to make for axle slots too which will look nice n smooth.

Slow slog at mo, but moving forwards none the less.

[Jon]

VERY quick doodle of what I mean with side covers:-

http://i61.photobucket.com/albums/h63/pitstop-paint/Swingarmupdatemockup.jpg

And shape/scale on bike. Im estimating about 3-4" of clearance on bottom brace:-

http://i61.photobucket.com/albums/h63/pitstop-paint/Swingarmupdatemockup2.jpg

No time for proper photoshop effort. Could do lot of airbrushing in that time n my spare times minimal.

[NoZ]

nice hand job =o)

[Jon]

lol

[Jon]

Had a quiet afternoon of prep-work today so dug out my side scoop that’s been sitting waiting for anyhting like free time to come along. Lol.

Got the airbrushing done. Not 100% happy with it, but got another day or two till clear coat it properly along with commission helmet so can fine tune it between now n then.

http://i61.photobucket.com/albums/h63/pitstop-paint/SN850270.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN850273.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN850262.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN850268.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN850276.jpg

Mechanically Im still kinda stuck for something to do till swingarm finished or get camcap bolts. Hey ho, be the other way round when those bits arrive as fabrication central from there on in. Can try mocking bits up roughly I suppose, but really want to get my teeth stuck in making/fitting parts now got some spare time in evenings.

[Jon]

Productive afternoon here. Was clear coating some comission stuff so found myself with some time between coats to do bits.

Scoop got thrown in with rest n cleared. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN850344.jpg

Get it sanded/polished tomorrow n can mount loosely to see how looks. No point bolting up solid tho till got plumbing finished to turbo.

On that front got bits ordered up for my oil feed from engine to turbo. Uk firms were wanting £60-80+ for adaptors and line, which is ridiculous to say the least. Sourced bits sperately on Egay from UK, USA, and Japan and came to £36 inc P&P for whole lot. Bit cheaper. Lol. All anodized alloy fittings too unlike most of UK suppliers. Shows the mark up theyre adding to prices tho!

An4 braided hose and An4 to M10x1.5 fitting for engine from UK:-

http://i61.photobucket.com/albums/h63/pitstop-paint/oillinebits1.jpg

An4 end fittings for hose from USA:-

http://i61.photobucket.com/albums/h63/pitstop-paint/oillinebits2.jpg

M12x1.5 banjo and bolt/washers for turbo from Japan:-

http://i61.photobucket.com/albums/h63/pitstop-paint/oillinebits3.jpg

Was quite happy getting that bit sorted n on theyre way. Drilled n tapped big M16 oil pressure bolt below ignition cover on engine to M10x1.5 to suit adaptor I ordered:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN850332.jpg

Need to make a 2mm restricor for oil feed line once it gets here so turbo doesn’t overfeed itself n smoke like mad. Not a big job tho, just fiddly.

Since seem to be focusing on this area for now as can make bits for it with nowt holding me back I looked at the oil drain outlet. Looked online and they were stupid money! Decided to have a go n see if I could make one myself.

Loads of billet off-cuts kicking about off engineer mates. Picked one bout right size:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN850333.jpg

Drilled a couple holes for mounting to turbo. Drilled n tapped central hole for something to get a hold of in lathe. Central hole will be drilled out to oil hose hole later on. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN850334.jpg

Attacked with grinder to remove larger sections quickly:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN850335.jpg

Clamped by bolt into lathe n smoothed it off a bit, lol.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN850336.jpg

Wasn’t expecting Yantosh levels of engineering given its only my 3rd or 4th time to use lathe, but came out alright I think, for something that aint even going to be seen once on. Should do job. Drilled out centre to 14mm so no restriction to oil flow. Quick notch to give bitta grip for hose n clamp:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN850337.jpg

Gasket on turbo was fooked so grabbed an offcut of gasket material. I know theyre only couple quid new, but way I figure it that’s a couple quid towards something else. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN850339.jpg

Quick chop n bolted it on to turbo. Good fit:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN850341.jpg

Don’t think Ive got any oil hose with big enough internal bore kicking about but I`ll have a proper look for some. Want a good 12-13mm internal bore ideally.

Need some sort of bulkhead fitting for other end of drain hose into clutch cover. Seen some online but pricey. Got a few ideas in my head so might be able to make my own one of them too n save another few quid. That’s the next job for me really.

[Fight_fan]

Love readin ur updates Jon, ur a handy little fucker aint ya!

[Jon]

Try to do the best with what Ive got to hand yeah. :)

[Jon]

Started on oil drain into clutch cover. Had a few ideas for making bulkhead fitting myself to save few quid. Stumbled across some braided hose bits in random box, yanked em n out popped a remote oil filter assembly from my VW trike engine build bout 10 years ago. Lol. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN850345.jpg

Salvaged the hose n nice blue end fitting. Looked at threaded fittings in alloy block closely n stripped em off. Using 2 end caps, one of angled olive end pipes, and one of centre sections I had instant-ish fitting. Result! Chopped down one end of centre section and one nut thickness in half so wouldn’t foul clutch.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN850347.jpg

One end of fitting on inside with ½ thickness nut. Nice 12mm bore throughout and a hose fitting to bolt straight onto. Quick lick of wire brush n touch-up pens and looks slightly posher than actually is. Lol:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN850377.jpg

Other end of 12.5mm inside bore braided hose went onto adaptor I made yesterday on bottom of turbo. Should do the job n decent bore size so little restrictions to flow.

Got scoop sanded n polished also:-

http://i61.photobucket.com/albums/h63/pitstop-paint/Banditsidescoop1.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/Banditsidescoop2.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/Banditsidescoop3.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/Banditsidescoop4.jpg

Loosely bolted in place for now:-

http://i61.photobucket.com/albums/h63/pitstop-paint/Banditsidescoop5.jpg

Where Im up to now then:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN850391.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN850385.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN850393.jpg

Dunno whats next, but got some inner drive at mo to get things done, and some free time. Works steady instead of daft for once so taking advantage!

[Elapid]

That is great Jon. Looks evil.

Kris.

[JDinOZ]

I just wana say that im deeply fkn impressed.. thats an epic job man great eye for detail and creativity! very inspiring mate keep us updated :)

[Jon]

Cheers guys. Yeah I`ll keep updating as do bits, dont worry. Be updates n pics till finish it n show/ride it.

[Jon]

Made an oil breather catch tank today. Had cylinder of billet in pile that was given with rest of stuff:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN850395.jpg

Almost exactly same diameter as stainless tube I had left over from exhaust:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN850396.jpg

Attacked it with the grinder n lathe, etc for few hours n made 2 endcaps. Not perfect, but best I can do:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN850398.jpg

Cut up and old polishing sponge from my paint buffer that was bin fodder. Made a simple filter to catch most dirt:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN850397.jpg

Couple of O-rings to seal ends and length of threaded bar between both caps so can screw em on. No way I could thread the ends in 60mm diameter. Lol.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN850400.jpg

Drilled couple holes n used old oil fitting left over from turbo drain hose and one of a compressor that died n went in skip while back. Welded em on inside to keeps things neat:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN850404.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN850406.jpg

Drilled n tapped bottom cap in M6 for a drain plug for any oil/water that builds up in breather.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN850408.jpg

Finished assembly with ends screwed on:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN850409.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN850410.jpg

Just needs a damn good sand/polish. Going to make a clamp bracket for it to mount it on bike once figure out where its going as get more bits mounted. Another bit made n sat ready to go tho.

Few pics from Mr. Yantosh of my swingarm. Welding done. Just couple little alloy flush fit covers for axle area to make to hide adjusters/spindle, etc. Not far off tho. Blade wheel gives idea of scale:-

http://i61.photobucket.com/albums/h63/pitstop-paint/swingarmwelded1.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/swingarmwelded2.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/swingarmwelded3.jpg

With turbo oil feed pipe parts mentioned in other post that takes me up to £397 by my reckoning inc. bike. Linz reckons slightly more, but sure my sums are right. In that area anyway.

Hose n end fittings/adaptors for hose came through post. Just waiting for turbo banjo from Japan so can hook up oil feed line.

[Jon]

Another few odds n sods today.

Chopped up an old connector off scrapped compressor. I drilled the oil filler cap slightly undersized then hammered the pipe/fitting into place for a tight leak free fit. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN850411.jpg

Got a length of carbon fibre hose left which slips on nicely. This will connect to smaller fitting on breather catch tank I made other day once mounted. Other bigger fitting will connect onto original breather hose on cam cover of engine.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN850412.jpg

Chopped about some leftover scraps of exhaust pipe.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN850416.jpg

Made a t-piece for my dump valve to fit into main up-pipe somewhere. Thick ass bit of rubber tubing off a washing machine in local skip fits nicely. Just need couple of jubilee clips for it. Should do the job.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN850432.jpg

With Yantosh almost finished swingarm I started organizing bits for fitting it into frame. Going to have to make some spacers, etc, but no biggy. Had a panic attack when realized I needed swingarm bearings for new swingarm……………AND THEY AINT CHEAP! Check out the prices sometime. Up there with carb diagphrams in scaryness price factor. Lol.

I sold the bikes original B6 swingarm (cleaned up /repainted) to my mate Rob early on in build. His old one was flung under his shed and sat there rusting away. I picked it up in passing while on mainland last week on off chance that bearings might be usable and right size to suit B12 swingarm. Bit of a longshot, but worth a look. Knew pivot spindle same size on 600 & 1200. Got Yantosh to measure new swingarm, and was amazed to find outer bearing size same too. I was even more amazed to find that although the B6 swingarm was dangerously rusty and fit for nothing but the bin, the bearings were in good shape! Result!

http://i61.photobucket.com/albums/h63/pitstop-paint/SN850433.jpg

Getting steel bearings out of a steel swingarm tho without damaging em was a problem. Wouldn’t drift out at all. Since swingarm was scrap anyway I chopped as deep as dared with grinder, and then used a lump hammer and fine chisel to chip away and crack the steel prising it apart slightly.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN850434.jpg
Bearings slipped out fine n rollers in good shape beneath loadsa grease.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN850435.jpg

Cleaned n greased em up n seem in good order with no play. Should do the job for few years n saved a big chunk of cash.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN850436.jpg

Sat on doorstep n sanded n polished up catch tank this evening. Looks blingy. Lol:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN850437.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN850438.jpg

Also had a nosey at turbo oil feed bits today. Still waiting on banjo, but got rest of bits here. End fittings and adaptor to engine bolt together fine. Cant figure out how hose ends go together tho?????????

An4 hose, an4 end fittings, cant see what Im missing……….

Inner cone fits in hose end exactly:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN850418.jpg

Outer fitting which screws over inner threaded bit above has angled sections inside to obviously grab outer edges of braided hose as inner cone pushes hose outwards as tightened up. Outer of braided hose much smaller than inside of fitting tho so wont hold it.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN850422.jpg

Am I missing something. Is there some sort of olive that goes in there, or are the hose/fittings wrong size even tho both an4 !!????? Confused.com.

Ive got petrol/oil hose I can use that slips over inner section of ends and can be jubilee clipped. Can then sell on braided hose. Just seems daft to go that route when Ive got fittings n braided hose for it. Just cant figure out how go together. Doh!

Any ideas cos Im stumped.

[Jon]

Bitta research and looks like the hose end fittings I bought are for normal rubber hose rather than the teflon lined braided stuff I bought. Stuffed end fittings back on egay, n went back to guys I got hose off and got 2 ends ordered off them. Look the same externally, but totally different inside and have an olive setup. Matched to hose I got so straight fit. Couple quid extra, but not end of world. Flog on other ones again to recoup cost.

[Jon]

Went out to garage today to do some more bits, then quickly realised theres naff all I can do on the bike now. Ran out of small bits to do totally.

Cant get intercooler/turbo bolted on properly till get camcap bolts, and cant start plumbing bits in till have those bolted on.

Done everything I can in preparation for swingarm coming too.

Bit of ptfe tape on the turbo oil feed engine adaptor n bolted that in, n that’s all I could do today. Lol.

Banjo for oil feed pipe connection to turbo turned up today from Japan tho, complete with thankyou note and free bizarre keyring. Lol. Screwed into turbo by hand tho on trial fit so all fine. Once get new oil line end fittings can bolt it all up.

http://i61.photobucket.com/albums/h63/pitstop-paint/SN850444.jpg

One thing I did notice tho is that although the banjo connection bore is same 4.6mm (or whatever it is) as AN4 braided hose:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN850449.jpg

the banjo bolt itself has a much smaller bore.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN850445.jpg

2.5mm drill bit is tight fit in hole giving me its size. Banjo n bolt was bought on ebay from a Japanese tuning firm especially for T-series garrett turbos, so looks like has oil flow restrictor built in which is a bonus as saves me making something up. Can add restrictor inline if needs be, but reckon that size will do just fine tbh.

Well builds definitely on hold till get cam caps or swingarm now, as totally stumped on what to do next really. Made everything I can for further down the build line so got stack of parts made n ready to bolt on which will save time when needed.

[Jon]

Another hour or so this evening.

Chopped up stainless exhaust can hanger/clamp n made a neat little clamp/mount out of it for my catch tank I made.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN850453.jpg

Bolts onto that unused lug on the front of the cam cover that sticks forward. Had bout 10” of braided oil hose left from turbo oil drain which was just long enough to reach from catch tank to cam cover breather outlet which was cool. Carbon fibre pipe in pic will be going onto smaller bottom inlet on tank:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN850455.jpg

Be glad when on 2 wheels as access to other side is a complete twat! Lol.

Also started mocking up a support bracket off cam bolts to take some of weight of turbo off headers. Bit rough n ready till get everything exact, but should help avoid cracked headers down the line.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN850459.jpg

A mate Coco donated 4x Bandit 600 cam bolts he had kicking about so theyre on way in post to me. Going to drill and tap centres to M10 for something to bolt to and get that bracket work above finished off and neatened up, etc. No point in doing that yet tho in case needs remade as needs to be fairly accurate. The shaped 5mm stainless section is the old high level exhaust can bracket that was on the bike originally. Was not far off right size and solid!

Another generous forum mate Struv donated a set of Honda VTR passenger footrest assemblys to project which is great as was missing them with bike. On the way to me in the post again. Nice swoopy design so should look the part when polished up. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/VTRfootrests.jpg

Totally different mounting hole spacing obviously so going to make some thick alloy billet adaptor plates outta this n tap fresh holes, etc to match bits together.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN850461.jpg

[Jon]

Todays mail as well as SF mag included the cam cap bolts off Coco and my new oil feed line ends.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN850481.jpg

Got the hose assembled finally and plumped into turbo oil inlet via big banjo:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN850483.jpg

Other end screwed onto adaptor in oil gallery below ignition cover:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN850486.jpg

Bolted up the turbo to the exhaust headers properly with the gasket in place, etc. Bracket work I made seems pretty accurate to where cam bolts will be on head on drilled n tapped them.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN850487.jpg

Standing back from the bike with the side scoop off I couldn’t help but think how I like it naked also with the turbo and mechanicals on show. Nice n in yer face and un-subtle! Lol. Wee stubby exhaust out of old piston (I like loud, all my bikes are straight through anyway) on end.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN850501.jpg

Just looks lot smaller n less bulky without scoop.

http://i61.photobucket.com/albums/h63/pitstop-paint/SN850498.jpg

Could just bang intercooler down in front of oil cooler n have smaller and easier pipework run to plenum and forget about scoops leaving other side as is. Lot closer looking to initial doodle I did when brought bandit home. Might look odd with just turbo hanging off one side tho n other side normal, or maybe not. Seen plenty turbo v-twins done like that n liked the brutal unbalanced look of that style of setup.

Dunno just a thought. Like it both ways tbh, just mechanicals being on show appeals to me also. Decisions, decisions………………..

[Fight_fan]

I prefer if naked too mate! Looks tuffer IMO...

[Jon]

Seems to be the majority opinion on most forums too bud. Dunno for final yet tho. Need to look at it a few times n have a think.

[Jon]

Got the cam bolts drilled n tapped tonight on one side. Brackets finished off and everything bolted up solid. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN850524.jpg

Tried mocking up a little cover instead of side scoop out of old bit of carbon hugger to get an idea. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN850520.jpg

Not convinced at moment so bolted scoop back on for now till made mind up. Did notice tho that without the exhaust bike looks miles better.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN850525.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN850526.jpg

Maybe that’s the problem, not the scoops which I like. I`ll give it some thought n see what I can come up with pipe wise. Something small and minimal would solve the issue. Case of trial n error seeing what looks best really till Im happy. Lol.

Rear footrests turned up in todays mail from Struv. Should look alright once polished up as sit nice next to bike.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN850518.jpg

Made a very quick start on making up billet adaptor plates, but not got far yet.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN850527.jpg

That’s the next thing to fiddle with n get bolted up.

[Jon]

Finished the rear footrest adaptors tonight.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN850580.jpg

3 holes, one of em threaded to M8, and one of em countersunk at front to clear footrest bracket. Makes everything line up with bandit frame lugs anyway.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN850579.jpg

After a good sand to get rid of grinder cuts, etc, and a bit of spit n polish n don’t look half bad bolted on.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN850582.jpg

Nosied at stainless chav exhaust tips today too. Thinking something short n stubby would be ideal for a hint of exhaust without being bulky like can I was using. Huge assortment available out there n not mega money.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/stainlessexhausttrims.jpg

Angled turnout one would be sensible for directing gas/flames away from my fat leg. Lol. Might have a go at making something tho as not much to them tbh. Got length of 60mm stainless tube left over from exhaust. Cant mandrel bend it, but can mount straight bit at an angle at turbo flange to get the kickout angle I need. Simple slash cut end to match angle of scoop. Cue blue peter mock-up.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN850567.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN850568.jpg

Should be able to make something half reasonable in that style. Short as hell n lot less visually bulky than big end can on there. Can keep big can for mot`s if have any problems with tester being an arse. Lol.

I`ll keep playing about n mocking things up till find something Im happy with. Got a couple mad ideas for it, but reckon they`ll be scrapped as bonkers. Lol.

Yantosh is close as dammit to finished my swingarm too which is major excitement. Just the end covers to finish n be on its way in a big box so I can rip it open it like a big kid at xmas. Lol.

[Jon]

This is what Ive been up to last few evenings. Some folk will like it, n some will think it looks like a novelty codpiece, but I like it so its staying. Lol. Sorta ties in with the claws in amongst the bodywork airbrushing. Just wanted something different basically. Sorta twin megaphones on acid. Had to be sneaky making em to hide the fact arc welds are messy looking.

Few templates to get basic shapes and joins accurate:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN850609.jpg

Taped them together and offered up to bike so could get an accurate idea of shape. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN850607.jpg

Took em apart again and wrapped round 60mm stainless tube so could mark off accurately the shapes prior to cutting.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN850610.jpg

Viciously attacked the tube with a grinder while cursing every spark that bounced off my eyeballs. Lol. Chain drilled out the shape where the tubes meet. About 2mm undersized so had a lip to weld to. Plan is to weld on inside of tubes to get nice neat outside join.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN850611.jpg

Welded up inside:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN850612.jpg

Cut the tube at an angle to turbo so pipes stick out about 15 degrees or so away from my fat legs. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN850653.jpg

Next was mounting flange for bolting to turbo. Again undersized hole chain drilled n filed so had lip to weld on inside. Bit of a twat welding 8” down a tube, but worth the effort I think.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN850647.jpg

Good scrub and wet n dry session for a brushed shiny-ish finish and bolted on. I like em even if no-one else does. Lol.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN850665.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN850651.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN850663.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN850667.jpg

[legion]

awrite laddie yer bike is lookin' huir uv a bent! ur ye? join ussssss!

[Jon]

EH!??????[?]

[Jon]

On its way in the post! Yantosh from BFT (Blunt Force Trauma) done his magic yet again. Standard B12 arm next to my one.

http://i61.photobucket.com/albums/h63/pitstop-paint/Stdarmvsmyarm.jpg

Give it a week to get here by pack mule and an old guy in a rowing boat (not quite, but feels like it sometimes), and can spend a week or so of evenings sanding n polishing it to Bling factor 9. lol.

Then spend a few nights making up spacers, etc to make it fit bike, then make a few spacers to get wheel in, then a few more spacers to get sprockets to line up, make a torque arm, etc, etc. Be worth it tho. Should look sweet.

[Jon]

Good day, bad day really today.

Took my long suffering daily hack ninja fighter up for mot today n failed with flying colours. Lol. Well not really, brakes needing stripped/cleaned and the swingarm and rear wheel bearings shot. Guy stuck it on frame stand and could move back wheel 2-3 mm left and right, AND turn it left right by same too. Lol.

Guy couldn’t believe Id kept it upright with rear wheel steering for the 50 miles to mot station. Told him it had felt a bit odd for months, n that I`d been dropping off edge of back tyre through twisties on way up to mot. Lol. Guess if yer used to old 80`s bikes with flexi frames you can ride arse off anything. Ooops!

Was gonna sort parts, but fuck it. Ninjas my next project build after bandit. Might as well cheer the bike up after it carrying me for 30-odd thousand miles in rain, snow n never letting me down. Still running original battery, clutch, and throttle/clutch cables it was made with in 1997! Cannae fault it. Be another build thread to read after this bikes done then. Lol. Got some radical plans for it down a concept bike/café racer vibe, keeping about ½ the bike as is now n making rest from scratch.

Anyway back to bandit. About an hour after got back a BIG box arrived from the postie! Well actually from Yantosh, but delivery guy did his part last 10 feet from his van. Lol.

Taa-Daa!:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN850801.jpg

Flush fit cover:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN850802.jpg

All spindle n adjuster gubbins behind:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN850803.jpg

Other sides cover has to stick out 10mm or so due to shape of spindle and nut, etc, but not end of world. My side mounted number plate gubbins will be going there anyway so wont stand out once all together.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN850804.jpg

Mount for my weird fold down numberplate/spec panel idea.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN850805.jpg

Didn’t have any real free time today as working into evening sanding/polishing after airbrushing commission stuff (busy, busy again, lol). Stuck a spindle through arm n another through wheel tho to get an idea of how its gonna look as been picturing this swingarm for about 6 months in my head, so a LITTLE bit excited. Lol.

http://i61.photobucket.com/albums/h63/pitstop-paint/SN850818.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN850814.jpg

Hell yeah! Looks great and just the right wheel behind tailpiece distance to look right.

Jump back a few feet.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN850810big.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN850809big.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN850816big.jpg

Didn’t have bearings in arm so sat lob-sided on spindle. Once polished up, etc I can get an accurate measurement n cut a couple spacers. Looks like only 3-4mm each side though so not far off.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN850815.jpg

Next week or so of evenings will be sitting sanding n polishing crap out of swingarm tho. Bling, bling. Lol.

[NoZ]

that Yantosh is a clever sausage! Looking good Jon

[Gix11]

Love that spindle/nut cover. Looks great.

[Jon]

Well just finished having a dirty weekend! Polishing that is. lol. Bout 10 hours of sanding from 120 grit (to get rid of scrapes/chips), through 400 grit, and then finally looking like a friggin chimney sweep for good 5 hours polishing with my polishing mop n £15 granny drill. Came up quite well I reckon. Got rid of 99% of marks/scrapes and dings in alloy.

http://i61.photobucket.com/albums/h63/pitstop-paint/SN850924.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN850927.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN850928.jpg

Not a bad shine:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN850930.jpg

B6 crush tube and bearings obviously exactly the right size for gap in frame, but dont match recesses in B12 arm at all, so gonna have to wait for Yantosh to send me up the B12 crush tube, and then chop up the B6 crush tube for couple small spacers for the ends. Not end of world tho, just a lot of pissin about.

B6 chain runner also doesnt fit arm, so going to chop that about next couple evenings n make it fit. lol.

Once get arm in can start mounting shock/linkages, and start making dogbones and wheel spacers, etc, etc. Never ends. lol. Be something of a victory though to get it on its own wheels at last. 8-)

[Jon]

Was convinced postie had lost my bearing crush tube from Yantosh so set about making one out of old bit of tube. Then Yan told me it was in post on way somewhere as sent late. Doh! Lol. Hey ho more lathe experience.

Made crush tube and steel spacers for bearing inners to exact frame gap. Fitted greased up recycled bearings. Also made some outer spacers to stop side to side play. Measured play at 6mm, so made (2x) 2.5mm spacers to leave 0.5mm each side as in photo to allow for tightening up bearings in frame and smooth pivoting, etc. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN851069.jpg

Same other side obviously, and also cleaned up and mounted B12 chain runner donated by Jezza. Cheers bud! Saved me bodging B6 one to fit. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN851066.jpg

Looks like its all ready to bolt in tomorrow n can start on centralizing rear wheel as missing few original spacers so few bits to make.

[Jon]

Well few hours yesterday evening and this afternoon and swingarms bolted up tight.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN851140.jpg

No sideways movement I can feel and nice smooth pivoting action so spacers I made seem good.

Had to move fuel pump, re-route loads of hoses and wiring under tank, etc to make shock reservoir clear everything which took a while, but got it bolted in finally.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN851133.jpg

Had to move lower suspension rocker mount on frame down about 20mm as was having interference problems between miss-match of parts and swingarm bracing, etc. Thankfully on bandit the same chunky steel plate runs right down to where stupid centrestand would have went so just had to drill fresh holes. Suspension tie-bars/dogbones too short unsurprisingly, but easy items to make.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN851135.jpg

Don’t have any steel bar small enough for them as has to clear shock and inside of arm and everything Ive got is huge slabs of billet alloy. Lol. I`ll grab a bit of bar off egay though cheaply Im sure. Nothing available locally which is annoying as so close to bike being on wheels.

Got back end of bike ratchet strapped up to garage roof joists to take back end of bikes weight for now. Few blocks underneath sump just in case, but removed rest of pallets, etc bikes been living on forever. Weird seeing ground clearance under the bike. Lol. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN851141.jpg

Had a look at back wheel spacers as was missing one. The one spacer I have and brake caliper hanger must go on disc side as wheel is central at that in arm. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN851137.jpg

Other side has 3mm gap to arm. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN851138.jpg

It’s a recessed spacer into sprocket carrier though so bigger than looks in photo above. Also stepped like other side below as bearing runs on it. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN851142.jpg

Closest thing I`ve got to it is this lump of alloy about twice as big and a solid lump. Would take several hours to cut down on my baby lathe, but possible. Wasn’t convinced alloy would be up to job as supports wheel bearings. Asked Yantosh for advice n he says it`ll be fine so got some lathe work to do to put it mildly. Lump in lathe is waaaay too big. lol

Not a big item. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/Wheelspacer.jpg

So yeah back end almost in. A spacer needed, and a bit of bar needed to make dogbones out of (off to scan egay). Not far off rubber touching ground at last.

[Jon]

Finished turning (not lathing, sorry Yan, lol) up the wheel spacer. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/NewWheelspacer.jpg

Slotted into wheel bearing, wheel recess and onto spindle a treat Nice smooth fit. Bolted wheel in loose for now n got the 2mm gap I was after.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN851168.jpg

Slid wheel spindle as far forward in swingarm slots as possible n nipped up bolt. Yup same wheel rim gap either side.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN851158.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN851159.jpg

Clamped a big billet bar of alloy onto rear sprocket, just out of interest to see what Im in for when sorting chain run, as that jobs coming up fast. Looks like a 2-3mm spacer behind front sprocket will sort it. Lot closer than imagined. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN851161.jpg

Chopped a big bit of bar (about 20x20mm) out of my skip stash. An old leg off an industrial table, but nice billet alloy under coating. Bit of chopping/grinding/drilling n should do as a rear caliper torque arm. Kept it clean n simple chunky square look to tie in with arm. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN851169.jpg

Good sand n polish next evening or two for another bit of bling. Lol.

Ordered up some 5x30mm steel bar off egay too to make suspension dogbones/tie bars out of. Bitta chopping n couple of holes when turns up in mail n should be able to drop bike onto its tyres for first time. Woohoo.

[Jon]

Not a shitload done today as helping our eldest replace knackered bits again on his bmx. Does about 100+ miles a week on it stunting up n down cliffs on his way. Well judging by parts he gets through. lol. 2 new wheels n brake cables today.

Anyway sanded n polished up torque arm today n got it bolted in. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN851187.jpg

Not exactly groundbreaking progress, but every little bits a step closer ultimately. Looked at my garage too n reckon Ive got a cunning plan that will free up chunk of space for when bandit comes down off workbench very soon. Give me some space to move about the bike on each side as cramped in there to say the least. lol.

[Jon]

Sod all to report today, but I guess everyone has the days where they get nowt done. My free time today was spent taking my Harris for its mot. This un:-

http://i61.photobucket.com/albums/h63/pitstop-paint/MeHarris.jpg

Couldn’t have picked a better day for it. Scorching hot sunshine, dry roads. 100 miles of empty twisty mountain roads to get to mot station and back. Damn! Lol. Passed easily though so that’s cool. Midrange was a bit off even though pulling like a train, so made a mental note to clean carbs when got back as been sat for a while with old petrol in it.

Quick 5 mins got carbs off. Tanks held on with rubber straps after all so nice n easy access. Found shitload of crumbly emulsified crap in carbs. Yummy! Lol. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN851207.jpg

Quick clean, banged carbs back on n sweet as a nut again. Looking forwards to ripping up the mountain passes again. God I love this bike.

Whats any of this got to do with the bandit. Errr……..not a lot. Oh yeah couldn’t chop up metal bar that came through post today to make dogbones for swingarm, as I was too busy riding. Lol.

[Jon]

Chopped up and drilled the metal for dogbones today. Cut and drilled the pair clamped together so knew the measurements would be exact. Had to notch one side to clear inside webbing of swingarm. Quick tidy up n spray silver n were ready to bolt on.

Here they are drying in sun along with standard one to show length difference.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN851227.jpg

Bolted them on and let the ratchet straps go holding the bike to garage ceiling. No-one around to help so had to hold back end of bike up on one hand while undoing straps with other. My arse certainly puckered up as undid the strap, but didn’t drop it. Lol.

On its rubber for first time. Big step to me anyway. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN851234.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN851233.jpg

Sat on it to see how low it was. Fookin hell I could walk over back of bike n sit down! Bent knees sitting on seat and Im only 5` 7” or 8”. Thought turbo weight on one side would be huge unbalance, but not that bad really surprisingly. Be even better balance once rest of stuff mounted on other side.

So yeah that’s the good news. Bad news, well the front end needs raised couple inches as weight of bike sunk it down further than thought. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN851231.jpg

Only a few bolts though to slip forks down through yokes couple inches or so. No biggy.

Back end………..well that’s another story. Sank down few inches also which is perfectly normal under bikes weight. Problem is its too low as only 2” clearance to seat undertray.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN851228.jpg

That 2” is used when sit my weight on bike as tyre `just` touches undertray. About the right amount of static sag and shock doesn’t feel that soft really. Bout same as most bikes firmness wise. Stiffer than standard bandit shock and swingarm isn’t that long over stock really.

Options then. Well normally I would have ran the back end higher unloaded to allow for settling under bikes weight. Cant do that though as set it as high as would go because of lower link and swingarm underbrace touching.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN851230.jpg

Was set as high as possibly could be unloaded right down to 1mm clearance.

I can run a standard length (slightly shorter) shock in there to clear underbrace, and then jack up back end a bit to allow for settling under its own weight.

Im also maybe thinking of removing the back half of the original plastic undertray underneath as don’t need the toolkit space, etc under the seat.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN851232.jpg

That would give me good 4” probably wheel travel extra. Let the wheel ride up inside the back end like the bikes that gave me the motivation for this build did.

So yeah options available, just not sure what route to take right now……….

Was thinking of getting bike off workbench and onto ground this weekend, but might give that a miss till sort this issue and bleed the brakes, etc which will make getting it down a ramp, etc easier.

[Jon]

Ahh just noticed shock body has good 2" of preload adjustment at least as set at minimum. I`ll rack that up n see how much of sag that reduces. Should be a fair chunk of lift at wheel end of swingarm. Take it from there really.

[Jon]

Spent a couple hours today sitting playing about with suspension settings and pivot mounting points to try sort ride height out.

The rear shock preload had good couple inches of adjustment at top so wound that up as had it right at lowest settings. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN851243-1.jpg

Doing that and playing about with other bits n bobs reduced sag to very minimal amount and improved ride height back to something sensible. Good clearance to undertray.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN851245.jpg

Sat on seat and jumped up n down on it and couldn’t bottom it out so seems ok. Got a bit of adjustment left if need to increase it slightly once on road, but cant be far off.

Drop front forks back through yokes 2” which raised front end up a bit. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN851244.jpg

Sat on bike throwing my weight up n down on forks n couldn’t bottom them out so seems close. Again like back end though got adjustment there to play with once on the road so can raise it again if needs be.

So yeah back on its own rubber n sitting a lot better now. Still seriously low, but sensible clearances now. Looks good to me anyway stance wise. Bottom frame tubes are good as level with road now too.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN851241.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN851236.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN851238.jpg

Next stage is get it off workbench really and onto garage floor so can move it about and start bits on other side I cant access at moment. Get chain run sorted, chain on, chain guard, mount intercooler, make another scoop, start plumbing, etc.

Need to rearrange garage totally too and somehow free some space to work in. Got an idea in mind, but will take a fair bit of lifting about. Ninja needs to go up on workbench once bandit comes down too as that’s next project bike for me. The guy I bought the bandit off lives about a mile away, so gonna organise him to come round somepoint n give me a lift up n down with bikes. He`s like wrestler sized (6`5”, 20-odd stone, n size 14+ shoes!) so should make light work of it all. Lol.

Next installment will be whenever I can organize help lifting about everything.

[Deano]

i think you will have to either raise the forks through and strap them down to the height you need or put some heavier springs in them. i think you will find the bottom of there stroke quicker than you think

[Jon]

Out filling n bleeding the brakes tonight. Peice of cake. The big busa/bandit rear caliper was more of a pain than the fronts. lol.

Didnt fancy trying to get it down ramp off workbench without some way of stopping it as fair angle and so is my driveway. No clutch cable or chain yet neither so need the brakes working.

Hopefully get it down on the floor asap.

[Jon]

Was busy clear coating and basecoating comission stuff, etc today so had a bit of time in between things. Wasn’t tied to the airbrush for once. Lol.

Linz was up town doing shopping and wasn’t too keen on helping get bandit down ramp just in case something went wrong. She said herself `what use would I be?` which is fair enough. She`s only 8-odd stone, but a pair of hands is a pair of hands.

Decided to just go for it myself in end so if anything went wrong Linz wouldn’t blame herself. Get it done n stop worrying about what `could` happen. Wasn’t too bad with brakes working, just eased it down ramp inch by inch. Back wheel onto ground fine. Front wheel about ½ way down ramp and ramp slipped off edge of table! Felt it going and tensed up and shut my eyes, but knew it couldn’t drop more than about 8” to the ground at most. Opened my eyes wondering why hadn’t dropped and realised Id been so panicked Id grabbed handle bars so tight that I was holding front end of bike in air by bars. Lol. Mental note to self drill n bolt ramp to workbench next time.

Anyway once my heart slowed down a bit I heaved it back into garage on its wheels. Be a lot easier to move once engines running as my driveways on a slope of about 30 degrees. Lol. On solid ground now tho which is a great feeling.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN851292.jpg

Weird being able to walk up to it and throw a leg over after it being on work table for soooo long. One thing I noticed is theres a little bit of play in handlebars. I`ll need to track down where it is, but I suspect its in the riser block where I used a short section of 22mm bar to connect to old risers wheras riser block drilled at 7/8”. Can soon turn up a bit of bar tho for that to get it tight fitting.

Getting ninja up onto bench was piece of cake. Just walked it up ramp on tickover using clutch and letting engine do the hard work.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN851295.jpg

That’s the next project, my trusty all weather workhorse. 30-odd thousand miles in worst of Scottish winter weather and still on original 13 year old battery and cables, clutch, etc, etc. Cannae fault it. Head n sump apart recently n like a new engine still inside, n not even any cam-chain stretch. Failed mot on swingarm bearings other week so getting ripped apart n given a new life. Going for a funky very minimal concept bike meets café racer/fighter look. Be a cheap n cheerfull build once again.

Rearranged bikes so my trike at garage doors now so can get it in n out easier to use it. Looks cramped in there, but needs tidied desperately. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN851297.jpg

Added bonus of trike at garage doors is all I have to do when working on bandit is reverse trike out onto driveway and Ive suddenly got about 12` x 8` of free space that’s only got my harris in one corner of it. Plenty space to park bandit in middle and be able to work all the way around the bike with ease which will be a welcome change after all this time. Will make getting rest of bits done n made a shitload easier for me.

[Jon]

Did a few hours at bike today since the weekend n bit of spare time.

Turned up a spacer on lathe to slip behind front sprocket to get chain alignment right.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN851387.jpg

Got that back together n then chopped a few inches off sidestand as was miles too long now bikes so low over stock.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN851391.jpg

With chain run right ha d a look at chain. One that was on bike when got it only had bout 100 miles on it, just covered in grime n surface rust from sitting. Bike also came with a brand new chain in box.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN851395.jpg

Going to add some of weathered chain once cleaned up to new chain to get the extended length I need. New chain came with a rivet link, but of course I`ll need 2, so ordered one off egay for £5 delivered.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/chainlink.jpg

Takes me up to £407 now total I think inc bike. Once get the link through can chop up one chain and make a suitable length chain out of the bits. Easy job.

Started making up a chainguard as concentrating on back end at moment. Want to get whole back end finished off before start on side scoop/intercooler/plumbing, etc. Bit of 2mm alloy and couple of stainless strips n bolts n looks alright.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN851406.jpg

Still need to sand/polish alloy top piece, but I`ll probably sit n do that tonight.

Close up of chainguard struts. Bit of stainless trim off a panel I removed from my hearse interior. Nice shape to them as wrapped round covering mounts n welds nicely. Waste not want not. Lol. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN851404.jpg

Also bolted up my side mount numberplate. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN851400.jpg

Found these nice bullet shaped rubber bolts out of my scrap pile. Used to be furniature feet. lol. Serve a dual purpose though as grip the ground when number plate in its other position for shows, etc. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN851399.jpg

Heres the back of the plate with my bike specification sheet on it. Big chunky alloy swivel mount to swingarm. Routed out an old stainless exhaust spring out of a random box which is ideal. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN851401.jpg

Park up bike at show, flip down plate with foot, lean bike onto sidestand and rubber spikes grip ground and stop it flipping back up. Voila one spec sheet to stop people asking same questions over n over again. Lol. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN851398.jpg

As soon as you get back on bike and stand it upright the number plate pings back up to normal position. Shouldn’t move much during riding as exhaust spring pretty damn strong. Lol. Had looked at electronic servo, and cable to handlebars to do same job, but in the end decided simpler is better for the amount I`ll use it.

Still need to mask off n spray rest of lens on number plate light, but I`ll get that done asap n get it mounted on plate here-ish.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN851392.jpg

Wiring will run inside plate surround to keep things neat as possible.

Productive day and another few bits out of the way.

[Jon]

Odd hour here n there last few days.

Masked off one small light outlet underneath on clear lens back light and sprayed rest of clear lens alloy look silver. Looks alright for a whole 67 pence. Lol. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN851425.jpg

Wired it in to lights hiding wiring inside numberplate surround and as hidden as possible back along swingarm so not too obvious. Chain guard also sanded/polished n mounted. Looks not bad. Chain link came through post so made up my longer chain out of 2 chains I had.

http://i61.photobucket.com/albums/h63/pitstop-paint/SN851435.jpg

Got that on then found the chain was touching the rear tyre! Took out back wheel and spaced behind sprocket and remade front sprocket spacer several times till was happy with spacing front and back and chain run. Cant be more than 1mm run-out between both sprockets as measured it to death. Lol.

Got about 2-3mm gap now between chain and tyre so should be fine.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN851437.jpg

Lots of hours n pissing about for not a lot to show. Lol. Way it goes sometimes though. Think that’s the back end done now tho so can move onto getting intercooler and dump valve, etc, etc mounted n plumbed in.

[Jon]

Chopped out parts for other side scoop tonight and roughly shaped the parts using same method as last time of hammer and wooden telephone pole. Lol. Used same templates as last scoop to ensure symmetry.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN851476.jpg

Get bits shaped up properly and welded next couple evenings. Needs offered up to bike and bent about a bit with a hammer to get same curves as other sides scoop. After symmetry between both sides so wanting to get scoop mounted in exact position so can work out intercoolers position and mounting to cylinder head. Bit backwards but only way I can see to work out positioning of everything.

Should enclose the intercooler fine once all done tho as slides inside rough mockup of pieces fine.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN851477.jpg

Good few evenings of fabrication ahead of me but last of big components to get bolted onto bike as such and once that’s on all the parts are in position to plumb together. Got a cunning cheapola plan for the plumbing too to try out.

[Jon]

Got scoop pieces welded up tonight and bent about a bit to match other side as close as possible. Still have to weld on some mounting tabs once everything else is bolted up, but not far off as need it.

Propped up in position roughly.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN851490.jpg

Will my bum look wide on this? Lol. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN851485.jpg

Intercooler should slip in nicely.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN851507.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN851499.jpg

Will probably re-make intercoolers scoop and mounting brackets as not really up to par with finish I`m after now. Try make the brackets a bit more in line with where I needing them to be now too as I need to curve back to cylinder head to securely mount it all. Maybe repaint intercooler n its scoop metallic silver or something too.

Dump valve t-piece will go on end of intercooler outlet roughly here on show, but facing back slightly to cut down on air/rain getting forced into it at speed.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN851503.jpg

From there it’s a 8” or so straight run to the pitot tube setup on the bottom of the plenum chamber (top right of picture below). :-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN851497.jpg

Should be more than enough length to ensure good air pressure and velocity to give pitot a good signal pressure to work from.

Going to kick my trike temporarily out of garage over weekend and wheel bandit into middle of floor again so can get an accurate measure of positioning of side scoop compared to other side and then get accurate measurements for intercooler mounts, etc n start making n bolting up some mounts for it all. Take me a wee while to make everything, but hopefully pics give an idea of my plans in meantime.

[Jon]

Finished off the fabrication tonight, all be it rougher than a dogs arse. Lol. Everything roughly hacked out with grinder at this stage to get everything fitted up and bolted together n figured out.

Made a saddle clamp setup to securely hold intercooler. Utilised old swingarm dogbone links as length I was after n good steel n saved cutting new bits. Waste not want not. Lol. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN851529.jpg

Big alloy slab bolted to side of head. Driller n tapped and a big slab runs across to support intercooler/scoop, etc.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN851530.jpg

Mounting tabs welded onto inside of scoop, etc. Everything bolted up tight to check for fit n alignment compared to other side, etc. Old bit of carbon fibre hugger makes nice wee cover for ugly clamps/mounts.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN851526.jpg

Big pile of bits to sand/fill/paint/airbrush, and couple bits of alloy needing some serious grinding n smoothing before polishing up as roughly hacked out at mo. That`ll be me busy for few weeks of evenings. Lol. Least I know they`ll fit once blinged up tho.

[Jon]

Not a lot tonight. Started wading through the big pile of parts needing painted/filled/airbrushed n sanded/polished, etc. Fair pile.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN851531.jpg

Sanded n polished alloy parts n generally made em look better. Removed rough edges from cutting em out with grinder. Bolted on n look lot better.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN851553.jpg

Sanded n primered other parts. Slapped some filler on scoop section join too. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/SN851558.jpg

Most of parts just getting blast of 2K black tbh except scoop. Should get those parts coated in black tomorrow evening ready to bolt back on. Scoop will take me a fair while to mould smooth and airbrush like other one with skeletal hand, etc. Lot of work, but I enjoy that bit of it, even though I airbrush all day for work. Lol.