View Full Version : Project Budget Cafe Fighter
Well not finished my `project budget dragqueen` quite as yet as you can see from my build thread, but Im not far off done and the remaining stuff to do is mainly buying parts which I don’t have dosh for at minute. So I thought sod it might as well think about next project in line for me and make a start stripping down and planning it out.
Bike in question is my long suffering daily ride ZX6R fighter. Was standard till hit a stag years back which wiped out cosmetics. Lol. 3 days n £50 rebuild got it on road again as below.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/Ninjafinished001.jpg
Stayed that way for many years being my daily transport through rain n 1` of snow n worst of Scottish highlands weather. 800 mile weekends touring with my wife, etc, etc. Lived outside mostly too, yet never broke down once. Got a garage now and work from home airbrushing so no need to commute any more. Failed its mot recently as swingarm bearings shot so using it as a good opportunity to give the bike some much needed tlc as heading towards ratbike status as getting bit rough round the edges.
What Im aiming to do is make it minimal and light. At mot it weighed in at about 190kg with 2/3 tank of fuel which is already way below 207kg kerb weight of original bike. Has had some jetting n free flowing can so pushing out 100-105 bhp at wheel. Great daily bike as super reliable. Still running original battery and cables and clutch, etc it left factory with 13 years ago! Lol. Had head and sump apart and like a new engine inside. Not even any cam chain stretch. Great handling. Constantly falling off edge of back tyre 2-up with luggage. Good gas mileage even. Perfect bike for twisty little mountain roads up here as nimble n light and geared right down. Cant fault it really. Time to spruce it up n improve it tho. Muwahahahahaha……………
With the heavy stainless guns/rockets n theyre supporting 5mm thick steel stripped off it should drop weight a lot below the 190kg its at now, by at least 10kg if not a lot more. With the bodywork off you can see its pretty lightweight potential.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/Ninjanakedcutdown1.jpg
What Im aiming to turn it into is a minimal concept bike/café racer sorta fighter. Practical as no polishing to keep on top of and live 50` from ocean, so black frame, etc. Just a get on n ride kinda bike for everyday use n shopping runs, etc, but still funky. Something along these rough paint doodles from my brainstorming sessions. Twin stacked lights between front nose fairing side plates sat behind mesh for flush unit. All under rear seat, etc flush plate. Side fairings, etc thin alloy plate so light. Rest of bike what Ive already got to make it a cheap ass build. Blank colour to show shapes better.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/NinjaConcept-blankcolour.jpg
And the colour scheme Im thinking is top of my list so far.;-
http://i61.photobucket.com/albums/h63/pitstop-paint/NinjaConcept-blacktogreen.jpg
Green`s probably in metallic or flakes from Kawasaki green to british racing green or thereabouts. Double yellow racing stripes down the top/middle of bike a la Lotus.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/GreenYellowLotus2.jpg
Bikes now on my workbench as bandits a rolling bike now n not far off a running bike which`ll be very cool. Time to work.
Ive opted to not strip bike just yet, but to concentrate on getting subframe/body panel mods done n dusted and other parts made up, so then its just strip, paint/polish all the parts and assemble without any hassle as everything will be made already and bolt on.
How Im gonna work back end/subframe without and fancy posh Tig welding gear to weld aluminium is to keep top spars of original subframe which gives me front seat mountings already and can use existing seat and build around it. Remove bottom spars of subframe like below.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/SN851295-1.jpg
And build up new seat unit in sheet steel cos can weld it together myself. No alloy welding services or anything to fall back on up here on a remote island. To get strength back into subframe Im going to add in some triangulation again which is what little funky angular subframe sections above will be hiding. Something along these lines which bolts to main frame chunky crossmember and braces up to 2 cross members on original subframe top section. Roughly like this doodle.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/Ninjanakedsubframebrace.jpg
Made a rough start tonight in an hour or so. Stripped panels/undertray n all crap off subframe to get a proper look. Shitloads of black boxes as per sportsbikes, but there`ll be loads of nooks n crannies to hide them away in on re-assembly. All clipped out of way for now.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/SN851588.jpg
Bare subframe finally found. Lol.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/SN851593.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN851602.jpg
Frame crossmember is pretty major so good place to work from for subframe re-inforcement.
http://i61.photobucket.com/albums/h63/pitstop-paint/SN851590.jpg
Going to weld up an assembly that bolts onto shock mounting, etc in thickwall steel so plenty strong. Sort of like this.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/SN851608.jpg
Which will run up to the back crossmember at back of seat.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/SN851606.jpg
And up to crossmember just at back of fuel tank in above pic. I`ll add in webbing where possible too to make sure its plenty strong. Should be more than up to job I reckon judging by how flimsy original subframe lower mounts are.
This setup will give me the low profile lower subframe run Im after so can be hidden behind little angular sections on frame.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/SN851605.jpg
I`ll then chop off lower run of subframe and clean everything up leaving top run in position. I`ll keep section behind front seat as has plenty of handy mounts already there I can use to mount battery box and electrics tray, etc, etc.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/SN851596.jpg
Well that’s the rough plan for now. Progress might be slow right now as main priority is finishing `project budget dragqueen` off. Not much left to do on her now tho apart from spray a side scoop. After that its spending on last parts which I cant afford right now. Leaves me time to make a start on this project tho in meantime. Loads I can make and strip down without cash injection.
Here we go again! lol
Gitzy
28-09-2010, 06:13 AM
I love your build threads Jon, sooo much info and pics.. its great, keep it up.
:D ^^^ what he said ^^^ :D
lucky ur to have a free air brush boy at hand mate! :D
quote:Originally posted by Gitzy
I love your build threads Jon, sooo much info and pics.. its great, keep it up.
Cheers bud. Find it theraputic chill out time for me. Also good detailing things as folk spot things as you go along n point out things you hadnt thought about n lend opinions on better ways of doing things.[8D]
Also stops you bodging things to speed the build up as everything is seen.:D
quote:Originally posted by NoZ
:D ^^^ what he said ^^^ :D
You following me. lol
jon
quote:Originally posted by Surt
lucky ur to have a free air brush boy at hand mate! :D
Yeah it is handy.:D Just have to prod him with a pointy stick every so often.:)
Quick hour tonight. Not a lot, but can get a lot done in little time. All adds up eventually like my bandit build. Spent good 10 minutes of it humming n hawing about chopping the subframe. One of those no going back moments for me. Not like theres anyone up here on my island that can alloy weld the bits back together if I change my mind. Needed bottom rails off tho to get access.
After the first slice tho worry was gone. Grinning like a manic grinder wielding maniac while my face got splattered in a hot aluminium shower. Pure bliss. Lol. Cut everything rough as can take flap disc on grinder to it later to tidy up rough edges properly and trim everything flush. Purely cut for access at moment. Fookin lower subframe alloy box section weak as fook once removed. Could bend it round my knee by hand!!! Shows how close they cut things on sportsbikes to save weight.
After the carnage n couple bits clamped in place.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/SN851609.jpg
Cut a bit of 2” x 1” thick wall (bout 2-3mm) steel box for in between back frame section. Nice snug fit between plates and sides of subframe rails to stop any potential movement. Clamped up in place with vice grips for now.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/SN851610.jpg
Cut a nice recess underneath too to add a bit more support strength. All helps. :-
http://i61.photobucket.com/albums/h63/pitstop-paint/SN851612.jpg
Couple bolts through n be solid in there. :-
http://i61.photobucket.com/albums/h63/pitstop-paint/SN851613.jpg
Placed another 2”x1” thickwall bit of box section in running down to shock mount on frame cross member. Only then realized the shock sits off centre by 10-odd mm. Weird, but not a problem. :-
http://i61.photobucket.com/albums/h63/pitstop-paint/SN851618.jpg
Mitred it at bottom for better fit n strength. Couple tacks of weld for now to hold it together. I`ll weld up the whole assembly solid once done. :-
http://i61.photobucket.com/albums/h63/pitstop-paint/SN851614.jpg
Next up is make a little braced section that welds to other end which is sitting on frame rail at moment. This will allow it to bolt down solid to shock mounting bolt.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/SN851615.jpg
Then weld on a bit of box section running back up to another frame cross member just behind tank and make mounts to bolt on there where tank bolts on. A bit of webbing/box section between this wee piece and the main box section beam below n should be pretty solid in comparison to original setup. :-
http://i61.photobucket.com/albums/h63/pitstop-paint/SN851616.jpg
Side shot n profile looks right compared to what Im trying to achieve.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/SN851619.jpg
quote:Originally posted by Jon
quote:Originally posted by NoZ
:D ^^^ what he said ^^^ :D
You following me. lol
I stalk all the greats :D
So why stalk me then.:D:D:D
So why stalk me then.:D:D:D
cos yer a marmite freak muhahahahahaha I have to keep tabs on my minions
Another hour or so tonight.
Cut a bit of the same box section diagonally to give better access to shock absorber bolt. Couple blobs secure it to end of main spar for moment. :-
http://i61.photobucket.com/albums/h63/pitstop-paint/SN851620.jpg
Bit of grinding down n original fuel pump n filter mount should slot back onto its original position onto shock bolt too. Note insulation tape plaster where box section slipped on pillar drill n whacked me fat thumb. Doh! Lol.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/SN851624.jpg
Bit of same chunky 2`x1` box run up to frame spar at back of tank. Trianulgated with bit of 1`x1` for strength. Tacked again for now. :-
http://i61.photobucket.com/albums/h63/pitstop-paint/SN851622.jpg
Need to cut out a bit of plate to weld to top so can bolt assembly to tank mounts along with tank on top of plate. Should make whole thing solid.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/SN851623.jpg
Hopefully get bit of plate cut out/drilled tomorrow evening n tacked on. Couple of holes for those bolts at back of assembly n that’s about it apart from final welding up.
Took assembly on n off few times making cuts, etc and its an absoloute F**k*r to get in n out of position as made everything so tight fitting as been welding it in place clamped up. Does go though with some brute force flexing remains of original subframe up few mm to slide it in. Better tight fit than sloppy loose tho end of the day. Once welded n cleaned up properly n bolted in place it can stay there. Lol.
Hour odd tonight got a bit of thick plate cut n drilled n tacked on. Cut down original little seat catch too, with tank sat back in place all bolts down tight to frame cross member as per original setup. :-
http://i61.photobucket.com/albums/h63/pitstop-paint/SN851629.jpg
Back end drilled n bolted up to frame. Not structurally loaded the bolts, but stops any upwards flex or anything untowards. :-
http://i61.photobucket.com/albums/h63/pitstop-paint/SN851630.jpg
Original front seat slides back into original mounts n position which saves hassle/cost of new mounts or seat, etc. Profile underneath looks right too. A lot more slimlined. Little angled sections at back of frame will angle inwards towards new subframe rail also which will makeit even more slimlined underneath visually.
Tried jumping up n down on seat and cant feel any flex or movement at all, even tho everything only tack welded at moment. Feels solid.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/SN851635.jpg
Was going to take off subframe at this point n weld up properly and neaten up edges, etc, but realized it now locates exactly in several planes, so nigh on impossible to remove with shock absorber bolt sticking up. I`ll wait till stripping down bike fully as then subframe will just slide out and can weld n neaten it all up then. Main thing is it fits n does its job. All welded into one assembly anyway so no worries.
Couple inch gap under front seat between seat n subframe onto which undertray will sit. Handy little gap to shove some of electrics black boxes in. :-
http://i61.photobucket.com/albums/h63/pitstop-paint/SN851631.jpg
Loads of handy mounting points behind seat to mount bodywork and battery box solidly, etc. Could come in handy later on so leaving em all there for now. Might have to chop length back a bit as get seat unit mocked up, but nae probs with Mr. Grinder. Lol. :-
http://i61.photobucket.com/albums/h63/pitstop-paint/SN851632.jpg
Unbolted a few odds n sods n already the bike has shrunk physically by miles. Loads of stuff to come off front of forks yet which will shrink it even more. :-
http://i61.photobucket.com/albums/h63/pitstop-paint/SN851633.jpg
Suppose next stage is to neaten up back of frame where chopped off lower subframe rails n mockup little angled covers and seat, etc in cardboard and gaffer tape so can get accurate templates for steel sheet.
After pissing about with cardboard tonight trying seat shapes I realised couple things.
1. I couldn’t get shape I wanted (i.e. tapering to back of bike) with back section of subframe still there.
2. Getting a decent shape, and trying to remember practicality aint easy. End of the day this has to be a more practical bike than bandit project. Needs 2 seats!
Took few pics n resorted to shaping up a plan on computer to see what way to take things.
This is original pillion seat and cowl in position which is nowhere near shape Im after. :-
http://i61.photobucket.com/albums/h63/pitstop-paint/SN851641.jpg
The seat and cowl do taper really nicely to back end though and of course have nice compound curves and finished edges, etc to them. Cant see it in photo but tapers few inches narrower at back of seat and has nice rounded shape at tip too. :-
http://i61.photobucket.com/albums/h63/pitstop-paint/SN851636.jpg
What Im thinking then is to chop the rest of original subframe at red lines below, which is behind structural areas Im using anyway. Then make up a welded on section to my steel crossmember which will support back end of pillon seat much lower down. :-
http://i61.photobucket.com/albums/h63/pitstop-paint/pillionframemockup.jpg
Pillion seat will be moved forwards several inches with new mounts so centre of its over existing crossmember anyway and supported solidly and safely. Moving pad forwards also shortens front seat slightly giving me a stubby seat unit overall shape wise. Pillion pad angled down so gives me profile Im after, and can then panel in sides as per plan and have shape Im after but 2 seats also. Summit like this rough mockup.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/Seatmockup.jpg
Then can run undertray sheetwork up and tuck under edge of seat cowl at back for neat finish and have just enough space behind for some sort of led lighting.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/undertraylightsmockup.jpg
Dunno best idea Ive got at moment anyway to compromise between shape/2 seats. Not gonna leave me space for battery under there tho, but sure can cram it elsewhere down the line. One of the fairing side panels would easily hide a battery somewhere if cant get it under tank.
Had a rethink last night. Going to cut of few inches of subframe at back n have a go again at mocking up in cardboard to shape I really want as per original doodles. Want the shapes right, and space for battery under back hump, so practicality can take a back seat. Lol. Can always get one of those inflatable sucker pad pillion pads to stick on when needed.
Think Im going to have to go for 3 peice design so top is flat-ish like top of tank, but follows curved side profile as per my doodles, then run side peices up to meet it n weld together. Giving me a squarish edge, but reckon thats probably spot on given rest of bikes going to be angular anyway.
Going to try out a few variations over weekend in cardboard n see what works best.
Not a shitload today. Bought some more grinder discs n neatened up back of frame, etc so had nice clear space to work with mocking up.
Spent a while mocking up several different seat shapes with scrap card n gaffer tape, which all looked good from side on profile, but absoloute wank from any other angle. Maybe its just the cardboard, but don’t think it`ll work.
Side profile looks like initial drawing.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/SN851678.jpg
Buuuuuut of course 3 part design just doesn’t work right when move to slightly different angle n looks wank.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/SN851679.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN851683.jpg
Bit disheartening, so stood back n decided to go with a really simplistic one piece curve I can easily make and see how that looked.
Not the shape I had in original doodles, but sometimes what works on screen and what works in reality from different angles are two completely different things. Lol. Best option so far anyway shape wise. Also roughly mocked up frame angled sections to see how they`ll work in reality as curve inwards substantially to join undertray sheet work.
Side profile. :-
http://i61.photobucket.com/albums/h63/pitstop-paint/SN851666.jpg
Only one little piece needing welded in at front. I`d weld it from behind to keep join neat. Recess it couple mm and then a bit of seat foam or upholstered little rectangle would finish surface off nicely and act as butt stop.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/SN851668.jpg
Ok from back too. Maybe trim the original front seat pad shape a bit to match bodywork. :-
http://i61.photobucket.com/albums/h63/pitstop-paint/SN851665.jpg http://i61.photobucket.com/albums/h63/pitstop-paint/SN851669.jpg
Decent space underneath to hide battery and build up a chunky bit of frame work to support it all and a stick on pillion pad when required.
Still needs a bit of playing about with the angles, etc but reckon got potential. Changes design profile a bit, but still works I think.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/NinjaConcept-newseatshape.jpg
Decisions, decisions………….. Simple curve or work at 3-piece design shape some more!?!?!?!?
Plus of course I cant help but feel original seat cowl n chopped about seat pads has potential still too. Just got a nice shape about it.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/SN851685-1.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN851689.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN851690.jpg
Maybe chop down both pads and cowl length wise into something short n stubby. :-
http://i61.photobucket.com/albums/h63/pitstop-paint/mockupofseatstumpy.jpg
Lot to think about. Anyone any ideas?
RevHead
03-10-2010, 09:53 AM
definently lift the rear seat cover to level,an shorten it ,an inch or 2,^^^^^^^^
Yeah looking like best option at mo. I`ll mock something up.
Maybe at a lesser angle it works better n slightly more passenger friendly. Lol. Maybe 2 degrees angled back at most. Looks angled, but that’s photo really as back end of bike is good 3-4” higher than stock as ZX12R shock in there as 2-up workhorse. Practically level seat, but looks angled back in relation to tank which is look Im after.
http://i61.photobucket.com/albums/h63/pitstop-paint/SN851691.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN851694.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SN851695.jpg
Got a nice tapered rounded back end to it.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/SN851636-1.jpg
Seats flow nice together too.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/SN851653.jpg
Sorta like this mockup. Shorten front edge of back seat and cowl by 2-3” and move forwards to overlap front seat pad by couple inches too, giving a stumpy/short look. Original seat pads way too long anyway for comfort. My arse aint fat enuf to fill em. Lol. Panel in sides n curve undertray up underneath to tuck in to back edge of cowl.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/finalseatmockup.jpg
Best I can think of tbh balancing neatness n practicality. Fairly thin profile n mismatch angle between forward slant of tank n seat cowl keeps things in line with original doodles.
Its either this or Z style single curve idea methinks. Leaning towards this tho tbh, even tho no room for battery, I reckon I`ll get a neater finish overall on panels.
Flipping around the image above gives this.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/finalseatmockup2.jpg
Doodling that profile onto original sketch n looks pretty good to me anyway.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/NinjaConcept-newseatshape2.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/NinjaConcept-newseatshape2green.jpg
Swear Ive spent a lot more time deciding on seat shape than took to build subframe. Lol. Way it goes sometimes with a build tho.
Decided in the end the seat cowl would stand out like sore thumb compared to rest of bodywork, and would always be just a seat cowl, so threw it in a corner. Lol.
Went back to single curve setup, trimmed right down by an inch or so with a narrower tapered rear edge, and angled down. Practicality not great, but going to make up an angled pillion seat pad that clips on, which restores seat angle to horizontal for occasions its needed. Rest of time I can have the look I want.
Rough mockup on bike. Front seat pad needs cut down by 3” I reckon to match up with bike doodles below. :-
http://i61.photobucket.com/albums/h63/pitstop-paint/ducktailmockup1.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/ducktailmockup2.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/ducktailmockup3.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/ducktailmockup4.jpg
Mocked up on original sketch. Reckon it works. Not going to be for everyone, but Im liking it. Angled back café style with a nice aggressive spike profile. Angular look matches in well with rest. :-
http://i61.photobucket.com/albums/h63/pitstop-paint/NinjaMockup1.jpg
Maybe sharpen up the lower panels a bit to match angles.
http://i61.photobucket.com/albums/h63/pitstop-paint/NinjaMockup2.jpg
Still playing about with it all, but reckon it’s the way forwards. Just working through the creative process with trial n error. Sorry if its boring yer all. Lol.
Can start building up the subframe at back now tho as made a decision. Save up the kids cereal boxes n make some accurate templates n can start chopping n welding some sheet up.
Nother hour tonight head scratching n pissin about. Got the sizes of a R1 gel battery off the net other day as know theyre fairly small, so got one of them in mind for the bike once done, due to theyre smallish size and fact I can mount it sideways, etc. Had old dead bandit battery kicking about so had something not far off right sizes to mock up with.
Try as I might I couldn’t for life of me make the battery fit inside the tail shroud no matter which way up I put it. Really want battery in there so don’t have to think about stuffing it elsewhere. Under the tank on the ninjas is a mass of ram air guff. Pressurised airbox n valves/hoses all over the place. Not much spare room for much more than an anorexic ant!
Chopped front seat pad down by around 2” and quickly recovered it again for now. Bit more sensible sizing as my ass aint THAT big. Lol. Don’t like seats you can slide around in back n forth. Looks better too.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/battin1.jpg
By cutting front pad down I realized my battery problem was solved as was enough of a gap to slide it down in. Leaning it at slight angle to match tailpiece panel n fits in snugly. Just need to make up a few bits of sheet to support the battery and a strap or something n job done.
http://i61.photobucket.com/albums/h63/pitstop-paint/battin2.jpg
Without cardboard on pic below. Also tacked on a bit of box to start making up strong framework so tailpiece can support passengers weight. Messy as hell for now, but no point making it pretty, or welding properly till know its right. :-
http://i61.photobucket.com/albums/h63/pitstop-paint/battin3.jpg
Got some 4mm plate scraps, so going to make a plate that comes from back box section back to those 2 threaded bosses on original subframe next to battery, and curve/arch it upwards to match curvature of tailpiece to provide strong support. That`ll be next few evenings work making templates/chopping n smacking shit out of it to try get it to curve. Lol.
Plenty of gaps under there tho for electrical gubbins, plus the gaps under front seat pad too. Should be plenty space for it all to live.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/battin4.jpg
Times being split between this project and my turbo bandit project so moving forwards slowly. No great rush tho. Got a long harsh winter on its way up here so be lots of shed time. Lol. Weathers too good at moment so been out n about on my Harris Z enjoying it. Empty mountain roads n no traffic/junctions/police. Bliss. Too good to lock myself away in shed. Lol. Works busy too so little free time at mo.
Cut another more accurate cereal box seat cowl with a flatter top profile to accommodate seat. :-
http://i61.photobucket.com/albums/h63/pitstop-paint/seatsubframemockup1.jpg
Keep cutting templates till get it accurate. Better wasting cereal boxes than steel. Lol.
Cut out some 4mm stainless steel plate I acquired off a mate up town out of a skip as he got shitloads of it. Bastard to cut, but feckin solid. Should support pillion weight well off cosmetic seat steel:-
http://i61.photobucket.com/albums/h63/pitstop-paint/seatsubframemockup2.jpg
Spent ages cutting out supports that went down to original alloy subframe, then threw them in bin as wasn’t convinced of strength. Instead Im gonna cut n weld on some small lengths of the same 3mm wall box section then weld everything solid in one lump. Better safe than sorry.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/seatsubframemockup3.jpg
Battery can come out front way if needed. Updates when get some free time to do some more. Lol.
Try not to spend too much time in garage leaving my wife n family widowed. Was sitting staring braindead at crap on tv this evening, n me fantastic wife says “I thought you`d be in the garage rather than sitting about bored”. Whoosh I was gone. Lol. Another quick ½ hour or so chopped bits, tacked them on. Some of offcuts of box section n thin sheet scraps from bandit side scoopwere quickly formed into a basic battery tray. Rough n ready but once cleaned up n welded properly n drowned in 2K black will look a lot better. Not that anyone can see the bits once together anyway. Lol.
http://i61.photobucket.com/albums/h63/pitstop-paint/battbox1.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/battbox2.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/battbox3.jpg
Got some thin rubber matting kicking about I can line battery tray and pillion plate with when goes back together.
Suppose next item to look at it putting on some mounts or a tray in gaps to mount electrics on. After that its just bodywork sheet metal to make up I think. Oh and a quick detatchable plate underneath to hold pillion footrests. Thinking something solid that footrest assemblys bolt to, and then the whole lot bolts to undertray with 1 or 2 bolts for speed when needed.
Been airbrushing bandit side scoop last few evenings so not got much done on ninja.
Did a bit tonight tho. Started on an elcetrics tray for under front seat pad. Cereal box mockup/template. :-
http://i61.photobucket.com/albums/h63/pitstop-paint/ninjaelectricstraymade1.jpg
Bitta sheet meets grinder n a hammer. Sits in place ok. :-
http://i61.photobucket.com/albums/h63/pitstop-paint/ninjaelectricstraymade2.jpg
Threw all the black boxes in randomly to make sure they would fit. Should be alright once tidy things up a bit n mount everything neatly, etc. :-
http://i61.photobucket.com/albums/h63/pitstop-paint/ninjaelectricstraymade3.jpg
Seat pad slips back on without any force. Still a gap between seat n electrics. :-
http://i61.photobucket.com/albums/h63/pitstop-paint/ninjaelectricstraymade4.jpg
I`ll get mounts made for the tray to bolt onto subframe n holes drilled to mount all the boxes/relays, etc next couple evenings. All the wiring reaches easily though which is cool. Need to lengthen battery leads 8” or so, but not exactly a big job.
Couple bolts tacked on as mounting studs. :-
http://i61.photobucket.com/albums/h63/pitstop-paint/leccytraymounted1.jpg
Mounting holes for everything drilled. Also made n tacked on some lugs for the original rubber mounting fixings for the relays. Time consuming yeah, but better having relays rubber isolated, and bit better than zip-tying everything in place. One of my pet hates when buy a bike is finding a big rats nest of wires/boxes shoved into a space n zip-tied together in a mess. Lol. :-
http://i61.photobucket.com/albums/h63/pitstop-paint/leccytraymounted2.jpg
Everything slotted in n loosely bolted. Tight as 3 relays, reg/rec, fuse box, ignition module, etc, but will be nice n neat once wires clipped up properly. :-
http://i61.photobucket.com/albums/h63/pitstop-paint/leccytraymounted3.jpg
All at a nice low profile so seat pad clears everything once on. :-
http://i61.photobucket.com/albums/h63/pitstop-paint/leccytraymounted4.jpg
Well think that’s everything bar neatening up n final welding once subframes off bike on stripdown. Onto sheet metal work now covering everything up I guess. Lots of cereal box templates n cutting/welding. Lol.
Not a shitload tonight, but progress of sorts.
Measured up size of 1.5mm sheet I`ll need for seat unit metalwork. Way bigger than what I have which is a pisser as nowhere to get steel from up here other than Egay! Must be somewhere on island to get metal from, but Ive asked around n drawn up nothing but blanks.
Stripped off all guff from front end tonight anyway, and guns/rockets and all supporting metalwork from other side, etc, etc. Took about a sodding hour as everything rusted into one big blob! One of side effects of living right next to sea for many years n winter riding.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/ninjafrontendstrip2.jpg
Got 2 piles this size now. Bout 2 feet deep in places! Must be good 20-30kg between it all as most of metal bar is at least 5mm steel. Loads of weight considering it was only 180-odd kg with 2/3 tank of fuel at last MOT test! Note big ground section on bellypan from jumping too many humpback hill sections of local roads. Ooops. Lol. :-
http://i61.photobucket.com/albums/h63/pitstop-paint/ninjafrontendstrip1.jpg
Bikes fookin tiny! Feels like a 250cc stood next to it, and I’m short. Lol. Gonna be light as hell as not much going on bar few sheets of thin alloy, etc. No big clocks on front, n no real seat unit length at back, etc. Cant get over how small bike looks tbh. :-
http://i61.photobucket.com/albums/h63/pitstop-paint/ninjafrontendstrip3.jpg
Off to scan Egay for some sheet steel for seat panel, n hassle a few local mates about local suppliers. Loads of boat builders, etc up here. Must be getting materials from somewhere.
Not done a lot of late. Been working on my daily driver Hearse to get it through its MOT n clean up few areas, etc, etc. Went through MOT test fine then fuel tank developed pinhole leak so had to strip that completely off n repair it, etc. Pain in the arse job, but all sorted now. Gonna wire brush n underseal whole underneath of car next few days too ready for winter. Bloody cars. Lol.
Anyway chopped a couple of matching headlight plates tonight. Just 1.5mm steel as not going to be visible when done, and car spotlights that were on bike weigh next to nothing. Re-using them as small and lightweight and pretty narrow which fits in with my plan. Couple bits of bar spacer to make to fill gap back to headstock brackets, but no biggy. :-
http://i61.photobucket.com/albums/h63/pitstop-paint/Ninjalightsrough1.jpg
Side on profile looks right anyway.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/Ninjalightsrough2.jpg
Probably weld on couple brackets to bolt the bodywork onto once made it up. Same shape as doodle below, matching original doodles shape wise. Step at back clears bottom yoke. :-
http://i61.photobucket.com/albums/h63/pitstop-paint/Ninjalightsrough3.jpg
Thinking cover gap between side plates on top and bottom surfaces too, so enclosed narrow unit, and then mesh over front so lights not as obvious. More like an air intake in appearance. I`ll get some cardboard templates chopped about n see what looks like mocked up next few days. Original doodles had the light unit joined to the tank and running under the top yoke, but not sure how practical that would be. Don’t fancy removing top yoke to take tank off. Lol. Maybe some sort of split design or leave tank as is. I`ll get a better idea once start cardboard/tape mocking up.
Up town tomorrow in car n found a engineering place up there. Going to stick my head in and see if can get some big enough sheet off him for the seat unit. Be handy having somewhere on island I can get metal from instead of shipping it in all the time.
Lots of pissin about with cardboard n gaffer tape tonight. Got shape roughly hacked out to see how looked n fitted. Not bad at all really. Sides and top will be out of same bit of steel so have slightly curved top edges in reality. Some black mesh (still got some fireguard mesh scraps, lol) recessed slightly at front for that stealthy look n should look alright.
http://i61.photobucket.com/albums/h63/pitstop-paint/Nosefairingmock1.jpg
Will need to curve bottom edges in slightly once made by 1cm or so to clear bottom yoke, but not far off clearing. Ignition barrel catches, but looks butt ugly on top yoke now so be getting moved somewhere discreet anyway so not a problem.
Top section runs round headstock and tucks under tank mounts to bolt down. Keeps visible fasteners down to a minimum. A single bolt underneath somewhere at front will hold secure without masses of bolts. :-
http://i61.photobucket.com/albums/h63/pitstop-paint/Nosefairingmock2.jpg
Side profile nice n neat n more or less inline with sketches. Clean n geometric and inline with tank top slope. :-
http://i61.photobucket.com/albums/h63/pitstop-paint/Nosefairingmock3.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/Nosefairingmock4.jpg
Gonna sit tonight n draw out accurate templates neatening up shapes, etc so can transfer to steel n cut em out n get it made.
Didn’t get up town today, but going up tomorrow so I`ll hound that engineering place for some sheet while there. Lol.
Gix11
27-10-2010, 10:55 AM
Love your shed Jon, so much stuff everywhere! Custom made body work rocks!
Cracked on for couple hours this evening at nosecone.
Accurate paper templates other night from initial cardboard box mockup.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/makinnosecone01.jpg
An hour or so hacking it out with trusty cheap n nasty grinder, shaping it over my knee with a hammer, and forming the folds by wedging the sheet in the gap between my garage doors n shoving hard. All high class tooling me. Lol. Couple welds n coming together.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/makinnosecone02.jpg
Didn’t have any sheet big enough so top lugs had to be welded on. By clamping with vice grips to hold flush, I welded front n back then ground back. Nowt a wee bit of filler wont sort and strong join. :-
http://i61.photobucket.com/albums/h63/pitstop-paint/makinnosecone03.jpg
Curved couple of bottom edges in slightly to clear bottom yoke at full steering lock. :-
http://i61.photobucket.com/albums/h63/pitstop-paint/makinnosecone04.jpg
On the bike n looks alright in its roughness.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/makinnosecone05.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/makinnosecone06.jpg
JUST clears bottom yoke at full steering lock which was a concern.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/makinnosecone07.jpg
Wee rabbit ear lugs I welded on wrap around headstock of frame.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/makinnosecone08.jpg
And bolt on under front of tank to keep number of fasteners down on bodywork.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/makinnosecone09.jpg
Looking at it by eye the tank and headlight cowl slope (i.e. top edge) are inline as per original plan so looking good. :-
http://i61.photobucket.com/albums/h63/pitstop-paint/makinnosecone10.jpg
Part of my concept doodles success to the eye is the use of parallel lines throughout the bodywork for nice flow. Seems on target so far anyway. Those lines (tank/headlight cowl) closely match the bottom of the seat subframe too, so all seems well at moment anyway. Don’t need all the lines within fractions of a degree or anything, but as close as possible by eye will make end result look a lot better IMHO.
Stepping back n I’m liking it.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/makinnosecone11.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/makinnosecone12.jpg
Needs some mesh frenched (junk fireguard to the rescue again, lol) in to front of nosecone and generally tidied up. Bit of dressing up with a hammer/file, and basic fillerwork and preparation for paint will make it baby smooth and a million times better as per bandit side scoops, but not bad even in this rough stage. Something different for cost of nowt and couple hours work.
Sheet metal wise Im going to have to resort to building the seat unit out of several pieces as my search for large sheets on island drew a blank. Lot more work, but will work ultimately, just time consuming making the joins invisible. Hey ho, its gonna be a long harsh winter up here anyway. Need something to do. Lol.
I'm sure you'll find something to keep you occupied lol
Couple bits last few days.
One of original light brackets with a bit of bending about was ideal for a bottom bracket for bolting cowl to. Couple tiny M4 bolts underneath to secure cowl keeps things neat as completely out of view. Saved time/materials making one from scratch too. Lol.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/lightbtmbracket.jpg
Chopped up some scrap fireguard mesh and bonded it into inside of light unit countersunk slightly. Bolted up n Im liking it. Lines look good. Mesh will be sprayed black when finished properly. :-
http://i61.photobucket.com/albums/h63/pitstop-paint/lightmeshin1.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/lightmeshin2.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/lightmeshin3.jpg
Put a couple bends in a sheet of steel to make a start on seat unit. Going to have to make it out of several pieces due to size of material I have and lack of places on island to get bigger sheets. Not end of world tho.
Not chopped it yet tho as unsure as to shape. Red line below is bottom edge of seat unit. :-
http://i61.photobucket.com/albums/h63/pitstop-paint/seatstart1.jpg
To get sharp point between bottom edge of seat and seat top like drew originally I`ll need to chop about subframe pillion seat support a bit and angle downwards by miles to more like the yellow lines position on picture. Its either that or curve it up to meet top like I sketched on in marker to keep seat length down. Doesn’t look too bad tbh. :-
http://i61.photobucket.com/albums/h63/pitstop-paint/seatstart2.jpg
Reckon it`ll be a case of chopping the subframe about tbh, but not sure as yet. Decisions decisions. Lol.
Nipped back out to shed for ½ hour this evening n chopped n rewelded all pillon pad framework on subframe, etc. Looks more inline with angles Im after now. Nice sharp point where seat top and seat bottom will meet when done. Mucho better. :-
http://i61.photobucket.com/albums/h63/pitstop-paint/seatreadjust.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/seatreadjustmockup.jpg
Get the sheetwork chopped to shape roughly n start tacking on some side sections next day or two. Gonna take a while to build up whole shape, but got all long cold winter to piss about in shed. Lol.
Hour or two spent tonight with the old cereal boxes n tape/scissors again tonight. Exciting night life I lead. Lol.
Got the side panel shape templates worked out fairly accurately after several goes. Thank god the kids eat a lot of cereal as ideal thickness for accurate templates.
Side view showing basic shape. Bottom edge is oversized so I can trim that back few mm once get undertray made, etc. More than covers subframe mods anyway in depth. Fit round seat pad seems not bad. :-
http://i61.photobucket.com/albums/h63/pitstop-paint/sidepanelsmockup1.jpg
Bit of curving n shaping and shouldn’t look too out of place where meets tank. Wont be perfect but wont stand out as being hideously troll ugly like my ex-mother. Muwahahaha. Going to try fabricate some push-fit tags that will fit into the original rubber side panel bungs which are still on tank. Will save having fasteners on view. :-
http://i61.photobucket.com/albums/h63/pitstop-paint/sidepanelsmockup2.jpg
My art lecturers always said to step back from your work every so often to see the whole picture. Further back n seems to have profile Im after overall. :-
http://i61.photobucket.com/albums/h63/pitstop-paint/sidepanelsmockup3.jpg
Going to have to make each side out of 2 pieces as no material big enough. Marked it out ready for chopping n welding next few evenings.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/sidepanelsmockup4.jpg
Got stack of 1mm grinder discs sitting so can slice it out accurately. Making 2 identical sets for both sides. Figure frame/tank/seat identical both sides so make 2 sets at same time so perfectly matching. Area where meets back section of seat I bent the other day Im cutting good 20mm or so over size so I can line it up accurately n have some to spare. Lol. Guaranteed my bends on back section the other day aren’t mm perfect, so this way I can line everything up at back end n chop off excess.
Also in picture is my big 5kg box of welding rods which arrived today that I got off egay for much cheapness. Was running low and they were going for silly cheap price so grabbed em. Stock me up for a fair while.
holyman_999
03-11-2010, 01:03 PM
Loving this build mate. Gonna look mean as when it's done!
quote:Originally posted by holyman_999
Loving this build mate. Gonna look mean as when it's done!
Hope so bud. Not got cash to throw at it for expensive german fibreglass, so trying something different.:D
LKC73
03-11-2010, 07:58 PM
Jon, i like the build aswell. She will be one mean looking machine complete.
holyman_999
03-11-2010, 10:06 PM
Cash does not maketh the fighter, my brother... Anyone with cash can punch out a blinged-out, shiny, go-fast, german-fibreglass, carbon-fibre, twin-turbo, nos-powered, killer fighter... and don't get me wrong, I get the horn for them as much as any other fighter-lover. But, I have seen just as many budget, backyard-made, custom fighters that give me that same feeling, maybe even more so, because you know that despite the lack of funds/tools/knowledge, the owner has had a crack, and generally poured his heart and soul into it.
and that's why we're all here, cause we love to ride, and we love to fuck with the thing we ride...
and some of us are also here for the boobies.
Chopped out side panel sections tonight using nowt more fancy than a grinder. These are other sides sections as Id already welded together one sides.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/LHSsidepanelfab1.jpg
Welded other side, ground back weld to pretty flush on front surface. Nowt sanding n paint wont sort. After an hour or so hand forming the piece over my custom curve shaping implement (my kneecap, lol) I had one side 99% right. Pretty chuffed with it tbh. :-
http://i61.photobucket.com/albums/h63/pitstop-paint/LHSsidepanelfab2.jpg
Curves in with seat pad shape, and then back out to curve into back section. :-
http://i61.photobucket.com/albums/h63/pitstop-paint/LHSsidepanelfab3.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/LHSsidepanelfab4.jpg
Time to stand back n scratch me beard, lol. Looks right to me. Be spot on once trim the bottom edge slightly, etc. :-
http://i61.photobucket.com/albums/h63/pitstop-paint/LHSsidepanelfab5.jpg
Good flush fit against tank recess too. Was a twat to get right but sitting pretty good I think.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/LHSsidepanelfab6.jpg
Also tucks under seat pad well.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/LHSsidepanelfab7.jpg
Cheated with the rubber tank fixing point on tank, as realized a allen bolt head was a perfect snap fit into rubber bung so just tacked it onto back n job done.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/LHSsidepanelfab8.jpg
Will need to move things around so can get enough access to shape other side panel, and weld/bend it, etc next few evenings. Once have both done tho I can get back section square and chop off side panel excess length n weld into one unit. Happy so far tho. Working out better than thought. I’m no engineer. If I could airbrush bodywork on I’d be fine. Lol.
Got other side sections welded n roughly shaped tonight. Seems pretty close shape wise to other side anyway. Need to weld on a rubber fixing tab at front still tho. :-
http://i61.photobucket.com/albums/h63/pitstop-paint/RHSsidepanelstart1.jpg
Both sides still need wee bit of tweaking about to make perfect fitment wise, but certainly not bad anyway. Also need to cut n weld in a recessed front panel in ere. :-
http://i61.photobucket.com/albums/h63/pitstop-paint/RHSsidepanelstart2.jpg
From back its slightly off too symmetry wise, but certainly coming together. Can see it as one piece all trimmed in my head anyway. Lol. :-
http://i61.photobucket.com/albums/h63/pitstop-paint/RHSsidepanelstart3.jpg
Think Im gonna have to line up the 3 pieces by eye n tape measure as close as possible and then cut off side panel excess n tack em together. Be a lot easier to tweak the shape about once all in one piece instead of clamped. Should hopefully be able to get it all close as dammit by eye n lots of pissin about bending it about, etc. Could take me a while tho. Lol.
Another hour tonight n decided to concentrate my efforts on one side at a time. Clamped rear section to subframe as square as could measure, and by eye. Also ran a bit of string with a weight on end from the headstock, down center line of tank/seat, etc which lined up with centre line on back section n all look close. Lump hammer held a bit of weight on front seat pad to make sure was sitting properly on subframe and not on side panels or anything. :-
http://i61.photobucket.com/albums/h63/pitstop-paint/seatweldup1.jpg
Gave me a line to look along n all seemed good and level with tank, etc.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/seatweldup2.jpg
Lined up, clamped, marked n chopped excess off side panel. Welded together then trimmed lower edge back, etc to final shape. Few mm of overlap over subframe spars at lower edges which gives me a bit of space to recess an undertray into. Looking pretty good tho.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/seatweldup3.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/seatweldup4.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/seatweldup5.jpg
I`ll get a go at doing same with other side panel tomorrow and then can tweak about the shape slightly here n there, but really not far off which is fantastic. I`ll make a template of side Ive done so get other sides shape identical as possible. Should work out alright anyway.
JackTar
06-11-2010, 08:45 AM
Looks good mate but how the fuck do you get to that bike?
Tell me about it bud. Have to think thin.:D
12` x 10` shed, but got my trike in there which is 11` x 6` wide at back end. My Harris, my turbo bandit dragbike thing, the ninja on workbench, pillar drill n lathe, mountain of tools on floor/roof/shoved in gaps, welding gear x 2, etc, etc. Fookin tardis.:D
hypo ss
06-11-2010, 10:11 PM
you need a bigger shed mate
BANDITROD
06-11-2010, 10:34 PM
fuck that looks tuff as nails mate i love that headlight you have made
quote:Originally posted by hypo ss
you need a bigger shed mate
Was big enough when built it.:D Then got offered lathe/pillar drill/mountain of tools/welding gear x2/bike workbench, etc for free so couldnt turn it down. Then got offered bandit that formed base of my `project budget dragqueen` build at a price I couldnt say no to.:D
I`ll extend it somepoint so have more space to fill up. lol.
quote:Originally posted by BANDITROD
fuck that looks tuff as nails mate i love that headlight you have made
Cheers.[8D] Trying something different again with this build. Hopefully will work out ok when done.[xx(]:D
Got other side done same as other today. All welded up, etc. All joins will need lick of filler n shaping slightly, but thankfully I know someone who can do me filler/paintwork/airbrushing for next to nowt. Lol.
http://i61.photobucket.com/albums/h63/pitstop-paint/RHSpanelweldup1.jpg
Looks not too bad. :-
http://i61.photobucket.com/albums/h63/pitstop-paint/RHSpanelweldup2.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/RHSpanelweldup3.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/RHSpanelweldup4.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/RHSpanelweldup5.jpg
Need to tweak it a bit here n there with my trusty kneecap/hammer combo. Get a bit of steel cut out n welded in to cover the battery area next I think n get a bolt or two through somewhere to mount it securely at back. Onto frame little angular infill panels n undertray after that.
Left a bit of a gap shape wise at back lip. Thinking I`ll slip a narrow LED strip light in there between seat panel and undertray panel once all done.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/LEDlightmockoop.jpg
talented and gets stuff for free... meh! lol
Another wee bit tonight. Seems like I get nothing done each night, but does add up slowly but surely.
Couple small tabs on inside at front secure it nice n tight to original side panel fixings at back of tank. :-
http://i61.photobucket.com/albums/h63/pitstop-paint/Seatfixings1.jpg
Wanted a nice solid mount at back so went with a Tiny little allen key bolt into a threaded hole in subframe extension. :-
http://i61.photobucket.com/albums/h63/pitstop-paint/Seatfixings2.jpg
Also cut n welded in a section to fill the gap and cover the battery. Slightly recessed as there`ll be a little arse-stop pad stuck on there to neaten things off when done.
:-
http://i61.photobucket.com/albums/h63/pitstop-paint/Seatfixings3.jpg
All feel bloody solid with no movement at all. Gonna start working out templates for little triangular frame sections and undertray next few days.
Gix11
09-11-2010, 04:40 PM
Don't know if it will help or not mate, but I did the same thing as you and made all my mounted solid a firm. Ended up being a pain in the arse as vibrations from the rest of the bike and riding would cause funcky rattling noised etc, and to add to the fun it would blow the tail end bulbs all the time (in fact it still does as I have fully sorted it). I'm sure you've factored that in but just thought I'd mention it as a few rubber bushes go a long way and that rattling noise will drive you mental!
Going to stick on some foam and thin rubber matting onto the back of the panels at contact areas. Hopefully keep rattles to a minimum n below what I can hear over race can. lol.
Only did bout an hour tonight as fookin freezing up ere n start to feel it quickly standing still pissin about with cardboard n scissors. Alright when movin about doing stuff but standing about me old kneecaps start to seize up. Lol.
Made a series of cardboard templates till got shape of frame extensions right. Cut out both.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/01-1.jpg
Got one side formed anyway. One fold n lotta curving to follow seat unit later.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/02-1.jpg
I`ll roll the edge meeting the frame slightly to make it less obvious. These sections will be same finish as frame so looks part of it shape wise as opposed to bodywork. Looks right tho n looking side on profile sits right matching subframe spars leaving me nice flat undertray to hide subframe. :-
http://i61.photobucket.com/albums/h63/pitstop-paint/03-1.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/04-1.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/05-1.jpg
Not sure if gonna weld these sections onto seat unit or undertray as yet but doesn’t make much difference either way really tbh. Get the other one folded n shaped up tomorrow then can look at mounting em.
Spent a good few hours last few evenings n this afternoon sorting out seat unit shapes n getting other triangular side piece on. :-
http://i61.photobucket.com/albums/h63/pitstop-paint/RHSofseatdun1.jpg
LHS was straight forwards enough, but RHS took twice as long as just couldn’t get curves right though a lot of problem was access as up against the garage wall.
Must have had seat unit off and on the bike a hundred times easily tacking bits on or re-shaping a curve slightly, etc, etc. Taken forever to get it right. Pretty happy with it now tho. Going to need skims of filler here and there at join points, etc and to level out any slight hammer marks, but should be alright once all sorted n painted up. Looks right to my eye n all feels solid. All one piece and 3 allen bolts hold its on tight.
Can finally start on making a template for undertray now. Seats got a nice waist shape to front of it tho.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/RHSofseatdun2.jpg
Had an attempt at the undertray template tonight. Does need a slight curve in it underneath n a complicated shape to match up with frame spars, etc. Gonna take me a few attempts so need to start poking the kids with a pointy stick to eat more cereal so I’ve got more template material. Lol.
Hopefully yer can see what I’m aiming for anyway. Wanting a flush one piece setup that tucks under seat unit and hides literally everything right down to swingarm. Should look good if can get template right. Lol. :-
http://i61.photobucket.com/albums/h63/pitstop-paint/NinjaUtrayMockup1.jpg
Here's where I’m up to anyway at moment. Looks a lot better with those triangular sections in place now.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/NinjaUtrayMockup2.jpg
Need to source some alloy sheet for the fairing panels and other small panels too. Gonna have to be Egay I reckon given where I am n all. Be onto those templates once get undertray finished off. Project moving quicker than expected tbh as not spending much time on it at all really. Bikes hardly going to be recognizable by time it’s done. Lol.
LKC73
16-11-2010, 08:53 PM
Nice stuff mate, keep them pictures rolling in.
Not done a lot during last week really. Bit here n there pissin about with templates, etc. Xmas orders for airbrushing commission work (helmets/phone covers, etc) through the roof so busy busy.
Old clothes tumble dryer died the other week so robbed the sides off it before went to dump. Pretty thin shitty steel but easily shaped as about the same thickness as the cardboard template. Just as well really as shaping it was a complete bastard of a job as had curves all over the place. End of the day though the undertray is just a cover so can get away with thin steel.
Not perfect, but looks not bad.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/ninjaUtray1.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/ninjaUtray2.jpg
I`ll get a go at mounting it next few evenings if get a chance. Thinking make up 6-8 little threaded tabs of metal and then take the whole seat unit off the bike to tack them on lined up. Either that or make the tabs way over sized, tack em onto seat unit while on bike then drill through undertray and tabs on seat unit to get holes to line up. I`ll give it some thought as to best way to do it. Got a big jar of neat little stainless steel cross head self tapping screws there too. Might be easier option.
Welded some nuts to some little tabs cut from scrap offcuts, welded them to underside of seat unit, etc.
Bolted up with little 8 little domed M5 bolts n looks about right. :-
http://i61.photobucket.com/albums/h63/pitstop-paint/ninjaundertraydun1.jpg
Little gap at back for LED strip rear light of some sort when make on on rebuild. I`ll make up and weld in a bit of plate to mount it on before strip down.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/ninjaundertraydun2.jpg
Couple small bits I want to bend about and trim slightly, but an hour or two next few evenings neatening things up should take care of the little bits n bobs. Can then can get onto making templates for other panels which will be a breeze compared to seat unit. Lol.
Pissed about in garage tonight with scissors n scrap cardboard for an hour tonight. Bit rough n ready start to mocking things up, but it’s a start. Stuck a printout of my initial paint doodle up on the garage wall to give me something to work from. Lol. Mudguard and swingarm panels pretty accurate tho. Fairing top half of side panel just first draft as such so long way from final shape. Gives me a rough idea tho to work from.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/ninjabodywerkmokup1.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/ninjabodywerkmokup2.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/ninjabodywerkmokup3.jpg
Mudguard has a flat sections at sides which are ideal to mount my additional panels to for a flush fit. Trim back length a bit though to yellow line for more stubby/minimal look. :-
http://i61.photobucket.com/albums/h63/pitstop-paint/ninjabodywerkmokup4.jpg
What I really need to do is take the trike out of the garage so I can stand back from the bike with a clear view to work out shapes/angles of the fairing panels in relation to the seat lines/nose fairing, etc. Get a better mockup done next few evenings if get a chance.
LKC73
24-11-2010, 07:46 PM
Jon, Just my opinion, but leave the side fairing panels off, and make yourself a belly pan up to the engine case's. Those side panels will from what i see take away from the industrail look of your engine and undo alot of the work you put into the headlight and tail unit. But thats just me, you may have a better idea of the end result.
Still a great build man in what your doing with what ya got.
usy
quote:Originally posted by LKC73
Jon, Just my opinion, but leave the side fairing panels off, and make yourself a belly pan up to the engine case's. Those side panels will from what i see take away from the industrail look of your engine and undo alot of the work you put into the headlight and tail unit. But thats just me, you may have a better idea of the end result.
Still a great build man in what your doing with what ya got.
Dunno bud. Still pissin about with cardboard at moment. Fairings were part of initial plan tho. Nothings set in stone tho at this stage. Case of trying things out n seeing what works n doesnt.
Another ½ hour or so of pissin about n beard scratchin tonight. Fairing panels reduced in size a lot, n angles looking not far off between all the bodywork panels. Tryna get all the bikes lines close to perpendicular with each other. Other side exact copy of this side as alternator cover far chunkier that other side of engine. Same mounting positions for panels also in couple places. Will need to make up few mounts tho, but fairing panels will be solidly mounted in 3 points as per original HUGE fairing.
Looking a bit closer anyway. Fairing panels only 2 pieces, but had to tape together bits of scrap card in pics so looks like 3 pieces. :-
http://i61.photobucket.com/albums/h63/pitstop-paint/ninjafairingmockoop1.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/ninjafairingmockoop2.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/ninjafairingmockoop3.jpg
Planning on leaving it open at front of fairing panels. Keep that whole industrial/geometrical look rather than try panel everything in. Some nice radiator/cooler covers, etc will keep things neat behind there.
Little bit going on swingarm at back right size/shape, but cant mount it till bike rebuilt I think tbh. Taped on randomly at moment. Plan was to make mounts off hugger mounts, but may have to sort mounts when putting bike back together tbh. Swingarm angles going to be different.
http://i61.photobucket.com/albums/h63/pitstop-paint/ninjafairingmockoop4.jpg
Angles need to flow with rest of bike, but Im planning on lowering back of bike slightly when rebuild it all. Back end of bike is good 3-4” higher over stock as got a ZX12R shock in back of bike as nice n firm for 2-up use. Just that couple inches too high n makes front end pretty twitchy at low speeds on wee mountain roads round here when on by myself. Been that way for bout 10,000 miles but gonna make new dogbones n lower by 2” at back on rebuild as just that bit too twitchy n feels like front wheel wants to tuck in sometimes.
More beard scratchin tonight. Lol. Wedged the bike more upright, and shoved my trike out garage door couple feet so could step back n get better view of bike as a whole n get some pics to look over.
I’m likin it tbh. Pretty inline with initial doodles n look I’m after.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/ninjerfairin1.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/ninjerfairin2.jpg
Added on some little folded over sections to top edge to fill in gap to frame and neaten up radiator top, etc. :-
http://i61.photobucket.com/albums/h63/pitstop-paint/ninjerfairin3.jpg
Taking the side shot into photoshop I drew on the lines of the panels n theyre not that far off perpendicular. Few degrees here n there but nothing to lose any sleep over. Only area needing attention really is the lower section of the side fairings where the lines are majorly off. I`ll chop n tape the adjustments tomorrow night n should be pretty close then to final shape.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/ninjerfairin4.jpg
Getting metal up here on island impossible yet again, as per everything else. Lol. Looking on Egay for some aluminium sheet and thinking I`ll be going for 1.5 - 2mm sheet to be reasonably flex free once mounted to bike, yet easy enough to form folds/curves in. As long as stick to a maximum of 500x500mm sheets they can be purchased and sent up here to me cheaply enough by normal mail, without paying more for courier charges than the metal itself! Just measured biggest panel of side fairing n can get out of a sheet 450x450mm so just inside. Lol.
TheRussian
26-11-2010, 08:52 AM
this should look great. with all the pannels like this should look solid!!! reminds me of stelth fighter:) here is an idea :)
http://www.asfphotos.com/upload/1290762162.jpg
Yeah been said before off one of my mates bud. Stealth bomber black was a suggestion. lol
Not a lot today tbh. Adjusted angles on bottom section of fairing that were slightly off. Looks a bit better now:-
http://i61.photobucket.com/albums/h63/pitstop-paint/ninjafairinmods1.jpg
Ordered up (2x) 500x500mm alloy sheet off Egay. Went for the 2mm thickness in the end so nice n sturdy n solid. When that comes through I can start chopping out the panels n bending them about, etc. My first expenditure. Lol. Cant remember exactly how much, but was under £20 inc delivery up here anyway.
I`ll get front mudguard chopped down and couple of new lower fairing mounts made up (old ones rotten) in meantime so ready to go once alloy gets here.
Definitely garage weather up here today n yes that 5.5 – 6` wide strip of loose stone shingle is the main/only road to main island. lol. Gritter’s don’t come to a lot of smaller back roads up here as tend to end up on they’re side in ditches, etc. Makes for interesting driving. Lol. :-
http://i61.photobucket.com/albums/h63/pitstop-paint/SnowyHoose1.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/SnowyHoose2.jpg
My hearse is under there somewhere.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/SnowyHoose3.jpg
Weekend so spent few hours in garage sorting out rotten/snapped fairing mounts. Fairing mounts are integral part of oil cooler and lower radiator mountings on this bike. Got some of them unbolted, but the rest were rusted solid into on orange blob so had to be ground off and remade. Some of the junk.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/Fairinbracketsortin1.jpg
Remade the steel brackets supporting the oil cooler, etc. Heat from welder n grinder sparks very welcome on my hands. Lol. The alloy parts were heavily corroded and couple snapped lugs, but managed to grind off and re-tap the main boss to M6. Should be fine as lower mounting for fairing sides.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/Fairinbracketsortin2.jpg
While chopping out rot I peeled back the rubber cover on the radiator fan thermostat switch. Contacts green n completely rotted out. God knows how many years the switch/wires haven’t been doing anything.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/Fairinbracketsortin3.jpg
Tried to spin radiator fan n that’s rusted solid too. Saying that the fans never had to switch on in the 11 years I’ve had the bike. Temperature gauge barely moves on bike. Never that hot up here n no traffic or traffic lights to be sitting still in. Straight 80mph+ cruising everywhere on empty roads up here. Fan will be getting binned come strip down for sure. Dead weight literally. Lol.
Chopped couple inches off front muddy too. Bit rough n ready, but doesn’t need to be perfect till get to bodywork prep n paint.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/MuddyChop1.jpg
Stack of rough panel templates brought in.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/Fairintemplatesroughly1.jpg
Gonna draw out more accurate ones on paper over weekend ready for aluminium sheet arriving n can get chopping.
Been waiting best part of 2 weeks now for my alloy sheet to turn up to make body panels from. Cant do fuck all till shows up tho. Pissin snow has backlogged RM big time.
Want to start tearing bike apart n working through each peice, but cant really do that til made rest of panels n know everything will fit when goes back together.
On plus side tho I've went through about 50-odd paint ideas n finally settled on something at last. Pretty full-on paint everywhere build again as good advertising n holds my interest during build. Folk will be groaning at it being a big airbrushed project again I'm sure, but hey its my bike n my tastes n airbrushing’s what I do so cant be that much of a surprise. lol. They might be surprised tho as 95% of the airbrushing is going to be really ghostly subtle in background stuff.
My alloy sheet finally turned up in mail yesterday evening. Transferred template shapes to sheets last night and managed to just squeeze them all onto the sheet size I bought. Went out today and cut out the shapes with my trusty grinder and some 1mm cutting discs which are nice and accurate. Quick hand file of edges got them mostly smooth. I’ll round them off smoothly properly when prepping for paint.
Got plenty evil stares out of the windows of the local church bus going back n forth past my garage, but tough shit. I’ve got Sunday free from work and not about to spend it sittin church. Lol.
Looks like some Ikea flat pack furniture at moment, but everything labeled up.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/fairingbitscutoot.jpg
2 rough parts to left of picture are offcuts I’ll be using for small infill that cover gaps between fairing sides and frame and radiator, etc. Got templates for them already, but final shape dependant on curvature of fairing panels so best to wait till got them formed and double check my templates. Be sods law I’d cut them out undersized if not.
I’ll get out next few evenings and start mounting the panels, etc. Got a handy telephone pole right next to my garage to form the curves round. Lol.
Jockney Rebel
14-12-2010, 04:09 AM
,ur a brave man lol ....harris in this bloody weather me mum live s in ayrshire and she said it was bloody freezin..thank fuck im in oz lol
Yer its chuffin cold, but the snows gone now thankfully. Just gotta get out there n crack on tho or come summer the bikes still in bits. lol.:D
Couple hours tonight freezin my nuts off in the garage got both fairing sides made. One side fully bolted up, and the other just needing a bracket tweak next time I’m out to finish it off. :-
http://i61.photobucket.com/albums/h63/pitstop-paint/LHSninjafairinmade1.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/LHSninjafairinmade2.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/LHSninjafairinmade3.jpg
The little infill panel template I made before isn’t far off. A bit of adjustment onto alloy, and a couple brackets n bolts and should do the job.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/LHSninjafairinmade4.jpg
Front mudguard side panels just need drilled n couple small bolts to secure.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/LHSninjafairinmade5.jpg
The swing arm plates I’m going to have to guesstimate the mounting angle really allowing for lowering rear end couple inches on rebuild.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/LHSninjafairinmade6.jpg
For mounting I’m thinking of just tapping a couple small holes in the swing arm tbh rather than big clumsy brackets. People are always drilling holes to route brake hoses, etc, and cant see it compromising integral strength any. It’s a beefy swinger as is.
Another couple evenings should get everything finished off and mounted properly anyway. Fuel regulator came through mail today for my turbo bandit project too so got plenty to be getting on with. Lol.
Another hour tonight. Got the front mudguard sections mounted with some tiny allen bolts.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/ninjfairintweakin1.jpg
Also got the bracket for the other side done and the other fairing half bolted up.
Realised then that radiator hose travels on outside of radiator on RHS of bike, so had to tweak LHS of fairing outwards slightly to match, which changed infill panels shape yet again. Lol. Cut 2 out of 1.5mm steel instead of alloy so I can weld brackets, etc on underneath. Couple tiny allen key bolts again will be enough to hold. :-
http://i61.photobucket.com/albums/h63/pitstop-paint/ninjfairintweakin2.jpg
Then I realized that of course radiator cap on other side protrudes up too high by 5-10mm to clear infill panel.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/ninjfairintweakin3.jpg
Don’t really fancy having a big hole cut in panel to leave ugly rad cap visable so going to re-template and trim the panels I made so they sit at a slight upwards angle sorta like this so clear rad cap.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/ninjfairintweakin4.jpg
Be easily removable fairing and infill panels for radiator top-ups, etc, and hides good 90% of plumbing on bike.
Sort out these fiddly panels next couple evenings, and still need to mount swingarm panels, but getting there. Looking like what I had in my head now.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/ninjfairintweakin5.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/ninjfairintweakin6.jpg
Been busy last couple evenings finishing last bits of panel work.
Started by fitting plates to swingarm. Drilled through to tap a threaded hole and was surprised just how thin swing arm alloy is. Not much thickness to tap a good thread on. Remembered I had this clinch nut rivet gun on a shelf which came to me along with my lathe/pillar drill, etc from me mate Gixerjon. Hadn’t used this tool before n thought it would be the ideal opportunity to try it out. :-
http://i61.photobucket.com/albums/h63/pitstop-paint/NinjBdyworkMade1.jpg
Think this might be my favourite new tool. Lol. Instant rivet in threaded hole. So quick n simple n neat.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/NinjBdyworkMade2.jpg
Plate bolted on.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/NinjBdyworkMade3.jpg
Couldn’t drill other side as bike too close to garage wall on workbench, so I’ll have to drill the holes on bike strip down. No biggy tho.
Next I reshaped the infill panels to sit at slight angle so can clear radiator cap on one side. Tight, but just clears it. Welded on some tabs underneath, and couple small allen key bolts n job done. :-
http://i61.photobucket.com/albums/h63/pitstop-paint/NinjBdyworkMade4.jpg
Edge is fairly neat, and I’ll fit some domed or countersunk bolts on reassembly to minimize they’re protrusion.
Got a nice slight bit of shoulder width at front end. Some new radiator/oil cooler covers when building it back up n should be neat enough. Most of water cooled spaghetti is hidden from vie anyway. :-
http://i61.photobucket.com/albums/h63/pitstop-paint/NinjBdyworkMade5.jpg
Couple pics of bodywork done n dusted.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/NinjBdyworkMade6.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/NinjBdyworkMade7.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/NinjBdyworkMade8.jpg
I`ll start stripping whole bike down somepoint soon. Want to do a few things first though. Need to keep it in one piece for wee while while I work out every last bit of proposed paintwork and place it all out in my head. Print out a few mock-ups n generally piss about for a bit with ideas, etc.
Things I haven’t made yet such as rear light and indicators can wait till rebuilding as only small components. Rear footrests are going to be incorporated into some new rider rearsets, or detachable from them maybe. Keep seat unit clean of clutter. Number plate probably side mount, again keeping things clean. Indicators LED and hidden somewhere, or maybe have a go at making some bar-end ones. There’s certainly nothing major needing made that’s stopping me from ripping the bike apart n working through each piece now.
boris
17-12-2010, 06:55 AM
I love the nutserts too mate bestest thing I have ever bought in my life hey I was the same as you had it sitting around for ages then needed something like that for the bike and now I use 1 every opportunity I get lol
Not done anything to strip bike yet as been busy doing bits on my turbo bandit project (project budget dragqueen).
A lot of standing around thinking everything out paintwork wise, etc and deciding on paintwork layout n the colour coding of parts, etc. Much easier having it all worked out this stage than later on when bike in a million pieces. Lol. Climbed up on workbench today n sat on bike too. Feels very small and light weight, and generally `right` which is a good sign.
Original rearsets are bolloxed from years of wear n tear n one sides held together with nuts n bolts from hitting a stag about 10 years back as my foot went straight through rearset. Lol. Planning on making a new set of rearsets incorporating the pillion pegs to keep the seat unit clean n neat, and give the pillion a bit more leg room over most sports setups that result in a shitting frog pillion position. Got a couple slabs of billet alloy tucked away that look about the right size to make some pointy units mirroring the shapes of the bodywork panels and having both sets of pegs on them. An inflatable sucker-pad pillion pad for times when needed or a permanent neat pad maybe. Dunno. Sorta like this rough mockup anyway.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/Ninjpillionseatmockup.jpg
Use original pegs n levers probably, but could always make new ones if needs be. Depends how they look on new plates. Was thinking originally having the plates cut out n skeletal, but solid would maybe match style n shapes on bike better.
Anyway not something I have to worry about for a while. Got `A LOT` of stripping, servicing and painting to do before anywhere near. Next update whenever I strip the bike apart, but not in great rush tbh. Got last few parts for my bandit on the way so crack on with finishing that off first so can concentrate fully on this project.
Rolled my trike back several feet today n cleaned up bike workbench a bit so could get a clear side view of bike. Lot more ground clearance under there than thought once removed mountains of tools/crap. :-
http://i61.photobucket.com/albums/h63/pitstop-paint/NinjaPaintidea1.jpg
A lot lighter looking than had in my head. Not stripped bike yet as concentrating on getting bandit finished n at least running if not set up before switch over to ninja properly.
I’ve been through good 50 paint ideas at least in my head. Everything from detailing every single part like my bandit to plain satin black, and everything in between. Lol. I’m after something relatively simple and constrained to bodywork panels rather than every component. Something clean looking that’s theme ties in nicely with the modern pointy styling of panels.
Watched Transformers on tv over xmas n figured it might be a theme idea. Been done a few times tho with Bumblebee/Optimus Prime, etc, but I’m sorta on the bad guys side. Lol. Found this pic on the internet while browsing about.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/NinjaPaintidea2.jpg
So I’m thinking a Barricade theme sorta like this crappy mock-up.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/NinjaPaintidea3.jpg
The shield on the side is the movie one, and the text on tail piece is the “to punish and enslave” text as per car in movie.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/NinjaPaintidea4.jpg
The panels solid colour with maybe ghosted in panelwork n vents, etc in background to break it up a bit, but really subtly done. One big central mural on tank.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/NinjaPaintidea5.jpg
Found a really good resoloution pic of above on internet which shows every last piston/wire/cog and right down to tyre tread, etc. Aiming for huge scale on tank painting fuel cap, etc to really maximize space for artwork. Probably 1 1/2` high or so, and going crazy on the fine detailing picking out all the tiny hydraulics, wires, etc in picture.
About this scale as mocked up on bike with a crappy printout to get an idea of size.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/NinjaPaintidea6.jpg
Pretty damn big! Lol. Print outs slightly too small if anything. Basically want it to cover whole top of tank. Maybe bursting through it style.
Frame and swingarm/forks satin black to contrast against the gloss polished paintwork black. Maybe polish the wheels up to go with the polished billet bits I’ll be making such as handgrips, new rearsets, etc. Undecided as to whether to polish frame/swingarm/forks too to contrast better against mostly black paintwork. Be easy enough as mostly polished anyway. Lotta polishing tho so maybe just keep on target for wheels, etc.
Pretty settled on this design I reckon. Something a bit different, and gives me opportunity to hide some hidden behind mesh red/blue strobe lights n a police siren in recesses of front fairing sides for “show use only” and not for winding up mates when come up behind em. Muwahahahahahaha…………
James Elliot
20-01-2011, 01:32 PM
That looks awesome!!!
Well my turbo bandit project is running. Cant set things up n generally fiddle about with it at moment cause turbos needing rebuild kit bought n installed. Even when get that done though bandit is pretty much done barring general setting up/tinkering, etc.
Getting real bored sitting about in afternoons/evenings after spraying work. Think its time to crack back on with this project again. Sitting there dry built after all. Want to get it rebuilt n all running/shiny next few months during summer months, as unfortunately going to have to sell it on when done. More chance of selling it on during summer after all. Not going to be asking a fortune for it, just need to clear my garage a bit n spend proceeds on bits for house. Sure I’ll fill the `project` shaped hole in the garage tho. Lol
Cleared up the garage today, binned a load of shite n scrap from tearing ninja apart in first place. Got gaps now to sit ront/rear ends in when remove them, and body panels, etc.
Going to start tearing it down next few days. Get it to the bare frame and engine. Theyre the first bits to clean up and spray really. Build it back up from there. Straightforwards build though. Pics as progress is made, but back on it now so will start shifting along.
Thought sod it, n decided to make a start since had an hour before dinner this evening. Can get a lot done in an hour tho.
This was piccy from before. Dry built, etc. :-
http://i61.photobucket.com/albums/h63/pitstop-paint/ninjastripstart1.jpg
An hour later n bodywork off, exhaust off, downpipes off, etc. :-
http://i61.photobucket.com/albums/h63/pitstop-paint/ninjastripstart2.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/ninjastripstart3.jpg
Pile building up quickly. Lol.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/ninjastripstart4.jpg
Bolts n rubber fittings, etc for each piece bagged n taped to relevant item. Saves a lotta hassle later on. Lol.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/ninjastripstart5.jpg
Well it’s a start. Probably disconnect wiring next n mark up each connector block and wire on removal. Again makes life a piece of piss when putting bike back together. Nowt worse than ripping bike apart n forgetting where a particular funny shaped bolt or wire goes. I don’t like headaches like that. Pain in the arse n slows you down on stripping bike, but speeds up re-assembly 10 fold.
So yeah feels good to be doing something in garage again. Sitting in house bored drives me up the wall. Wiring next, then front/rear ends off n that just leaves me frame off engine. Should be easy enough. Few rusty/sticky bolts, but heaven-sent compared to state my turbo bandit was in when got it. Lol.
LKC73
24-02-2011, 06:31 PM
Nice mate, keep up the work and piccys.
Caught up with airbrushing at moment. Couple day gap between stuff going out in mail and next lot arriving, so using it to my advantage to get bigger chunks done. My backs back to normal now so can hold up one end of the bike with one arm while taking off forks with other, etc. Much easier now with a working back. Lol.
Front and rear ends off and a few smaller bits so far. More wee bits to un-bolt though. :-
http://i61.photobucket.com/albums/h63/pitstop-paint/ninjaalmostapart1.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/ninjaalmostapart2.jpg
Written about 50-odd wire/hose labels so far n not even half way there taking wiring/plumbing off. So many damn electrics n hoses everywhere on this bike. Slow slog labeling everything up, but be plug-n-play on rebuild.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/ninjaalmostapart3.jpg
Nother day, or couple evenings n should be left with just a frame and engine sitting separately on bench n big box of bits. Leaving front and rear end assembly’s in one piece as easier to keep track of all spacers, fixings, etc and clean up one assembly at a time. Nice manageable sized chunks I can carry into house n clean up, etc.
Back to it again today. Took about 50 pictures as took each bit of the ram air plumbing, etc apart. Friggin hoses all over the place in n out of pneumatic valves n in n outta carbs, cam cover on engine, pressurized airbox, etc, etc. Marked every connection up like wiring with labels all over the place, but better to have pictures on file on pc just in case. Some of the bits clip together randomly. Lol.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/Ninjaapart1.jpg
Same with radiator connections to carbs, etc. Big folder of pics will make reassembly easier.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/Ninjaapart2.jpg
Got all small bits unbolted from frame. All but one of engine bolts came out fine. Last one wouldn’t shift at all though. Tried oil, heat n brute force. Had to chisel away and split nut off end of it as so rusted just mashed up when put spanner on it. Tried turning bolt with 4` breaker bar n wouldn’t turn. Was corroded solid into gearbox casing on engine.
Got aggressive with it with 5kg lump hammer and chisel slipped n my finger got whacked with big fuggoff hammer n cold chisel. Blood everywhere. Doh!:-
http://i61.photobucket.com/albums/h63/pitstop-paint/Ninjaapart3.jpg
Entire box of steri-strip stick on stitches, plasters, n half a roll of masking tape to keep 2 halves of my finger tip pressed together. Went back out armed with my evil surgeon black latex gloves to keep the oil out of my mangled finger. Muwahahahahaha.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/Ninjaapart4.jpg
Good thing about sportsbikes is they’re so damn light. Picked up n flipped frame/engine onto its side with my good arm. :-
http://i61.photobucket.com/albums/h63/pitstop-paint/Ninjaapart5.jpg
Climbed on top and armed with a sledgehammer and a suitable rod drift I hammered away at the engine bolt for good hour or so, inching it out of engine casing mm by mm. Took some beating! :-
http://i61.photobucket.com/albums/h63/pitstop-paint/Ninjaapart6.jpg
After an hour of hammering n swearing the frame/engine were separate. BIG pile of parts that were a motorcycle other day. Lol.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/Ninjaapart7.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/Ninjaapart8.jpg
I’ll get out tomorrow n box up all the random parts n generally neaten up the workspace so got room to move. Degreasing n painting engine first I guess. Most of engines not seen, so not too in depth, just a good scrub n coat of black gloss.
Not a shitload today. Basically bagging bits up and boxing bits up, etc and finding my workbench again. Lol. All neat n tidy n businesslike though.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/ninjafullystripped.jpg
I’ll get the engine degreased n sanded and sprayed black during the week probably, and got the first lump to bolt bits back on to. Everythings pretty damn rusty n shitty though from years of commuting so go my work cut out cleaning every bit up properly. Going to take longer than planned, but want it done right end of the day.
Rest of today I was checking over n cleaning up my trike as nice n sunny working outside.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/trikecleanup.jpg
Good weather coming soon by looks of it so giving her a good fettle as want to get it over to mainland on ferry for an mot next month or so so can enjoy summer cruising.
LKC73
27-02-2011, 09:04 AM
Mate you have taken that cafe project apart! But at least now you'll be able to work in a clean area.
Apart yeah, but every peice needs working through tbh. Brake calipers need pistons cleaned up, swingarm/rear wheel bearings fooked, etc. Everything rusted up n generally weathered. Bikes dragged me up n down the country for 11-12 years in worst of scottish weather. Always got me where I was going even in a foot of snow, etc.
Engines sound though. Did the shims, etc not long since. Had the head apart n sump off, etc and spotless inside, etc. Just good clean/paint of everything really.
LKC73
28-02-2011, 05:20 PM
Nice one Jon. It will be like new once your all done mate.
Lugged engine outside today. Sat for damn hours with degreaser and an old toothbrush scrubbing away at 1/2” of road grime/oil, etc. Scraped into corners with screwdriver, etc, etc. Sanded back flaky paint areas. Degreased it again, scrubbed it down with solvent as had plenty (Spray Gun Wash), then hot soapy water. Final rinse n dried off with compressor blow gun. Sounds easy in couple sentences, but PITA of a job. :-
http://i61.photobucket.com/albums/h63/pitstop-paint/ninjaenginepaint1.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/ninjaenginepaint2.jpg
Threw on some black, and a coat or two of clearcoat to give a bit of shine. Looks not bad considering wasn’t being too fussy as most of engine not seen when bike together anyway. :-
http://i61.photobucket.com/albums/h63/pitstop-paint/ninjaenginepaint3.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/ninjaenginepaint4.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/ninjaenginepaint5.jpg
Black, clean, shiny, job done really. Not being too picky really. Not getting as involved as did with bandit as bikes getting sold when done.
Lugged it back into garage as started to rain n clearcoat still tacky. :-
http://i61.photobucket.com/albums/h63/pitstop-paint/ninjaenginepaint6.jpg
Let it harden overnight n can bolt carbs, etc back on. Might start degreasing n sanding frame tomorrow.
Another long day of scrubbing away with degreaser and a toothbrush. Back of frame has hollow sections which were filled good 1” deep with chain gloop. Nice. Lol.
After degreasing several times, sanding with 400 grit wet n dry, and a good wash n ready to go after drying off.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/Ninjaframeblack1.jpg
2K primer, black basecoat and then 2K clearcoat later n looks pretty good. Hanging up drying.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/Ninjaframeblack2.jpg
Good gloss close up. Slight orange peel texture because of texture of cast alloy, etc. Not building up 20 coats of paint and sanding/polishing frame though. Lol. Black n shiny is good enough.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/Ninjaframeblack3.jpg
Carbs cleaned up and back on engine and plumbed into cooling system, etc. Ram air hoses n valves back on, etc.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/Ninjaframeblack4.jpg
Snapped a hose lug off airbox on disassembly so repaired that n cleaned it up ready to go back on. Few dead moths n other bugs in airbox ram-air scoops. Lol.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/Ninjaframeblack5.jpg
Leaving frame to harden up tonight and get it bolted back onto engine tomorrow n get airbox back on and few wee bits n bobs. Also aiming to get the bolt on subframe welding finished off and get that and radiator sprayed black ready to go on. See how time goes though.
Got about a ½ day at it again today. Frame threads, etc cleaned up, frame back on engine n bolted up tight. Loving the shiny black look.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/ninjaframeon1.jpg
Airbox on, all ram-air plumbing, random hoses, etc n coils n few other odds n sods hidden away in there.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/ninjaframeon2.jpg
Spent couple hours welding the crap out of the bolt on subframe as had only tacked it before. Solid as hell now though.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/ninjaframeon3.jpg
In the pile of parts to clean up and spray black tomorrow along with radiator/electrics tray, etc. I’ll dig out few more random brackets, etc too tomorrow n do the lot together. :-
http://i61.photobucket.com/albums/h63/pitstop-paint/ninjaframeon4.jpg
Should give me a big pile of parts to bolt back on on Friday and can get everything plumbed back up n wiring loom on, etc.
LKC73
03-03-2011, 08:29 PM
Starting to move along there Jon, nice going mate.
Kramer
03-03-2011, 11:48 PM
You still got the rockets? I reckon I could make some awesome mirrors from em..
Think they were in the bin pile tbh. Nothing to em tho tbh bud. Bitta pipe. Think I used some old aftermarket custom exhaust silencers. Pointy bits on end were the empty plastic thread bobbins from an industrial stitching machine.:D Like making stuff outta scrap.:)
Another chunk today. Got all this lot degreased, wire brushed/sanded, primed, black basecoated and clear coated today. :-
http://i61.photobucket.com/albums/h63/pitstop-paint/NinjaBracketPaintin1.jpg
All hanging drying at moment. I’ll leave it all overnight n can get a loada stuff mounted on bike tomorrow. Get bolt-on subframe on, electrics tray, fuel pump, wiring loom n all black boxes, front headlights, radiator n oil cooler mounted, etc, etc. Empties out my cardboard box of bits by good half. Lol.
As said before the radiator fan was seized up as never used. Sit on empty roads up here at steady 70-80mph. No junctions or traffic lights or sod all, so bikes always ran cool. Managed to free off fan today though. Spins freely again. Also noticed weathered sensor terminal on radiator has a small section sticking out. Be enough to solder a tab to to reconnect it.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/NinjaBracketPaintin2.jpg
Might as well get the fan and switch working if can while got everything apart. Busy bolting on day tomorrow if get time. Loada work stuff in mail somewhere so a race to get as much done as can before work goes manic again n limits my hours at build.
Making awesome progress, can't wait to see this one finished.
quote:Originally posted by sen
Making awesome progress, can't wait to see this one finished.
Yer me too bud. Its gonna look pretty cool when done. Shame its gettin sold when done though.:( One bike too many n dont fancy selling my Harris or turbo Bandit.
Another bit done today. Subframe bolted on, electrics tray n all electrics mounted, wiring loom on n soldered/zip tied up as much as can, headlights n brackets on, upper shock mount, radiator & oil cooler on, fuel pump, etc, etc. Starting to look like a bike. Need to take 2 bolts out to swing radiator forwards when come to fit headers, but no biggy.:-
http://i61.photobucket.com/albums/h63/pitstop-paint/Ninjaelecson1.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/Ninjaelecson2.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/Ninjaelecson3.jpg
Need to extend battery cables by 8” or so to reach new battery tray, but easy enough job to do. Got some spare cable, just need to get couple connectors.
http://i61.photobucket.com/albums/h63/pitstop-paint/Ninjaelecson4.jpg
Was getting a bit cold n pissed off working on it so gave up for the day. Lol. Hard to find the motivation to build when know its getting sold when done. Having spare cash to finish turbo bandit off, n space/time to rebuild my Harris is the driving force tbh.
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