Harris rebuild on Isle Of Harris

[Jon]

Do you imagine cyborg Lobo giving you a blow job when you ride the bandit?

Funnily enough no. Besides my cock aint long enough to reach that far up tank. lol

[Jon]

Made these oil cooler line guides which bolt to old frame fairing points. Better than zip ties and in keeping with rest of bike. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/HarrisJune01.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/HarrisJune01.jpg.html)
http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/HarrisJune02.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/HarrisJune02.jpg.html)

Ran out of things to do at this point pretty much as needed fairing to progress forwards but didn’t have the cash for it.

Got a bit of smoked lexan for the new clutch cover and had a go at engraving it with cheap dremmel copy and £3 ebay engraving bits. Not too bad for a first attempt. Kind of gives away the paintwork theme but then anyone that knows my mad max addiction would have guessed it was coming anyway. Lol. Not going for a straight goose replica though, more of an endurance racing team theme with a mad max tie in. Racing scheme with some photographic airbrush work in one band. Subtle compared to my turbo bandit build, but then anything would be compared to that. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/HarrisJune03.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/HarrisJune03.jpg.html)
http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/HarrisJune04.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/HarrisJune04.jpg.html)

Even engraved on the oil level marks as the whole clutch cover is windowed now. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/HarrisJune05.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/HarrisJune05.jpg.html)

Just waiting for a 16mm bit of alloy plate from Yantosh to make the spacer plate out of and can finish it off. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/HarrisJune06.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/HarrisJune06.jpg.html)

Finally got spare cash for the fairing (not screen yet though) and it was on 15% off sale so grabbed it. Arrived in one piece from Germany too. I was like a wee kid at xmas. Everything balanced roughly in position. So excited…

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/HarrisJune07.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/HarrisJune07.jpg.html)

Then camea lot of evenings of alloy fabrication once again. Combined fairing bracket, battery tray and headlight mount. Overkill maybe but a lot of weight at a fair distance from the headstock mounting points. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/HarrisJune08.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/HarrisJune08.jpg.html)

Bolted down. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/HarrisJune09.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/HarrisJune09.jpg.html)

Curved section comes round tacho in middle of bars then a couple of stainless stays outwards to fairing. Got them at an angle so that once on the bike all you can see is the couple mm of thickness so nearly invisible when riding. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/HarrisJune10.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/HarrisJune10.jpg.html)
http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/HarrisJune11.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/HarrisJune11.jpg.html)

Couple stainless brackets at rear edges to tuck it in and real nice fit to frame rails and round forks, etc. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/HarrisJune12.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/HarrisJune12.jpg.html)

Going to have a carbon fibre dashboard tucked inside with the oil temp/pressure gauges and idiot lights sunk into it. The screen is going to be smoked like the clutch cover. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/HarrisJune16.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/HarrisJune16.jpg.html)

Where I’m up to. All bolted up tight bodywork wise. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/HarrisJune13.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/HarrisJune13.jpg.html)
http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/HarrisJune14.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/HarrisJune14.jpg.html)
http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/HarrisJune15.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/HarrisJune15.jpg.html)

Going to start repairing fibreglass on the seat unit and prepping up the panels. I’ll get the screen ordered and drilled/fitted also at somepoint so can move on with paintwork in between work paintwork.

Apart from clutch cover its basically paint and electrics now.

[stiffsimon]

As per usual Jon absolutely gobsmacking. Your attention to detail puts most of us to shame but for me your innovative ideas are the hall mark of this build.Absolutely stonking bike.

[Gix11]

Not to mention that rad photo of you on the bike. That made me smile. Brilliant mate.

[Jon]

Cheers guys. Enjoying the build for sure and it's turning out better than I expected in all honesty as taken my time and done things right. Doing the turbo bandit thing gave me a good confidence boost to use.

[Jon]

Another busy few weeks here working on the bike every evening and weekend.

Got my wife and a passing courier driver to give me a hand lowering the bike down the ramp off the workbench and onto solid ground at last. Felt GREAT to sit on it properly at last. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris20071401.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris20071401.jpg.html)
http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris20071402.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris20071402.jpg.html)
http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris20071403.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris20071403.jpg.html)
http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris20071404.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris20071404.jpg.html)
http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris20071405.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris20071405.jpg.html)

Was on a high till came out next day and found out the billet brake reservoir had leaked all over the frame damaging the paint/clearcoat. On my list to touch up. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris20071406.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris20071406.jpg.html)

Changed the reservoir to a normal one with billet shroud, etc but tbh I’m still not happy with the brake lever feel. Got offered a fancy GSXR1000 radial mastercylinder off a friend so going to get that on instead. Should firm up the lever feel substantially compared to the tiny bore of the old one. Bit more up to the job.

Been battling with the bodywork every evening/weekend for last couple of weeks. Taken several days just to get the 2-3 mm of rattlecan paint off the parts using thinners, scraper and a power washer. Nightmare!

Tank needed bit of fillerwork for a few small dings and re-shaping welds, etc. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris20071407.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris20071407.jpg.html)

Seat unit was another matter. Gelcoat stress cracks, etc everywhere! Is 35-40 years old though so a bit worn out like me. Lol.

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris20071408.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris20071408.jpg.html)
http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris20071409.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris20071409.jpg.html)

For the cracks I used a dremmel to grind down into the seat unit along them. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris20071410.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris20071410.jpg.html)

Then I filled it all back in with fibreglass resin. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris20071411.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris20071411.jpg.html)

I also reinforced the back of the panel in the damaged areas to give a bit more strength and filled in behind the side mounting holes, etc too. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris20071412.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris20071412.jpg.html)

A hell of a lot of hours filling/sanding/filling/sanding, etc and all panels as good as new. Refitted them to the bike today and got busy with the fineline tape marking things out. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris20071413.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris20071413.jpg.html)
http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris20071414.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris20071414.jpg.html)
http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris20071415.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris20071415.jpg.html)
http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris20071416.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris20071416.jpg.html)

Aiming for something similar to this mockup. I’ve omitted the small silver stripe below the blue section now, but pretty much the same. Classic endurance racer meets Mad Max. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris20071418.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris20071418.jpg.html)

Up the centre of the tank will be some very small scale B&W artwork of moive stills in a movie reel style layout. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris20071417.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris20071417.jpg.html)

Going to take me 3-4 weeks to work through the artwork, etc as up to my eyeballs with work spraying as always. I’ll chip away at it one panel at a time though in my evenings/weekends.

[K6Thou]

Unbelievable. Jon, once again you have knocked it out of the park. Well done.

[ozzy1100]

Love the pics lol but love the bike in bike with green lines
Your a machine old boy

[Gix11]

Fuck you're good with that striping tape mate! I spent years trying to get that shit right. You've nailed it. It almost looks like some kind of TRON bike with just the black and green stripes. If I had half your skills I'd be a happy shopper.

[Jon]

Cheers guys. Going to take me several weeks of evenings to work through the paintwork as up to eyeballs with work stuff. Reckon it'll work out cool though.

[nick76]

I love the black and green look!! lol
I wish i had a 10th of the skills you do....

[hyofighter]

speechless , top stuff , more we demand more

[GammaBoy]

I'm not so sure about how close The Toecutter's open mouth will be to your crotch...

[Jon]

speechless , top stuff , more we demand more

Put first few teaser pics of paintwork up on my personal facebook page and business page last night if that desperate.:D Search `pitstop paint` on facebook and you'll find em. I'll do a proper forum update when got more to show.

[Jon]

I'm not so sure about how close The Toecutter's open mouth will be to your crotch...

Sure I'll live. lol. Photo layout might not be like that anyway tbh. I've chosen the stills I'm using and spraying them on in order they appear in movie from front of bike to rear.

[Jon]

Made a start on paintwork. Bit limited with airbrushing at that scale as faces are same size as my thumbprint. Worked out not bad on the detailing though considering the tiny scale. Wanted to challenge myself with the scale though and see what was possible. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/MyHarris201401.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/MyHarris201401.jpg.html)
http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/MyHarris201402.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/MyHarris201402.jpg.html)
http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/MyHarris201403.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/MyHarris201403.jpg.html)
http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/MyHarris201404.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/MyHarris201404.jpg.html)
http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/MyHarris201405.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/MyHarris201405.jpg.html)
http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/MyHarris201406.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/MyHarris201406.jpg.html)
http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/MyHarris201407.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/MyHarris201407.jpg.html)
http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/MyHarris201408.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/MyHarris201408.jpg.html)
http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/MyHarris201409.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/MyHarris201409.jpg.html)
http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/MyHarris201410.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/MyHarris201410.jpg.html)
http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/MyHarris201411.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/MyHarris201411.jpg.html)

Heavy metallic silver (almost flake), pearls blue and metallic hint over the red/black too. -

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/MyHarris201412.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/MyHarris201412.jpg.html)

Headlamps sprayed up too. Wiring soldered/heatshrinked inside, etc. Couple of carbon fibre lens protectors made up n sprayed with harris logo to match fairing. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/DSCF7383.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/DSCF7383.jpg.html)
http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/DSCF7387.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/DSCF7387.jpg.html)

Bolted the bits on this afternoon. Screen balanced in place for now. Waiting on a hole reamer coming in mail to enlarge fairing holes a few mm and then I can get the screen drilled and bolted down. Got some big silver `MFP` decals coming in mail for screen too. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/DSCF7403.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/DSCF7403.jpg.html)
http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/DSCF7401.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/DSCF7401.jpg.html)
http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/DSCF7398.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/DSCF7398.jpg.html)
http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/DSCF7406.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/DSCF7406.jpg.html)

Tank has silver on and a few coats of clear. Be sanding that back and getting the artwork done on the tank over next week or so. Going to get some wire and a battery ordered up too this week as got some of electrics parts here already such as blue LED dash gauges, idiot light led’s, etc. Can start hooking things up in evenings if get a chance.

[ozzy1100]

fuck looks horn

[hyofighter]

love it , top work man

[Gix11]

If I had half your skills I'd be a happy shopper.

Saved typing it again.

[wackyrider]

That's just nuts Jon. I'm just blown away mate. Top job

[xa-mont]

sweet as hell!

That paint work is coming up mint, and i reckon for the size of the pictures you're doing a great job of getting the detail into them.

[Jon]

i reckon for the size of the pictures you're doing a great job of getting the detail into them.

Yer its challenging bud. Doing the artwork isn't a problem, but when the faces are the size of your thumbprint it makes it 10x harder for sure. It's a good effect in reality though as the detail looks great. Photos close up are far more zoomed than human eyes when looking at it. :)

[TillerRider]

The work you have put into this bike is amazing and the paintwork is just outta this world, love it!

[DCRacing]

Absolutely floored at how good this is and your work...........

[Jon]

Cheers bud.

[Jon]

Hectic here. Only got 2 ½ weeks till the bike event I want to take it to. Going to be tight! Working on it every evening and weekend. Even sneaked a few days off work. Drilling my screen and the damn thing cracked on the last hole! – http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/DSCF7408.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/DSCF7408.jpg.html) Don’t have time and money to wait for another one to be made and shipped over from germany, so came u with a plan. Prised open crack and superglued it solid. Sanded down both sides so flush then made some infil panels out of that super thick weave carbon fibre adhesive stuff and some smaller MFP decals that came with the larger ones. Neat enough and crack underneath is invisible and strong. – http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/DSCF7424.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/DSCF7424.jpg.html) http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/DSCF7428-1.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/DSCF7428-1.jpg.html) Made a carbon fibre dash with LED idiot lights, blue led oil pressure/temp gauges and blue led engine `start` button. – http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/DSCF7431.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/DSCF7431.jpg.html) Made up a wiring loom. Got the battery through the mail and hooked up. Neat enough and everything works thankfully. Got a spark at plugs, etc too. Put blue led in the gsxr tacho too so matches. – http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/DSCF7607.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/DSCF7607.jpg.html) http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/DSCF7655.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/DSCF7655.jpg.html) http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/DSCF7654.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/DSCF7654.jpg.html) Tank sprayed up. – http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/MyHarris201416.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/MyHarris201416.jpg.html) http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/MyHarris201417.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/MyHarris201417.jpg.html) http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/MyHarris201418.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/MyHarris201418.jpg.html) http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/MyHarris201419.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/MyHarris201419.jpg.html) http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/MyHarris201425.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/MyHarris201425.jpg.html) Where I’m up to. The end is in sight………. – http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/DSCF7647.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/DSCF7647.jpg.html) http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/DSCF7646.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/DSCF7646.jpg.html) Just clutch cover to make and the seat unit to airbrush. Battling with clutch cover just now as engine oil will be here any day in mail. Killed my trusty old £15 Argos jigsaw cutting out the 16mm alloy clutch cover spacer plate. – http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/DSCF7648.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/DSCF7648.jpg.html) Thankfully got it replaced under guarantee. Busy shaping/sanding it at moment. Another few evenings and have the clutch cover done and on the bike. Really want to get engine fired up and see if the crank belt drives work and anti-dive front end, etc. No point hurrying with seat unit paintwork if these need more work or parts re-making. Won’t have time to do it for bike rally. Fingers crossed!

[slingy88]

Looking bloody brilliant Jon. I'm sure you are an inspiration to many, that as long as you have that fire in your belly, and a give it a go attitude, anything can be made a reality.
Luving the paint. You are a magician Jon, keep it up mate \m/ \m/

[Jon]

Looking bloody brilliant Jon. I'm sure you are an inspiration to many, that as long as you have that fire in your belly, and a give it a go attitude, anything can be made a reality.
Luving the paint. You are a magician Jon, keep it up mate \m/ \m/

Try my best bud. I might not have the best tools or budget but I'm prepared to put in the hours and effort. Does pay off in long run.

[ozzy1100]

fucking loveing this....

[MattyDucati]

looks sweet man

[Jon]

Well where to start. Bike was meant to be finished ages ago and on its way to a rally on the Isle of Skye. Went to the rally……..on my turbo bandit….

Wind it back a month or two…….

Got clutch cover finished off and fitted. –

http://i61.photobucket.com/albums/h63/pitstop-paint/pitstop-paint008/Harris15101401.jpg (http://s61.photobucket.com/user/pitstop-paint/media/pitstop-paint008/Harris15101401.jpg.html)

Got bike started up and running nicely. Thought I was on the finishing straight tbh. Was still cutting it close on getting it finished and to the rally but I was all go this end. Out in the shed till midnight every night after work getting the last bits worked through.

Then while on tickover the LHS belt drive decided to come apart jamming the engine and cutting it out. Feared the worst but after taking it apart I found the problem and spent a couple of evenings remaking parts so wouldn’t happen again.

Got it up n running again then the bike sitting on tickover made a light clicking noise and then cut out. Pushed the starter and only the LHS of crank was turning! FOOK!

Looked like the crank had sheared from the belt drive jamming up. Was the last straw really. I came in from shed dispondant to say the least and just emotionally/physically drained from working my ass off to the point of making myself sick and then this. Even considered selling it on as a project….

My wife came home from work and talked some sense into me and backed me fully in repairing it no matter what the cost. She knows how much this bike means to me. –

http://i61.photobucket.com/albums/h63/pitstop-paint/pitstop-paint008/Harris15101402.jpg (http://s61.photobucket.com/user/pitstop-paint/media/pitstop-paint008/Harris15101402.jpg.html)

She also told me to take a break from it for a while so I did. Had a great blast about Skye on the bandit, great rally. Spent the last month or so working on house refurbishment, fitting windows and woodwork, etc. My wife then bought me a crank as a surprise to get me back into it. –

http://i61.photobucket.com/albums/h63/pitstop-paint/pitstop-paint008/Harris15101403.jpg (http://s61.photobucket.com/user/pitstop-paint/media/pitstop-paint008/Harris15101403.jpg.html)

Got back out to shed last couple of days with a view to stripping out the engine and spending a few weeks/months rebuilding it and gradually saving up for gaskets, etc as I went along. Took plugs out and gently moved kickstart to see how bad things were while looking down plug holes with a torch. Fully expecting it to jam or some pistons not to be moving. Was kind of surprised to see all 4 pistons moving and the valves, etc opening/closing as normal. Nice clean piston bore walls, etc.
Was wondering if I had been so tired I had dreamt the snapped crankshaft! Lol. Plugs back in and jumped on kickstart. Pretty much bounces my 13-14 stone bodyweight off as high comp motor, but got it through few cycles and no weird noises at all, just the normal whump, whump.

Further investigation and found this! The woodruff key was snapped/ground down level with the crank tapered end as you can see. Also slight scores in rotor end in my hand to show it had been rubbing/slipping. –

http://i61.photobucket.com/albums/h63/pitstop-paint/pitstop-paint008/Harris15101404.jpg (http://s61.photobucket.com/user/pitstop-paint/media/pitstop-paint008/Harris15101404.jpg.html)

Basically the rotor had come loose (hence clicking noise when rubbing) and snapped/ground the woodruff key down. When I hit the starter the rotor was turning but since not connected to the crankshaft then the RHS of crank wasn’t turning. The pulley on the LHS side was spinning as connected to the rotor.

Plugs out and grabbed tapered end of crank in my hand with a rag for grip. Can easily turn over engine by hand. Think I’ve been BLOODY lucky!

Belt drives have been thrown in scrap pile already. Sick of them and their problems. Want to go touring on the bike without hassles and had nothing but problems with them. Tbh the vision of them I had in my head didn’t match the reality once running. Had this spinny belt fixation which overruled my common sense. Made the bike wider, heavier and more complicated for no good reason. Good break from building has made me realise it’s a hell of a lot better without them. More in keeping with the overall bike. Lighter, neater, and more focussed on handling/performance. Wasted a lot of time making parts to throw them in the scrap pile. Hey ho, lesson learnt. Had to try it to find out it wasn’t right for me or the bike. The crank I bought I got for a really good price so can get my money back or a profit even.

So where am I now with it. Well here really. -

http://i61.photobucket.com/albums/h63/pitstop-paint/pitstop-paint008/Harris15101405.jpg (http://s61.photobucket.com/user/pitstop-paint/media/pitstop-paint008/Harris15101405.jpg.html)

Belt drives removed. Waiting on new woodruff key arriving and can get both ends of crank, etc bolted back on. Need to modify the LHS cover to make it oil tight and re-make the RHS cover too. Going to make casings that match the clutch cover as I’m really happy with that. Neat and modern/smooth looking. Going to make 2 matching casings with engraved windowed covers so ties together.

Need to remount the coils and reg/rec under tank and change wiring about to suit. Finish spraying the seat unit and generally get it finished off. Going to spend my efforts detailing things more, making a few more parts, etc and trying to make it a much tidier build. Back on it now an hour or so a night and treating it as relaxation rather than fixating on it. No timescale set at all. If takes me a couple of months then so be it.

[GammaBoy]

Already looks cleaner... Loved what you were doing with the bike, but was never sold on the belt drives...

[Hagarr]

Probably the single biggest reason I sold my 15+ years of zeds was exactly that.

As soon as you put any decent power through an 'ol zed the rotors spin off and score end of crank along with ensuing long walk home.

GSXR's I've had since and never had the cylinder head off since 1996 when engine was built.

Sometimes taking time out works a treat.

Good luck, still love the build!

[ozzy1100]

there are ways and means lol

[Jon]

New woodruff key and bolt on today along with some permanent thread lock. Hooked up wiring to bandits battery and engine spinning over just fine for couple of seconds. Fingers crossed all is good again anyway.

Out in shed today working on engine casings. Up town on wednesday so going to try get a bit made up in time and welded to LHS casing so can be oil tight again. lol

[Jon]

New woodruff key came through so got alternator rotor bolted back on with a new bolt and plenty of permanent threadlock. Lol.

Recycled a bit of the old belt drives with a bit of trimming to act as base for the LHS engine cover window. Got it welded on up town (50 miles) by a small place that does fishing boat hulls, etc. Pricely sum of £5 for 5 minutes of tig work. –

http://i61.photobucket.com/albums/h63/pitstop-paint/pitstop-paint008/Harris9nov01.jpg (http://s61.photobucket.com/user/pitstop-paint/media/pitstop-paint008/Harris9nov01.jpg.html)

Bit of a repaint and some smoked lexan windows engraved with my dremmel and had a couple of nice `KWAKA` engine covers to cover up the belt drive holes. –

http://i61.photobucket.com/albums/h63/pitstop-paint/pitstop-paint008/Harris9nov02.jpg (http://s61.photobucket.com/user/pitstop-paint/media/pitstop-paint008/Harris9nov02.jpg.html)

Got the seat unit finished off at last. Been a hard slog of fibreglass/filler/paint but think it was worth saving as a one-off and love the shape of it. Kept my `comfy` seat. Back seat cowl has hidden fixings so nice n neat. –

http://i61.photobucket.com/albums/h63/pitstop-paint/pitstop-paint008/Harris9nov03.jpg (http://s61.photobucket.com/user/pitstop-paint/media/pitstop-paint008/Harris9nov03.jpg.html)

http://i61.photobucket.com/albums/h63/pitstop-paint/pitstop-paint008/Harris9nov04.jpg (http://s61.photobucket.com/user/pitstop-paint/media/pitstop-paint008/Harris9nov04.jpg.html)

http://i61.photobucket.com/albums/h63/pitstop-paint/pitstop-paint008/Harris9nov05.jpg (http://s61.photobucket.com/user/pitstop-paint/media/pitstop-paint008/Harris9nov05.jpg.html)

http://i61.photobucket.com/albums/h63/pitstop-paint/pitstop-paint008/Harris9nov06.jpg (http://s61.photobucket.com/user/pitstop-paint/media/pitstop-paint008/Harris9nov06.jpg.html)

http://i61.photobucket.com/albums/h63/pitstop-paint/pitstop-paint008/Harris9nov07.jpg (http://s61.photobucket.com/user/pitstop-paint/media/pitstop-paint008/Harris9nov07.jpg.html)

Got all that lot bolted on to the bike. Still got the reg/rec and coils to bolt on and wire back into loom but that’s the next job. God knows where I’ll put them as no room under tank or seat unit to spare. Small gap between top of engine and underneath of electrics tray but might be too tight. Worst case I’ll put them on show somewhere inside the front fairing. –

http://i61.photobucket.com/albums/h63/pitstop-paint/pitstop-paint008/Harris9nov08.jpg (http://s61.photobucket.com/user/pitstop-paint/media/pitstop-paint008/Harris9nov08.jpg.html)

After weeks of storms and rain the sun came out today so wheeled the bike outside to get some up to date photos and a proper look at it stood back. Pretty happy with it tbh. Looks lean, lightweight and purposeful with the belt drives gone. Few bits to do yet but not far off now hopefully. I’m 5` 6” to give an idea of scale. Not a big or heavy bike tbh. Pretty compact. –

http://i61.photobucket.com/albums/h63/pitstop-paint/pitstop-paint008/Harris9nov09.jpg (http://s61.photobucket.com/user/pitstop-paint/media/pitstop-paint008/Harris9nov09.jpg.html)

http://i61.photobucket.com/albums/h63/pitstop-paint/pitstop-paint008/Harris9nov10.jpg (http://s61.photobucket.com/user/pitstop-paint/media/pitstop-paint008/Harris9nov10.jpg.html)

http://i61.photobucket.com/albums/h63/pitstop-paint/pitstop-paint008/Harris9nov11.jpg (http://s61.photobucket.com/user/pitstop-paint/media/pitstop-paint008/Harris9nov11.jpg.html)

http://i61.photobucket.com/albums/h63/pitstop-paint/pitstop-paint008/Harris9nov12.jpg (http://s61.photobucket.com/user/pitstop-paint/media/pitstop-paint008/Harris9nov12.jpg.html)

http://i61.photobucket.com/albums/h63/pitstop-paint/pitstop-paint008/Harris9nov13.jpg (http://s61.photobucket.com/user/pitstop-paint/media/pitstop-paint008/Harris9nov13.jpg.html)

http://i61.photobucket.com/albums/h63/pitstop-paint/pitstop-paint008/Harris9nov14.jpg (http://s61.photobucket.com/user/pitstop-paint/media/pitstop-paint008/Harris9nov14.jpg.html)

http://i61.photobucket.com/albums/h63/pitstop-paint/pitstop-paint008/Harris9nov15.jpg (http://s61.photobucket.com/user/pitstop-paint/media/pitstop-paint008/Harris9nov15.jpg.html)

http://i61.photobucket.com/albums/h63/pitstop-paint/pitstop-paint008/Harris9nov16.jpg (http://s61.photobucket.com/user/pitstop-paint/media/pitstop-paint008/Harris9nov16.jpg.html)

http://i61.photobucket.com/albums/h63/pitstop-paint/pitstop-paint008/Harris9nov17.jpg (http://s61.photobucket.com/user/pitstop-paint/media/pitstop-paint008/Harris9nov17.jpg.html)

http://i61.photobucket.com/albums/h63/pitstop-paint/pitstop-paint008/Harris9nov18.jpg (http://s61.photobucket.com/user/pitstop-paint/media/pitstop-paint008/Harris9nov18.jpg.html)

http://i61.photobucket.com/albums/h63/pitstop-paint/pitstop-paint008/Harris9nov19.jpg (http://s61.photobucket.com/user/pitstop-paint/media/pitstop-paint008/Harris9nov19.jpg.html)

http://i61.photobucket.com/albums/h63/pitstop-paint/pitstop-paint008/Harris9nov20.jpg (http://s61.photobucket.com/user/pitstop-paint/media/pitstop-paint008/Harris9nov20.jpg.html)

http://i61.photobucket.com/albums/h63/pitstop-paint/pitstop-paint008/Harris9nov21.jpg (http://s61.photobucket.com/user/pitstop-paint/media/pitstop-paint008/Harris9nov21.jpg.html)

Get these last bits bolted on and wired up in next week or so. Oil and oil filter on order. Few touchups n stack of cleaning/polishing to do and hopefully not be far off finished at that.

[MattyDucati]

Love ya work it's looking sweet!

[Surt]

so have you used an oem alternator or else? tbh i hate the idea of using belt driven alternator esp if its pulley protrudes beyond the oem alternator cover so consider the change to better. as for the coils, rect and even fuse box and relays, i'd put them in the open spot as a part of mechanic beauty

[ozzy1100]

love it john

[Gix11]

Wow! I bet it's impossible for ANYBODY to walk past that bike without getting drawn into to some part or another. Brilliant mate.

[Jon]

Cheers folks. Pretty happy with it so far tbh. Looks a whole lot better with belt drives, etc gone thats for sure. More in keeping with performance aspect. Went back to original setup inside casing Surt. Just need to mount and wire in a reg/rec and should be fine. Output is a bit rubbish tbh as those big lights kill the charge. Saying that though I never really use headlights at all. Night driving on my roads is a bit dodgy to say the least with all the animals on the loose. lol

[Surt]

a belt drive looks good with a blower exclusively leaving alone a gearbox

[Jon]

Reg/rec mounted on a drilled alloy bracket down where alternator was. Gives me short run for wiring and most of wiring I needed was already there from before too. –

http://i61.photobucket.com/albums/h63/pitstop-paint/pitstop-paint008/DSCF8555.jpg (http://s61.photobucket.com/user/pitstop-paint/media/pitstop-paint008/DSCF8555.jpg.html)

Coils mounted in same fashion on other side. Yes they will get water spray down there but can’t see it being a problem tbh. I’ve always ran the same coils/leads out in weather for 10+ years with no issues. On show but kind of functional looking I think. Again the wiring was already there from before which was handy. –

http://i61.photobucket.com/albums/h63/pitstop-paint/pitstop-paint008/DSCF8563.jpg (http://s61.photobucket.com/user/pitstop-paint/media/pitstop-paint008/DSCF8563.jpg.html)

Spent a few evenings polishing the alloy back up after a year or two of turning white and furry. Did most of the touch-ups and fettling, etc. Added a bicycle speedo for the mot test, etc too. Basically changed about some small bits n pieces and re-checked everything I could. –

http://i61.photobucket.com/albums/h63/pitstop-paint/pitstop-paint008/DSCF8718.jpg (http://s61.photobucket.com/user/pitstop-paint/media/pitstop-paint008/DSCF8718.jpg.html)
http://i61.photobucket.com/albums/h63/pitstop-paint/pitstop-paint008/DSCF8719.jpg (http://s61.photobucket.com/user/pitstop-paint/media/pitstop-paint008/DSCF8719.jpg.html)
http://i61.photobucket.com/albums/h63/pitstop-paint/pitstop-paint008/DSCF8715.jpg (http://s61.photobucket.com/user/pitstop-paint/media/pitstop-paint008/DSCF8715.jpg.html)

Got the oil and filter at last after a couple of places messing me about with shipping. Clearly Scotland is a separate planet only accessible but space rocket once every 3 light years or something. Ended up ordering it from germany as was half the price of shipping compared to England. Go figure.

Straight out the night the oil came. Took out old filter and cut it open just to make sure there as no swarf or metal parts in there. Spotless inside thankfully. Oil in and filter. Hit the starter and nothing…… Then remembered I’d moved the coils. Quick swap round of HT leads, hit the starter and it fired right up shattering the total silence in the shed for last few hours. Almost pissed my pants with excitement/surprise at is roared right up. Might have swore slightly… –

http://i61.photobucket.com/albums/h63/pitstop-paint/pitstop-paint008/th_Alive.mp4 (http://i61.photobucket.com/albums/h63/pitstop-paint/pitstop-paint008/Alive.mp4)

Got the timing reset, stripped and cleaned out/set the carbs, cleaned the plugs, etc. Running spot on now. Been 70-80 mph storms up here ever since of course as is the law of sod! Snow, ice and hailstones on top for good measure. Wanting a dry road for it’s test run as the anti-dive front end is a bit of an unknown at the moment. Want dry tarmac in case I find its being jerky or pulsing/locking or anything. Waiting game now really to get a test run and see what needs adjusted.

Ultimately I’m in no rush given the weather. Mot and stuff in feb/march when road salts, etc have buggered off. Got photographer coming up about the same time for a magazine shoot so yeah it’s all good.

Looks like I’m onto my trike rebuild after xmas break. Airbrushing 7 days a week at the moment so I can get a week or two off work over xmas.

[Gix11]

Ha, yea, I saw that video before. That is one honest-to-god relief outburst! Awesome work mate. Who's doing the feature?

[Jon]

Ha, yea, I saw that video before. That is one honest-to-god relief outburst! Awesome work mate. Who's doing the feature?

Dave Manning (ex streetfighters editor) is freelance these days and has shown an interest from as soon as I started this project so gave the nod to him. Not sure what magazines it will be in but presumably `BSH` and maybe the german `Fighters` magazine or something. See what mags are interested I suppose.

[ozzy1100]

looks shit hot

[Gix11]

He'll do Flat-Out and world wide bomber for sure.