Harris rebuild on Isle Of Harris

[Jon]

Well the project train keeps on rolling. Keeps me mentally sane-ish having a project always on the go n distresses me.

Harris`s turn at mo. Had her 13-14 years now and been evolving along the way really. Was my daily transport for many years and been on touring holidays, etc 2-up with luggage. Been everywhere really in all weathers. Few bits been updated over the years as they’ve worn out or I`ve come across them cheap, etc.

Z1B lump, 998cc overbore, raised compression, welded/balanced crank, new/old stock head with light polishing, stainless valves, kent cams, 29mm carbs, etc, etc. Pulls like a train for an old girl. Enough grunt to keep me happy anyway. Love this bike to bits n probably be buried with it. Lol.

Before strip down. Looks ok but was a bit rough close up n a lot of bits I wasn’t happy with finish of, etc. Looked like a rat-bike compared to my tubby bandit so time to pimp it up a bit. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris1.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris3.jpg

Drove it onto bike bench 2 weeks or so ago n started pulling it apart. Few rusty bolts n usual crap with an all-weather bike. Got to this stage and couldn’t get last engine bolt out.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harrisrebuild0108122.jpg

2` stainless bolt passing through (2x) 4” alloy frame spacers was stuck solid even though copper greased it to death last time it was out years back.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harrisrebuild0108123.jpg

Got a hacksaw blade into gap between engine and frame and holding blade in my hand I could wiggle it up n down ½” at a time only. 2 evenings were spent out there on my knees sawing away at it. Lol. Chopped through it and then with a sledge hammer in one hand and a drift in the other I spent 3 hours hammering away at the 2 halves till eventually came out. Feckin solid! :-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harrisrebuild0108124.jpg

My mate Emoe from Haydencycles knocked me up a high grade stainless replacement for when goes back together. Bike wont be seeing same winter weather nowadays so should never get as bad again.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harrisrebuild1208126.jpg

A lot of years of bare alloy engine and living 50` from sea and the engine was a mess in areas I couldn’t reach to clean normally. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harrisrebuild0408121.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harrisrebuild0408122.jpg

Solid crud too. Built my own soda blaster and wouldn’t even touch it. Tried spraygun cleaner (100% solvent) and didn’t touch it. Only thing that shifts stuff between fins was a small screwdriver and lots of hours. Degreased whole lump to start with anyway. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harrisrebuild0508121.jpg

Got 2 cans of Mr Muscle oven cleaner sitting here and buying a powerwasher tomorrow (which I needed anyway) so should be able to get it cleaned up and sprayed shortly.

Was over mainland other weekend on my trike getting its mot n doing a bike show. Came back with these parts for it for free off some good mates. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harrisrebuild1108121.jpg

Old forks were bin fodder. Top halves were pitted to death, bottoms had cracks around seals, inside bushes, etc shot too. Useless yet bike still handled really well on these twisty mountain tracks.

Off a TZR250 reverse cylinder import model. Wasn’t sure about them seeing as theyre off a smaller bike but theyre just as big as gsxr ones and make my 80`s original ones look like toothpicks. Lol. Twice as stiff too so should be fine. Harris is a lightweight bike anyway so these should be a vast improvement over old ones. Same length too which is a bonus.

Pitting on lowers is about 5 spots this size. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harrisrebuild1208125.jpg

Cant feel them and need a magnifying glass to find em so Im happy. Good change of seals n oil, etc and should be fine. Free is my favourite price.

Wheel spindle is off something else but fits threads. Needs a spacer one end as slack in fork leg end.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harrisrebuild1208124.jpg

Have some nice billet risers already on too. Was planning on clip-ons but with my t-rex stubby arms straight bars are much better option. Probably make some billety ones same as my bandit for it as really like the look/feel of them.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Banditheadermods15-1.jpg

Drifted yoke stem out of old yokes yesterday and brought forks/wheel/spindle in house to get a proper measure up. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harrisrebuild1708121.jpg

By pure chance the wheel spindle fits perfectly in wheel bearings which is a bonus. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harrisrebuild1808121.jpg

Bit more wheel/disc clearance than old forks too.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harrisrebuild1808122.jpg

Measured up for spacers for top/bottom yokes, fork leg end and wheel spacers. Got a mate sending me some bar scraps up to make them out of. Got a wee lathe in shed so should be able to turn them all up myself.

My wife spent several days with wire brush on the grinder/drill buzzing back the frame. No blasters or anything on my island. Everythings a PITA to do up here as have to do everything yourself. About 10 layers of smoothrite and aerosol paints, etc. Just chopped off the rusted in bolts and drilled/ re-tapped few holes, etc so ready to go.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harrisrebuild1908121.jpg

Underneath paint is flaky nickel coating with a fair texture to it. Painted over it several times over the years with no problems so not worried about it. Main thing is getting a smooth finish this time as has always looked a bit crap in brush painted finish to hide the roughness and edges of plating. I spray for a living these days though so do it properly this time. Several layers of high build primer and smear of filler if needs be to smooth out roughest edges and should come up smooth. Planning on metalflake finish anyway so any small flaws will be lost under good 1mm+ of flake. lol

Got frame in sitting room this afternoon scraping n chipping out last of paint from corners and recesses. Thankfully my wife doesn’t mind bike bits everywhere. lol

General plan is keep the same general look as love the way it is, just finish everything better. Go through each piece and re-work it in same way as I did with tubby bandit really. Remake most of alloy parts to a better /neater finish. Engine silver with black gloss cases. Homemade belt driven alternator up one side using some toothed belts/alloy gears I had sitting about. Sorta like this.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/SN851285.jpg

Tuck that bandit alternator I picked up into gap by carbs.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/SN851288.jpg

A matching setup on other side of bike with a belt driven mag looking setup (more to come on that). Carbon fibre guards with of some sort for them both. Few carbon fibre detailing pieces here n there.

Clutch casing on mine is cracked n knackered so going for a 80`s endurance style of lifter setup as love the look of them.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Zraceclutch.jpg

General red/black/silver colour scheme and detailed to death with lots of home-made parts as Im a tight-ass womble. Lol. Paintwork wise I`ve got paintscheme worked out in my head already. Lol. While away before get to that stage though. Try push the boat out n do something really wild on it.

So yeah 2 weeks in and updates to follow when get summit done really. Not in any huge rush as want the end result right. Doing an hour a day or so, so things will keep chugging along.

[Gitzy]

Oooh I'm looking forward to this Jon, always entertaining you are..

[K6Thou]

The level of detail on the bandit was mind blowing mate. Can't wait to see what becomes of this build.

[Jon]

Oooh I'm looking forward to this Jon, always entertaining you are..

By always entertaining you mean slightly deranged. :p Hopefully I`ll do an alright job bud.

[Jon]

The level of detail on the bandit was mind blowing mate. Can't wait to see what becomes of this build.

Cheers bud. Some folk liked it, n some hated it with a passion. lol. Usual way though. I just build what makes me happy n folk make theyre own verdicts, etc. Hopefully my harris turns out well anyway. Do the best I can with what Ive got and fingers crossed. Take my time and do the same as with bandit really. Work through each peice, etc.

[stiffsimon]

Likewise your Bandit build was pretty bloody incredible especially considering where you live WTF. I used to live in Tongue on the far North coast so I know all about remote and shitty Scottish weather and twisty Highlands and Islands roads.Going to watch this one with interest

[El_Hefty]

hey do us a favour and show us some pics of your little island would ya.

Yep ill echo the others will be watching with interest

[Hagarr]

I have the same model and owned mine since 1983 and doing the same type of resto, good luck.

I originally used RGV USD and worked really well (same as 900 Ducati!) now run R1 forks with Radials, thread on here somewhere!

Look forward to watching the transformation.

[Gix11]

Yep, looking forward to this one as well mate. Everybody has said what i was going to say.

[Jon]

Likewise your Bandit build was pretty bloody incredible especially considering where you live WTF. I used to live in Tongue on the far North coast so I know all about remote and shitty Scottish weather and twisty Highlands and Islands roads.Going to watch this one with interest

Been through Tongue bud. Been most places tbh. lol. Love touring round scotland on bikes when get a chance. Yeah its not easy here as everythings a challenge, but get used to it n soldier on.

Keep getting random folk turning up at doorstep to nosey at bandit as heard about it, etc. Bit weird but gets me knowing more bikers local-ish. lol

[Jon]

hey do us a favour and show us some pics of your little island would ya.

Yep ill echo the others will be watching with interest

Not got many pics I can find on pc, but heres view from my doorstep in winter. Thats as cleared n gritted as it gets. lol. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/168483_107951849280563_4967918_n.jpg

Most of round my house is like this really. Water, rocks, sheep n not a lot else.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/541929_275757669166646_391329778_n.jpg

Where I live. Joined to larger Lewis/Harris Island by bridge. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/421956_265129586896121_118262787_n.jpg

Real contrast up here. Small island, mountains and loads of empty beaches like this close by too. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/179236_107950249280723_5175996_n.jpg

Good few standing stone circles further up island. Old churches, etc, etc. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/SN851036.jpg

I like it here. Not easy living but quiet as heck n next to zero crime so great for kids, etc.

[Jon]

I have the same model and owned mine since 1983 and doing the same type of resto, good luck.

I originally used RGV USD and worked really well (same as 900 Ducati!) now run R1 forks with Radials, thread on here somewhere!

Look forward to watching the transformation.

Now thats usefull info bud. These forks are comparable with the RGV ones tbh. Pretty impressed with them so far tbh and were free so grabbed em. lol. Harris isnt that heavy really even with big lump in it so should be a lot better than the buggered 80`s ones.

[Large]

why did i get an image of the Wicker Man flash into my head.

[Bob]

This is looking like a great build.

[stiffsimon]

Not got many pics I can find on pc, but heres view from my doorstep in winter. Thats as cleared n gritted as it gets. lol. :-

LOL I don't think many people know what you mean by gritted :)

[El_Hefty]

thanks for the pics great part of the world but as you say hard.

look forward to more build pics as time allows.

[Jon]

My wife spent 2 days or so with wire brushes on grinder and drill taking off ½” of built up aerosol and hammerite paint off frame, along with rust patches, etc. I spent a whole week of evenings scraping into corners with a knife and screwdriver to get it spotless. Lot of hours, but no blasters or anything on my island. Finally got it to bare metal and the old nickel plating which is stuck solid. Anything loose came off with grinder and steel brush wheel. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris2508121.jpg

Coated it all in Kurust treatment to be sure rust is neutralized. Built up several coats of high build 2K primer today in between work stuff. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris2808121.jpg

Kept throwing it on till started to sag/run, etc. Wasn’t being fussy though tbh as only using primer as a leveler/filler of sorts to get rid of edges of nickel plating vs. steel tube. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris2808122.jpg

Close up though and the ridges are very feint and leveling out nicely.

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris2808123.jpg

Going to sit and sand it back next few evenings in sitting room. Try level out things a bit more and remove overspray dust, etc. Reckon if repeat this process a few times I`ll get the tubes pretty smooth. Concentrating on outside visible faces more really. Going for metalflake finish anyway so if can get it reasonably smooth then flake will cover anything small tbh.

Ordering work paint next couple days so I`ll get some etch primer too for engine and can get that blasted n painted soon hopefully. Friggin DIY is eating all spare time at mo, but good to get some housey shit done too.

[Jon]

Built some fences this weekend and spent good 10 hours or so in sitting room sanding back frame and getting tubes whipped into shape. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris0209121.jpg

Taken sodding ages, but close up the spars are tubular and smooth. You`d never know just how rough it was before now. :-
http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris0209122.jpg

Another couple coats of primer (lighter this time) and a light sand and stick some black basecoat on and see where we`re up to. Make the decision as to whether going with original gloss black plan, or sticking to metalflake plan if theres still visable roughness. Decisions, decisions. Getting somewhere slowly. Knew the frame/engine refurb were going to eat serious hours though.

[Jon]

Getting bit sick of frame refurb now. Lol. Been bout 30-40 hours all-in so far. Put couple of coats of black basecoat on tonight though and the hard works sure as hell paid off. Nice smooth frame rails, no flaky nickel plating ridges, no rust, no dings, just proper looking! No clearcoat on it yet, just basecoat. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/HarrisRebuild1009121.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/HarrisRebuild1009122.jpg

Few wee nibs to sand out n touch up, etc but looks good. Was planning on metalflake over the top, but seeing the tubes turning out so good Im tempted to revert to my original plan n go gloss black frame. Easier for touch-ups down the line from stone chips/rust, etc. too.

[wackyrider]

That frame has come up great. Seems like all those hours are paying off.

[Jon]

That frame has come up great. Seems like all those hours are paying off.

Been a long slog but worth it now Im seeing the results. Sand out last of nibs/flaws n drown in 2k clear. Etch primer on way in mail for engine so thats next in line.

[Gitzy]

Great progress Jon, I'm glad its not me putting in the hours though sorry Mate lol..

[Jon]

Id rather it was someone else too. lol. Gotta be done though as wasnt resorting to hamerite and a brush yet again. Just a killer sitting sanding after 10-12 hour day of painting/sanding. :/

[Jon]

Got my frame 2k clear coated. Nice n shiny gloss black.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harrisrebuild2010120_zps70d43bfc.jpg

Spent an evening cleaning up bearing surfaces and running tap through threaded holes, etc.

Moved onto engine bolts/plates, and the spacers, etc. Well weathered n chipped/bashed to fook. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harrisrebuild2010121_zps3958e5b1.jpg

Bolts cleaned up fine and the alloy parts came up well with a few evenings of sitting on doorstep enjoying the sunshine. Bit of a file, then sand paper, metal polish n some elbow grease and came up like new parts which is what Im after with it all.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harrisrebuild2010122_zps63126128.jpg

Ordered some 6 pence each (inc delivery, lol) stainless steel washers off Egay. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harrisrebuild2010123_zps1537dabd.jpg

Drilled 6 holes and a bit of a sand n polish and got myself some trickish looking washers for next to nothing. I like em anyway. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harrisrebuild2010124_zps8e116365.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harrisrebuild2010125_zpsba5e1c39.jpg

The 6 hole thing is something that’s going to be repeated throughout the bike on the belt drive pulleys each side, and dozens of washers on the mechanical bits n bobs throughout the bike. Made 5 so far so only another several dozen to make as I go. OCD anyone!? Hoping the attention to detail will pay off though once all together. Not much hidden on this bike once together so want all the small areas to tie in and look good.

Builds gonna be slow as shite Im afraid. Pushing with DIY stuff on house/garden, etc at mo too. Just bought a tatty 125cc supermoto/trial bike needing engine rebuild (and full cleanup rebuild) too which is not for my eldest lad when he turns 17 next year. ;) Busy, busy. Got my trike to rebuild and a totrod to build too down the line.

That’s the next few years of boredom sorted. :D

[stiffsimon]

"a few evenings of sitting on doorstep enjoying the sunshine."

You sir are a star.I'm guessing you were wearing Avon skin so soft because I know how vicious those midges must have been ;)

http://t3.gstatic.com/images?q=tbn:ANd9GcSRe8zu6Z4LVC62HoyuMXCssxLriVelX _fKrBvPyVesLz59A2sW

[Jon]

Midgies are only vicious to tourists. Scots just put up with em. :D......................until theyre sure no-ones looking then run around madly wavving theyre hands in the air. :)

[Jon]

Updates a bit slow Im afraid but getting somewhere.

Got sidetracked as picked up a very cheap 125 m/x bike which Im secretly rebuilding for our eldests 17th next year. Rough as hell but was at the right price and local which isn’t easy up here.

Everything on it was rusted to death and fooked.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/28111201-1.jpg

Engine was interesting. Wheres the other valve? :-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/28111202-1.jpg

Ahh there it is. Lol :-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/28111203-1.jpg

Been slogging away at it painting/greasing/rebuilding every last switch and replacing every fastener with stainless, etc. At rolling chassis now though so back to splitting time with harris build again thankfully. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/28111204-1.jpg

Between that and spending couple weeks of evenings and weekends under my rat hearse to get it through its mot Ive struggled to get time at the build which has really F**ked me off tbh.

Been chipping away at it in evenings when I can though here and there.

Made a stepped spacer up to mate the harris spindle with the new bottom yoke.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris131112.jpg

Another couple of spacers and washers turned up saw the top yoke fitted up too.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris141112.jpg

Found a shitty old diesel piston in the garage which gave me an idea. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris18111201.jpg

Spent a whole weekend on my baby lathe turning inside of it out to fit the tacho inside. Piston was bigger than the chuck of my lathe and crown was few inches thick so took sodding hours! Lol. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris18111202.jpg

Going to mount it in centre of yokes. Not going to run a speedo as not really needed up here. More interested in the engine revs when out for a run anyway.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris18111203.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris18111204.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris18111205.jpg

Going to make up a big chunky set of billet bars and grips like I did with my turbo bandit (have a look if forgotten what they look like). Sorta like this.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris18111206.jpg

And going for single headlight too for smaller look.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris18111207.jpg

Got some 22mm solid alloy bar off Egay other day to form the inners from. Also ground off the ignition barrel mounts, etc from top yoke and sanded yoke/risers/piston, etc ready for polishing up. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris28111201.jpg

Need to make some spacers for central section to support piston, etc and out sections/grips, etc but chipping away at it.

Got my metal stand back from under the 125 m/x now too so can get the engine sprayed up. Only stand I had that was strong enough to take the weight of the lump and at a decent height for spraying. Lol.

[Gix11]

So many jobs, so little time! That's the problems with toys / projects hey Jon?

[EFE 1230]

awesome!

[Jon]

So many jobs, so little time! That's the problems with toys / projects hey Jon?

Always something bud. Sodding car was doing my head in lying out in the storms working on it for weeks. Zero interest in fixing the car. Still its sorted n mot`d again for another year and just in time for winter, etc. Just annoys me how many hours I wasted on that which could be getting spent on bike builds. Hey ho back on it now. Almost the weekend. Either finish these bars off or start painting the engine.

[Jon]

Taken a ridiculous amount of hours to finish these bars off but Im happy with the results. No expensive Italian exotica parts wise, just used parts that I already had and bout £15-20 of alloy offcuts. Cheap n cheerfull. Made the last of the spacers up and spent several evenings sanding and polishing each piece up. Was great to finally bolt the boxes of pieces together. Still need to strip the tacho and airbrush the clock face but will do that at same time as bodywork paintwork so ties in properly. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris14121201.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris14121202.jpg

Made spacers up which lock into piston central section and stop it moving around. Also made a gudgeon pin spacer for through the centre to finish it off.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris14121203.jpg

The levers were just too damn long looking so cut the ball ends off and drilled 3 little holes to match the grips and other drilled parts on bike. Also made an outer shroud up for the clutch lever perch to bulk it out a bit as was just too skinny looking diameter wise compared to rest of bars. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris14121204.jpg

As a finishing touch my mate Emoe made me up a one-off piston-esque brake fluid reservoir to match the piston central section of bars. Cool!:-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris14121205.jpg

Feels like Im getting nowhere on project but every bit helps I guess. Been flat out work wise trying to get finished for xmas. Taking 2 weeks or so off work as booked till April already, so planning on blasting and painting the engine up so I can get frame out of my bathroom and start bolting bits back onto a bike shaped object. :D

[Hagarr]

Cool certainly original ideas.

Just for interest whats your Frame number?

[Harry]

great work mate.....

[Jon]

Cool certainly original ideas.

Just for interest whats your Frame number?


Cant remember off top of my head but in the 130`s I think. Had it confirmed as a Magnum 1.

[Gix11]

That's really tidy Jon, I like it mate.

[Hagarr]

Its stamped on the steering stem bearing housing tube. It'll be HP... !!! You should still be able to see it even with Powdercoating.


Cant remember off top of my head but in the 130`s I think. Had it confirmed as a Magnum 1.

[Jon]

No chance bud. Mine was nickel plated originally so with that flaked off the numbers were barely visable, then add on top 10 layers of primer and black and clear coat, etc. Matches my log book tho as seen it before when had frame stripped down. Might stamp up a plate to put back on for mot guy but he knows its fine anyway.

[cadman342001]

Stellar stuff Jon, I guess living where you do has helped hone those skills of yours ! Lovin the 6 hole washers etc, very nice.

Andy

Had some great hols up on Skye etc. (my surname is MacDougall but never made it Harris ) when I lived in the uk. The west coast is a magical part of Scotland.

[Jon]

Had some great hols up on Skye etc. (my surname is MacDougall but never made it Harris ) when I lived in the uk. The west coast is a magical part of Scotland.

Lived on Skye and in Kyle myself for good 10 years or so before came over here. Good living apart from employment side of things which isnt easy unless work for yourself really.

[RevHead]

love all the hand-crafted parts ,what street-fightering is all about,

[Jon]

Big update as forgot to do it recently. Lol. Oops. Been busy in garage instead of on pc Im afraid.

Made this little frame bung on the lathe as original plastic/rubber one was crap. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris12011301.jpg

Started mocking up my clutch lifter setup in finest tradition of cereal boxes. Lol. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris12011302.jpg

Made up a little tacho block-off plate for engine. Internal o-ring so should seal fine. Original plate that was on there was weeping oil for years. Tacho on mine is electric anyway. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris12011303.jpg

After weeks of evenings chipping away at alloy corrosion with screwdrivers and wire brushes I cracked out the oven cleaner and powerwasher. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris12011304.jpg

Few go`s at that and some solvents and had a nice clean bare alloy block.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris12011305.jpg

Over xmas when I was shut down work wise I sprayed the engine. Getting full coverage was a PITA as all of engine is on view in harris frame, even the sump, etc. Had to spray underneath of engine and then once hardened do the top half of engine. All got 2 coats of etch primer, 2K primer, metallic silver basecoat and, 2K clear. Came up really well I think. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris12011306.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris12011307.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris12011308.jpg

Soooo much better between engine fins than before! :-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris12011309.jpg

Chopped out first parts of clutch setup in chunky alloy plate using my CNC machine……………just kidding. Bloody hours with my trusty cheap grinder, drill and a hand file. Slow work but gets decent results if patient enough. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris12011310.jpg

Re-made the bracket and spacers for my idler sprocket setup. Proper turned alloy spacers instead of stacked washers. New bearing also as was a bit notchy. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris12011311.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris12011312.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris12011313.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris12011314.jpg

Unusual maybe but saved me loads of hassle. Its an idea me an Mr Yantosh came up with many moons ago. Chain was gouging swingarm on the bike and eating through any chain runner I made in days. Swingarm runs at fair angle but any lower and wheels eating into subframe. Geometry was all wrong too as chain was tightening up over bumps. I snapped (3x) 630 pitch chain links in couple of days humpback bridge jumping. lol

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Snappedchain.jpg

Not had a single chain problem in god knows how many years with new setup.

35th birthday the other day so didn’t get much done other than starting another bit of my clutch setup.

Bubblewrapped frame up today to protect it while putting it on engine.:-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris12011315.jpg

Was stressing like mad as frame sits damn close to engine round front/sides of head. Thought I was going to scratch it to hell getting it on there. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris12011316.jpg

I was stressed to hell and sweating like mad. With the bubble wrap though it took me and my wife all of 10 seconds to slip it over and get couple bolts slid through. Was just a case of pulling/cutting the bubblewrap out afterwards. Sorted! My wife said `Well that was a bit anticlimactic` in a sarcastic voice. lol . Really happy with it as all super clean. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris12011317.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris12011318.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris12011319.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris12011320.jpg

Hoping to get clutch lifter arm finished tomorrow which is last bit of clutch to make. Not far off with it now.

Front forks are stripped and just waiting on seals/oil, etc for them. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris12011321.jpg

I`ll keep chipping away at assembling and cleaning them up. Can get front end on then along with my new bars, etc I made before. Should look nice.

After that I`ll be taking a small break from it for a week or two. Got my new headers through for my turbo bandit from Mr. Yantosh so need to fit and fettle them and get the bike up and running ready for summer thrashing. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris12011322.jpg

[geesexar]

im jealous that is lookin fuckin ace..bet your bustin your balls to ride it..nice work

[whale]

Fark, that's looking clean.

I'll have to call mine a rat Harris after seeing that

http://i152.photobucket.com/albums/s195/whale_63/Cowper-1.jpg

[stiffsimon]

Aah but yours has got a proper motor in it :rolleyes:;)

[Hagarr]

Some interesting engineering going on here!

Looking good.

[Jon]

Fark, that's looking clean.

I'll have to call mine a rat Harris after seeing that

http://i152.photobucket.com/albums/s195/whale_63/Cowper-1.jpg


Ooo nice harris! Mine was a real rat harris for many many years. Used to go 700+ mile weekends 2-up with luggage to rallys, etc with my wife, commute to work every day even in 1ft of snow. Was in a bit of a state tbh close up. Work from home now though so gives me the opportunity to take my time and build em up slowly instead of trying to cram mods into weekends.;) Hopefully it`ll come out nice.

[Jon]

Aah but yours has got a proper motor in it :rolleyes:;)

:D:p Cant go wrong with a big aircooled lump no matter what make it is. I saw a Z engined magnum in SF mag when I was but a youngster and decided thats exactly what I wanted. Got such a soft spot for Z engines. lol. Ended up going to London to get this one many years back. Been a steady evoloution since really. Got it real cheap as was in a right state cosmetically/mechanically so not cost me that much realistically. Maybe £2500 or so all in over the years inc. bike.

Motors a Z1B lump (pretty much exactly same age as me :D), 998cc overbore, raised C/R, welded n balanced crank, kent cams, 29mm carbs, etc. Not ground breaking but been damn reliable over the years n still goes great. Just something about the torque/noise of the big aircooled lumps that the modern motors cant match.

[ozzy1100]

any zook or z roller bearing air cooled goodness is sweeeeeeeeeet

[stiffsimon]

I like big Zeds........................oops cat's out of the bag

[Hillsy]

Nice work.

I'd be interested to see how that idler sprocket stands up over time with it being up top and under acceleration load.

[Jon]

Nice work.

I'd be interested to see how that idler sprocket stands up over time with it being up top and under acceleration load.

Ive ran the idler sprocket setup for good 8-10 years or so with zero problems and I ride pretty quick. Grunty motor too. Re-made the bracket and spacers twice as thick this time just to be sure. lol.

[Gix11]

Shit that's nice Jon. Good work mate. Many hours effort pay off in the end hey?

[Jockney Rebel]

fukin awesome my son ...and in Scotland too ..see ya can build anythin in the highlands lollove the work youve put in ..cant wait to see it whole

[Jon]

Progress is slow at the moment tbh. Been getting turbo bandit back together again with new headers, etc. Had to chop about few things and make up a support bracket off the head in stainless, etc. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Bandit25011301.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Bandit25011302.jpg

Had it fired up and sounded great. Boost n fuel pressure gauges flickering upwards into positive pressure just by blipping throttle to half revs in garage. Was getting ready for road test and carbs started pissing fuel out. Started stripping em off and found the return fuel line in the tank has a split so fuel system backing up into engine. Going to have to drain and drill bottom of tank and put in new fuel line internally, etc. PITA. Got me sidetracked at minute as want a bike on road for summer.

Also managed to score a complete top end (piston to cam cover) for £100 for the 125 Im secretly building for our eldests 17th birthday. 4000km on the clock so a good result as spent over 6 months looking for a new head for it. Lot better than the £260 bill I was looking at to replace parts with new. Still at rolling chassis stage so sidetracked with that too. Lol. Got a time limit on this one though for the big day. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/MX25011301.jpg

Pottering away at Harris bits when get the chance though. Sprayed up bottom yoke in 2K black and got front yokes/bars I made on. Really liking them! :-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris25011301.jpg

Finished off small bits n bobs on clutch setup and connected cable to bars. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris25011302.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris25011303.jpg

Works smooth and slightly lighter weight than original setup too which is nice. Still 10x heavier than a new bike as running heaviest springs I could find to eliminate clutch slip. Used to it though. Happy with new lifter setup. Seems fine.

Dug carbs out of the parts box. Bloody filthy and covered in years of crud! :-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris25011304.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris25011305.jpg

Spent several evenings in front of tv stripping them down and cleaning them out internally. The outside castings were quite rough but after several hours with degreaser and a fine brass brush they scrubbed up well. Used 400 grit wet and dry for the tops and bottoms to give a brushed finish. Didn’t see point in polishing parts as really rough alloy finish on them. Easy to keep clean this way too as carbs quite hidden away on complete bike. Clean and useable. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris25011306.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris25011307.jpg

The bellmouths were really battered at rear edges. Looked online at mesh covers, etc but stupid money!

Had a cheap ass womble moment. Lol. Chocloate spread jar lid and a scalpel. File and sand edges. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris25011308.jpg

Old sheet of fiberglass aluminium mesh I had lying around and some big o-ring things out of random box. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris25011309.jpg

Clip tightly onto bellmouth ends. Once painted up gloss black or something they should look alright I think. No-one will ever know theyre jar lids, except you lot. Lol :-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris25011310.jpg
http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris25011311.jpg

Should do the job and keep bugs out of there.

[Jon]

Car oil cooler sanded/polished up, New bracket made, stainless fasteners throughout, etc. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris1703131.jpg

Made new side billet crush sections with holes drilled to match bars, clutch lifter, etc.

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris1703132.jpg

Re-made my homemade oil cooler take-offs at back of head. Tight squeeze once carbs go on with clutch cable running across now too but all in there.

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris1703133.jpg

Polished up bellmouths and my pikey jam jar lids painted up a nice pearl red which I’ll be using for other small parts on bike such as brake disc centres, etc. Carbs cleaned up and stainless fasteners throughout them too.

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris1703134.jpg

Old section of a damaged carbon fibre hugger chopped up and sanded/clear coated in 2K. Better fit than original rusty chrome one and weighs nowt while looking better. Be a few carbon fibre bits n bobs on bike when done.

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris1703135.jpg

Where Im up to. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris1703136.jpg

Slow going at mo, but chipping away at it. Currently battling to tidy up swingarm and sidestand parts to get them on.

Sharing time between this, rebuilding every room of house, fitting double glazing, and of course turbo bandit on the road guff. That’s up n running n boosting fine, etc after having it apart n together dozens of times fine tuning/changing things. Wheelspinning like hell in the slippery winter weather n single track gravel roads. :-

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/SN855392-1.jpg

Turbos smoking like hell though and not worth repairing. Thankfully turbo guru Dave (FBM turbo fame) came to my rescue and is sending me up a IHI VF10 turbo for it off a Subaru legacy. Be a good match if ever move up to a 1200 engine too. Waiting for that to arrive then switch back to that and alter mounts, etc to make it fit n should be on road again for summer.

Only free time saver I’ve got in my favour is my wife made us scrap our car so no working on that all the time anymore. Lot of time and money each year saved which is cool. Bikes n trike as daily transport again and couldn’t be happier!

Spent extra money on a shitload of metal roof sheeting to re-roof my shed and garage. Warm n dry building very soon. Happy days.

[stiffsimon]

Impressive stuff Jon. Bike's is looking really,really good and I can't wait to see it finished and up and running.

"Wheelspinning like hell in the slippery winter weather n single track gravel roads."

Aah I remember those days well from living in Thurso and Tongue and not forgetting the deer materialising like magic from the heather and jumping out in front of you.

[Jon]

Not to mention the mobile chicanes.......................................... .................... or sheep as we call them. :)

[Jon]

Hi guys. Been a while since updated this thread. Been too busy with life, but I`ll keep updating when I do until it’s a finished bike.

Took some time out to rattle on with house renovations as felt a bit burnt out with bike building constantly. 6 months of every evening and weekend spent roofing, cementing, joinery, electrics, plumbing, decorating, etc has me sick of it and ready to build again through winter. Lol. Main benefit is I re-roofed my garage this summer so got dry workspace! YES!

Been blasting about on my turbo bandit thing all summer too. Done thousands and thousands of miles on it in all weathers. Back n forth on ferry to mainland, etc too touring with my wife. Great long distance mile muncher n going well. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/SN858175.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/SN858175.jpg.html)

Built this 125 m/x bike for my oldest son`s 17th birthday as a surprise. As you can see he was a little bit happy when got handed the keys. Been out teaching him how to ride it last wee while. Up for his test next few weeks. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/SN8580852-1.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/SN8580852-1.jpg.html)

Bought another one to do up at somepoint for my daughters 17th. TS125R with a low mileage GS125 4 stroke lump in with leccy start, etc. Got the rest of the parts for it stashed away in bathroom. Lol –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/TS125R05081301.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/TS125R05081301.jpg.html)

Been back onto the Harris build last few weeks doing some more.

Swingarm was chewed up in places from chains getting spat off over the years and some idiot previous owner running it without a chain slider. Loads of tool/stone dings too. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris05091301.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris05091301.jpg.html)
http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris05091302.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris05091301.jpg.html)

Not the sort of swingarm I could just throw in the bin and get another of though. Lots and lots of hours of remedial work later and looks like new. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris05091303.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris05091301.jpg.html)
http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris05091304.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris05091301.jpg.html)

Bought some carbon fibre sheet and stainless fixings from Egay. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris05091305.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris05091301.jpg.html)

Sprayed the rear R1 shock ends metallic silver to match the engine, etc. Bought some offcuts of neoprene rubber off Egay and made a shock cover to tidy up chipped bright yellow spring which I wanted to hide. Gives it a nice neat look I think. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris05091306.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris05091301.jpg.html)

Cut out the carbon fibre sheet into a new swingarm splashguard, airbrushed on a Harris logo and 2K cleared it. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris05091307.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris05091301.jpg.html)
http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris05091308.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris05091301.jpg.html)

The chrome sidestand bracket was rusty so painted that same silver and made some more drilled washers to tie in with rest. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris05091309.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris05091301.jpg.html)

Spent several evenings cutting down and reshaping big block of alloy into a polished sidestand, again to tie in with other drilled bits. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris05091310.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris05091301.jpg.html)

Bottom end angled to sit level-ish on ground. Old bar end weight cleaned up and used as toe lever. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris05091311.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris05091301.jpg.html)

Splashguard in place with more drilled washers n stuff. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris05091312.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris05091301.jpg.html)

Love the way it looks. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris05091313.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris05091301.jpg.html)

Used some more neoprene material and some carbon fibre offcuts as a flexible splashguard to cut down on rear wheel spray to carbs. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris05091314.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris05091301.jpg.html)

Chain adjusters were bashed to hell with hammer marks, etc to cleaned them up on lathe and polished them up. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris05091315.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris05091301.jpg.html)

Liking the way its looking. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris05091316.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris05091301.jpg.html)

The USD forks I was going to use turned out to be fit for the bin when I was rebuilding them. Were some bad gouges and scrapes in the sliders inside the fork legs. Teflon coated bushes were shot and had chewed up sliders amongst other problems. Just not worth rebuilding at all. Thankfully they were free in the first place.

Got some fireblade forks for it off Egay for £90-odd delivered. Turned up this weekend while I was away at a bike rally on the isle of Skye on the turbo bandit (even won a trophy for it which I was chuffed about). Exact forks I really wanted for it so real happy to get them for a decent price. Always loved the way they look, and good handling units too. In good condition and just need painted/polished lowers before ready to go in yokes that are already on. Test fit this evening to make sure. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris05091317.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris05091301.jpg.html)

Nice and chunky forks and RWU too which is really what I wanted. Few spacers on lathe and an old wheel spindle I have will fit too. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris05091318.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris05091301.jpg.html)

Spindle slots into my front wheel so should all go together fine with a bit of lathe work.

After a bit of measuring Im seriously considering a mechanical anti-dive setup like the early AMA and endurance racers. Got `just` enough space I think on front wheel spindle to pull it off. Would work nicely with my endurance style clutch lifter I already made.

Wheels stripped down. My one off discs, etc rusty from sitting in damp shed. They`ll get cleaned up and re-painted next few weeks though along with forks/wheels. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris05091319.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris05091301.jpg.html)

Wheels need same treatment. Weathered to death and 3mm of paint in several layers. Paint stripper didn’t touch it so Ive ordered up a pile of wire brushes for the drill to get the paint off. Get them painted and polished back up like new. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris05091320.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris05091301.jpg.html)

So yeah back on the case. Going to be a few weeks of sanding/polishing/painting now so have forks/wheels ready to go on. Concentrating on getting it to a rolling chassis stage basically.

[geesexar]

keep the pics comin Jon Im lovin this thread

[wackyrider]

Good to see you still going on this beast Jon. I love the amount of work that has gone into all the details.

[slingy88]

Never doudted you would be back Jon and busy as ever mate, well done.
Good to see the Turbo Bandit going good as well mate. Top Job all round :cool:

[Jon]

Busy on my days off yesterday/today replacing turbo bandit`s rear tyre and stripping/rebuilding forks with heavier oil, new seals, and general fettling. Off touring again on it next weekend so need it ready.

Still battling the tidying up of forks and wheels, etc on Harris ready for paint.

Did get a few minutes to balance things in place on the Harris to get an idea of how the belt drive alternator will work. Be a matching belt driven distributer setup other side, as one spinny belt just isnt enough. lol. Got a lot of parts to make from scratch over next few months!

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Mockup1.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Mockup1.jpg.html)

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Mockup2.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Mockup2.jpg.html)

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Mockup3.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Mockup3.jpg.html)

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Mockup4.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Mockup4.jpg.html)

[Jon]

Still waiting on wire brushes for drill to come in mail so I can clean up wheels. Forks will be painted next week with some work stuff Im prepping, and bolted in place though.

Last couple evenings I made an electrics tray. Scrap of stainless sheet salvaged out of local skip. Lol. –

http://i61.photobucket.com/albums/h63/pitstop-paint/pitstop-paint001/Harris02oct131.jpg (http://s61.photobucket.com/user/pitstop-paint/media/pitstop-paint001/Harris02oct131.jpg.html)

Few stainless bolts and brackets and job done. Gaps front n back for cables in and out. Might have to drill a few holes for mounting relays n stuff but no biggy. –

http://i61.photobucket.com/albums/h63/pitstop-paint/pitstop-paint001/Harris02oct132.jpg (http://s61.photobucket.com/user/pitstop-paint/media/pitstop-paint001/Harris02oct132.jpg.html)

Side plates are just frame infils really to hide the electrics from view. Offcuts of the carbon fibre sheet I used on swingarm. Tidies things up a bit and can always drill holes for switches if needs be. –

http://i61.photobucket.com/albums/h63/pitstop-paint/pitstop-paint001/Harris02oct133.jpg (http://s61.photobucket.com/user/pitstop-paint/media/pitstop-paint001/Harris02oct133.jpg.html)

Simple little part, but one more off the huge `MAKE ME` list. Lol. Need to keep chipping away at the build each evening from now on or its not going to see the road next year. So many parts to make from scratch.

Next pics should be the forks n wheels/discs, etc cleaned up and ready to start piecing together on the lathe.

[Gix11]

I love the fact you remember to take all these photos as you go along Jon. Makes for a great post mate! Cheers for sharing.

[Jon]

Long couple of weeks here with seemingly little to show for it. Must have spent over 30 hours of work getting the wheels, discs and forks into shape. Seems a ridiculous amount of hours, but were in a complete mess, wheras 99% new looking now.

Forks and discs cleaned up and painted. Forks are back in bike now. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris04111301.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris04111301.jpg.html)

Spent a lot of evenings sitting on doorstep with a screwdriver and butter knife scraping the 2-3mm of old paint layers off the wheels. Wire brushed on drill just didn’t get into much of it really. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris04111302.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris04111302.jpg.html)

Next problem was countless tyre lever marks and deep scratches on the rims. Another few hours with dremmel and sand paper levelling them out as best as possible. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris04111303.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris04111303.jpg.html)

Finally got there with em. 2K black and shiny. Sort of hammered finish to them, but that’s the casting so best I can do. Disc adaptors on. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris04111304.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris04111304.jpg.html)

Back together –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris04111305.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris04111305.jpg.html)

Found some piston valve caps kicking about in the shed on a shelf so threw them on too. Match the piston tacho surround and mastercylinder, etc. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris04111306.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris04111306.jpg.html)

Next job was trying to get random spindle to fit the blade forks. Turned down the fat end to fit in one side of the forks. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris04111307.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris04111307.jpg.html)

Found a huge nut and welded it onto the end of the shaft. Arc welders great at getting a lot of heat into things. Filled the nut up with molten weld and then shaped it back to a nice nut shape with the grinder. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris04111308.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris04111308.jpg.html)

Turned up an alloy spacer for the other fork leg. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris04111309.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris04111309.jpg.html)

Found a random nut for the threaded end and got a spindle that fits. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris04111310.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris04111310.jpg.html)

Next thing Im on to is ordering up bearings for the wheels. Planning on making up a mechanical anti-dive setup like the old 80`s endurance/race bikes so need to draw that up and figure out what bronze buses/bearings/track rod ends I need as all come from same supplier as wheel bearings so makes sense to order together and save on postage. Need a couple bits of 12mm alloy plate too. This sort of thing is what im after. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris04111311.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris04111311.jpg.html)

Got most of the parts and fittings worked out on paper as to whats attaching where, etc. Shouldn’t be too hard, just a lot of fiddly and accurate fabrication really. The one bit that was stumping me was the attachment to the back of the lower yoke. Nothing there at all to bolt to. Did look at steering damper brackets as an alternative, but stupidly expensive! Had a route about the shed and came across the old fork brace off the old 80`s forks I binned. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris04111312.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris04111312.jpg.html)

Seperating the ends off, and using some silicone offcuts from my turbo bandit build. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris04111313.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris04111313.jpg.html)

Gives me a nice chunky solid bracket below bottom yoke. Can fabricate a small bracket onto back threaded bolt holes for track rod end to bolt to. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris04111314.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris04111314.jpg.html)

So next instalment will be a fair few weeks Im afraid by the time I draw everything up and get the bearings/alloy. Got a stack of spacers, etc to make up on lathe and the anti-dive setup to make. Should be nice though and tie in with the endurance style clutch lifter I previously did on the bike.

[Redmohawk]

Looking good bloke

[Gix11]

What do you mean "seemingly little to show for it"? That is a great installment Jon. Those wheels look brand new.

[Jon]

What do you mean "seemingly little to show for it"? That is a great installment Jon. Those wheels look brand new.

Yer turned out alright in the end bud, just a heck of a lot of hours to refurb a couple of wheels. lol

[K6Thou]

Mate I wish I had the patience and attention to detail that you do.....

Can't wait for the next update.

[Jon]

Been a while since last updated but have been busy honest. Lol. Boxing day today and sat doing nothing so thought Id update the thread a bit.

After specialised doodles on the back of bits of scrap paper, cereal box templates and some researching I bought some big drillbits, bronze iolite buses and track rod ends, etc off ebay. Also new wheel bearings since its all apart anyway. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris26121301.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris26121301.jpg.html)
http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris26121302.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris26121302.jpg.html)

Made a stack of parts out of alloy and stainless, scrapped several of them, and redesigned and remade them again, etc, etc till I was happy with fitment and strength. And came up with this 80`s endurance racer style mechanical anti-dive front end setup. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris26121303.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris26121303.jpg.html)
http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris26121304.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris26121304.jpg.html)
http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris26121305.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris26121305.jpg.html)
http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris26121306.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris26121306.jpg.html)
http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris26121307.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris26121307.jpg.html)

Skipped over most of the work compared to my usual forum updates Im afraid, but I promised a full detailed article to MDM at www.flat-out.com (http://www.flat-out.com/).

Should be a detailed article appearing on there very soon with all the details on each componant and how it all works, etc. All solid and bolted up tight though at last. Everything bushed for a smooth operation. Calipers stripped, cleaned and repainted along with all the metalwork. Something a bit different anyway and didn’t cost much to do at all. Just a heck of a lot of grinder cutting and hand filing, etc. One of those times you wish you had some fancy tooling.

On my xmas break from work right now so currently battling with the rear end parts so I can get it up on its wheels. Cleaning up rear-sets and brake parts which are in same sorry state as rest of bike was. Years and years of quick weekend modifications to keep the bike on the road, and lots of winters of rust and alloy corrosion, etc.

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris26121308.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris26121308.jpg.html)

Unbelievably the calliper pistons are clean and and push back in by finger easily, so still useable.

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris26121309.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris26121309.jpg.html)

Also spent out on a new one-off sprocket for the rear wheel in dural alloy. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris26121310.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris26121310.jpg.html)

And some new back brake pads and a new chain also. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris26121311.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris26121311.jpg.html)

In the middle of making a new rear calliper mount at the minute, and almost finished the rear-sets which look like new. Few brake parts to paint and fit yet, but not far off. Been cut down and heavily hollowed out internally, and look a lot neater and lighter than before. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris26121312.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris26121312.jpg.html)

Hopefully get rear wheel/brake setup, etc in place and bike rolling in the next week or so before I go back to work. Only so much xmas tv I can stand……

On a xmas note I got my wife another dog for xmas. This ones quiet and doesn’t eat much tho. Lol. A friend on the Isle OF Skye made it for me cheap using a bike crankshaft, conrods, pistons, clutch basket and some odd`s n sod`s. Pretty cool. Definitely a male dog judging by the size of its nuts! lol –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris26121313.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris26121313.jpg.html)

[Redmohawk]

Excellent work as always.

I'd be a little concerned about the upper mounts being only single sided, don't want the torque arms wandering left n right under load. Brackets would most likey handle the stress, with some support from the outsides would be good insurance with each potentally seeing about half the weight of the bike under hard braking.

[Hagarr]

Great work as usual!

Whats the swinger off Jon?

[Jon]

Excellent work as always.

I'd be a little concerned about the upper mounts being only single sided, don't want the torque arms wandering left n right under load. Brackets would most likey handle the stress, with some support from the outsides would be good insurance with each potentally seeing about half the weight of the bike under hard braking.

Been mentioned by a couple of folk bud. I`ll modify them a bit when get a chance. The brackets will see a lot less than 1/2 the bikes weight as the ratio on the middle set of pivoting bars knocks it down by 1/3 or 1/4 even, and then split between 2 brackets also. Probably only 20-30kg per bracket or thereabouts at the most. I`ll re-inforce them before hits the road though. Probably brace accross between 2 brackets or something.

[Jon]

Great work as usual!

Whats the swinger off Jon?

Believe its an old Metmachex swingarm.

[Redmohawk]

Not trying to teach you to suck eggs or discorage you at all (I love the anti dive) My first experiance with postive "dive" on a bike was when I was 13. And learnt all I could about it back then through a teacher at trade school that was into bikes in a big way (speedway rider). Just a heads up on these sexy units.

A conventional forked bike can brake at 1.4 G before the rear tyre lifts , if your setup prevents dive as it's designed (and looks right to me) this load can be increased slightly due to the higher Cg of the bike under braking (front of bike doesnt dip)

Some setups can even go into positive and lift the front when the brakes are applyed, if your forks don't compress at all when you brake the brackets will be taking 100% of the braking forces. On a bike weighing 170 kg this could be 250 odd kg so 125kg for each bracket.

Thing to watch isn't so much the brackets and they're strength (as your already on that) , but on the design of the links to keep the anti dive rate at a constant relative to front end position. If not setup correctly the anti dive rate varies with position of the bike , this means whilst the brakes are applyed and you hit a bump the suspention will react differently as the spring rate of the forks becomes variable in relation to the position of the loaded front end.

Basicly while the brakes are applyed bumps (and how the front end will handle them) become an unknown, at light braking forces a small bump will most likely be delt with just like stock suspention. But under harder braking your forks (if the anti dive isn't setup correctly) may bottom out on the same bump.

Hope all goes well , just take it easy on your test ride .

[Jon]

Not trying to teach you to suck eggs or discorage you at all (I love the anti dive) My first experiance with postive "dive" on a bike was when I was 13. And learnt all I could about it back then through a teacher at trade school that was into bikes in a big way (speedway rider). Just a heads up on these sexy units.

A conventional forked bike can brake at 1.4 G before the rear tyre lifts , if your setup prevents dive as it's designed (and looks right to me) this load can be increased slightly due to the higher Cg of the bike under braking (front of bike doesnt dip)

Some setups can even go into positive and lift the front when the brakes are applyed, if your forks don't compress at all when you brake the brackets will be taking 100% of the braking forces. On a bike weighing 170 kg this could be 250 odd kg so 125kg for each bracket.

Thing to watch isn't so much the brackets and they're strength (as your already on that) , but on the design of the links to keep the anti dive rate at a constant relative to front end position. If not setup correctly the anti dive rate varies with position of the bike , this means whilst the brakes are applyed and you hit a bump the suspention will react differently as the spring rate of the forks becomes variable in relation to the position of the loaded front end.

Basicly while the brakes are applyed bumps (and how the front end will handle them) become an unknown, at light braking forces a small bump will most likely be delt with just like stock suspention. But under harder braking your forks (if the anti dive isn't setup correctly) may bottom out on the same bump.

Hope all goes well , just take it easy on your test ride .


Yeah from what I read up the `success` of mechanical anti-dive on race bikes was limited on anything but smooth tracks. Not really doing it for any real gain end of the day, more for looks and to do something different. Most race setups I looked at worked on 1:1 or 1:2 ratio setup. Got enough adjustment in mine to lower it down to 1:4 or more so should be able to wind its effects right down to minimal amount. Not much wrong with fireblade forks anyway tbh.

[Redmohawk]

Certainly looks the goods

[Jon]

Certainly looks the goods

Ta. Grinder n handfile job, but Im happy with it. Drilled n tapped fork clamps today and bolted straight through bodies of them so confident thats strong enough now. Examples I found online with 1:1 ratio had single 6mm bolt holding the top sections on to the bottom yoke which seemed a bit worrying. lol. Reckon everythings strong enough as alloy is twice as thick as examples I saw online anyway.

Cheers for info. Always good to learn more about it. Something new for me even though its old tech now. Fair bit of head scratching to make it fit the stock forks, etc but got there in the end.

Rearsets finished and bolted on today too. Got rear caliper mount 1/2 made too. Hopefully get it back on its wheels next few days before have to get back to work. :)

[Jon]

Bit more done. Back caliper stripped/painted and new pads. Made up a caliper hanger out of the old one cut down severely too. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/SN859363.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/SN859363.jpg.html)

After concearns about strength of upper anti-dive mounts I changed the layout by drilling and tapping right through main body of clamp instead. Stronger and looks neater too. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/SN859354.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/SN859354.jpg.html)

Last few parts made for the rearsets and bolted onto bike. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/SN859356.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/SN859356.jpg.html)

Used a scrap piece off carbon for a little heelguard for other side too. Bit neater with m/c tucked behind rearset this time. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/SN859360.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/SN859360.jpg.html)

Wheel on at last. Did my shoulder in a bit trying to hold back end up with one arm while lining up eccentric adjusters and spacers, etc with other arm. Worth it though to see it back on 2 wheels. Fitted new chain after this photo too. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/SN859369.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/SN859369.jpg.html)

The `jump on the table and clamber onto bike before camera timer runs out` shot. Lol –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/SN859371.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/SN859371.jpg.html)

Good to sit on the bike again after so long.

Need to make a new brake torque arm for it. Need another brake banjo for rear line and bleed both F&R brakes too. Few odds n sods to fettle/adjust tomorrow but rolling chassis more or less complete anyway.

[Redmohawk]

Very nice , and looks more in tune with the rest of the bike I think.

[Jon]

Another chunk done. Fitted chain and was fouling clutch setup slightly. Spaced it out with couple washers and fine. Also made up a small stainless clamp on protector plate for the frame under lower chain run. `Just` touches frame and no more with no rider weight on the seat, etc. Clears fine once sat on the bike but for all the effort it took to make it saves it rubbing slightly over crests, etc. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/SN859372.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/SN859372.jpg.html)

New back brake torque arm made up as original was too short with new minimal calliper mount. Big n chunky alloy but not that heavy once drilled to death. Drilled washers, etc again too to tie in with rest. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/SN859378.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/SN859378.jpg.html)

Had front end apart yet again to remove some niggles and doubts. Cut down excess width of alloy clamps on fork legs to give more fork slider potential movement. Good 3” now plus the 2” or so of static sag that’s already loaded on them. Plenty movement now. I also put a threaded bar across between the 2 alloy clamps to make sure they cant turn around the fork legs and go out of line with the anti-dive force pushing on them under heavy braking. Everythings solid now up front so leaving it alone at last. Lol. -

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/SN859380.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/SN859380.jpg.html)

Cleaned up exhaust. Took sodding hours n hours of sanding and polishing to get the years of winter riding smeg and rust off. All stainless Predator system with modified minimal race baffle and alloy big bore endcap, etc. Good 10 years old so good few stone marks on downtubes, but nothing you can notice when heads 6” away from them so all good. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/SN859384.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/SN859384.jpg.html)
http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/SN859393.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/SN859393.jpg.html)

Ordered up exhaust gaskets, new clutch cable and back brake banjo/bolt/light switch too along with a mountain of stainless bolts/nuts/washers, etc.

Moving quick at moment but have to go back to work in a few days after my xmas/new year break so will slow a bit. Good to get so much done though while got the time spare.

[wackyrider]

That exhaust has come up a treat Jon

[Jon]

Yer just a whole lot of elbow grease. lol

[Cleverchap]

Wow those headers have come up great. Nice work.

[Jon]

Reloaded pics so hopefully displays properly this time.

Another few bits done. Home life`s been a bit crazy of late and back at work after xmas break so slow going. Keeping me sane-ish though getting bit done on it here and there where I can.

Made up a big chunky billet alloy bolt on subframe to support the rear seat. Old setup was weak and seat plastics flexed a lot 2-up which caused a lot of stress cracks in fibreglass. Wanted something solid this time so came up with this. –

http://i61.photobucket.com/albums/h63/pitstop-paint/pitstop-paint007/arris20011401.jpg (http://s61.photobucket.com/user/pitstop-paint/media/pitstop-paint007/arris20011401.jpg.html)
http://i61.photobucket.com/albums/h63/pitstop-paint/pitstop-paint007/arris20011402.jpg (http://s61.photobucket.com/user/pitstop-paint/media/pitstop-paint007/arris20011402.jpg.html)

Not on view with seat fitted so didn’t bother polishing it up or anything. Solid as a rock though and no seat unit flex at all. Not too heavy with all the holes drilled neither.

Made up a stainless undertray for the seat unit out of some old shop shelves I scavenged a while back from a local shop refit (free). Bit of bending round a lamp post outside garage door and some sanding/polishing later and fits a treat. LED`s fitted running through one way diode and resistor setup to dim for light and full wattage for brake light. Just waiting on 3 more in mail to finish off. –

http://i61.photobucket.com/albums/h63/pitstop-paint/pitstop-paint007/arris20011403.jpg (http://s61.photobucket.com/user/pitstop-paint/media/pitstop-paint007/arris20011403.jpg.html)

Few stainless brackets and job done. –

http://i61.photobucket.com/albums/h63/pitstop-paint/pitstop-paint007/arris20011404.jpg (http://s61.photobucket.com/user/pitstop-paint/media/pitstop-paint007/arris20011404.jpg.html)
http://i61.photobucket.com/albums/h63/pitstop-paint/pitstop-paint007/arris20011405.jpg (http://s61.photobucket.com/user/pitstop-paint/media/pitstop-paint007/arris20011405.jpg.html)

Made up a passenger footrest assembly. Not going to be used in 2-up form often so made it removable for neater look. My turbo bandits my 2-up daily hack anyway. 2 bolts attaches it quickly to underneath of billet subframe. Recessed to give maximum wheel clearance loaded up. Undertray has curved section just in case too. –

http://i61.photobucket.com/albums/h63/pitstop-paint/pitstop-paint007/arris20011406.jpg (http://s61.photobucket.com/user/pitstop-paint/media/pitstop-paint007/arris20011406.jpg.html)
http://i61.photobucket.com/albums/h63/pitstop-paint/pitstop-paint007/arris20011407.jpg (http://s61.photobucket.com/user/pitstop-paint/media/pitstop-paint007/arris20011407.jpg.html)

Wanted to keep undertray clean and neat so went for side mount numberplate again. High enough up not to ground out I reckon. Waiting on a LED light for it. –

http://i61.photobucket.com/albums/h63/pitstop-paint/pitstop-paint007/arris20011408.jpg (http://s61.photobucket.com/user/pitstop-paint/media/pitstop-paint007/arris20011408.jpg.html)
http://i61.photobucket.com/albums/h63/pitstop-paint/pitstop-paint007/arris20011409.jpg (http://s61.photobucket.com/user/pitstop-paint/media/pitstop-paint007/arris20011409.jpg.html)

Has a twist though. Liked the flip down numberplate with spec panel I made for turbo bandit and decided to evolve the idea a bit. Keeps bike tidy when parked up too. Need to make up a spec panel to stick on. –

http://i61.photobucket.com/albums/h63/pitstop-paint/pitstop-paint007/arris20011410.jpg (http://s61.photobucket.com/user/pitstop-paint/media/pitstop-paint007/arris20011410.jpg.html)

Not sure what to work on next. Ideally it would have been the supporting framework for the front fairing/headlights/battery tray but don’t have spare £100 or so for fairing right now to work from. Will have to wait a few weeks.

Might start planning and cutting parts for the belt driven alternator setup. Going for this position now with it as much neater and more compact. Belt driven magneto in same position other side. Billet alloy or carbon fibre belt guards, etc. –

http://i61.photobucket.com/albums/h63/pitstop-paint/pitstop-paint007/arris20011411.jpg (http://s61.photobucket.com/user/pitstop-paint/media/pitstop-paint007/arris20011411.jpg.html)

Overall Im aiming for this kind of look. Colour/paint to be decided on, but gives a rough idea of what Im after. –

http://i61.photobucket.com/albums/h63/pitstop-paint/pitstop-paint007/arris20011412.jpg (http://s61.photobucket.com/user/pitstop-paint/media/pitstop-paint007/arris20011412.jpg.html)

[Jon]

Been a few weeks since updated. Don’t have a heck of a lot to show for it tbh. :/ Been busy with house renovations fitting double glazed windows, woodwork, plastering and all that fun stuff.

Put in a good few hours late at night and stuff in the garage making parts though where I could. Real slow going cutting bits out with the grinder then countless hours hand filing and sanding to shape, etc. At least its moving forwards though.

Made up this alloy light bracket out of some bar and the old rear brake torque arm. Battery box is parts of an old greenhouse. Lol. Battery will sit just behind front of fairing giving me a real neat short cable run to electrics tray under tank. Can’t cut brackets or mount it till have fairing to get sizes/position from, but one less part to make down the line. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris031401.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris031401.jpg.html)
http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris031402.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris031402.jpg.html)
http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris031403.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris031403.jpg.html)

Most of my time has been spent making the belt driven alternator setup. REALLY under estimated how hard this was going to be with my tools or lack of.

Started off with an old pulley wheel I wasn’t using. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris031404.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris031404.jpg.html)

With the casing off the magneto inner section sits on a tapered and keyed shaft on end of crank held on by central but. I say held on, but it tool a bearing puller to even loosen it! –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris031405.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris031405.jpg.html)

An old scrap random wheel spindle threaded into body to act as output shaft. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris031406.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris031406.jpg.html)

I turned the pulley wheel down into a bearing and seal carrier. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris031407.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris031407.jpg.html)

Ground the inner castings down inside the casing and `JUST` squeezed the carrier inside the casing. Was going to get it welded on but managed to make it a bolt together assembly using a 2mm nitrile rubber gasket I cut out which clamps between the parts. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris031408.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris031408.jpg.html)

This protrudes through the casing with a recess for an oil seal. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris031409.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris031409.jpg.html)

Theres a 1mm spacer between the support bearing inner race and the old alternator inner section so it can’t work its way off the crank. Would have like to get rid of that 0.5 kg inner section but my tooling/skills on lathe weren’t up to it with the tapered/keyway section, etc. Couldn’t cut casing thinner in width anyway like most people do as exhaust headers sweep hard left at front and alternator only clears headers by 4mm or so as it is. Not worried about ground clearance though as the engines are really high in the frame on these Harris’s compared to the old Z’s. I’m no Marquez getting 50-60 degree lean angles and got clearance for that sort of thing leant over.

Bought a huge slab of 10mm alloy plate from my local fishing boat builders for £20 which I thought was alright. Was considered an offcut for them the scale they work at. Lol -

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris031410.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris031410.jpg.html)

Cut out support plate with a grinder and roughed it to shape. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris031411.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris031411.jpg.html)

I’ll not bore you with the rest, but needless to say I spent weeks cutting/drilling/sanding/polishing/painting the parts and making umpteen spacers on the lathe so parts would mount and line up, etc. Alternator was a tapered shaft too but managed to weld some nuts to the original gear backplate to bolt the pulley wheel to. Taken a huge amount of hours to make a small part by hand, but think it turned out alright. Best I can do anyway. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris031412.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris031412.jpg.html)
http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris031413.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris031413.jpg.html)

Just needs some carbon fibre sheet ordered up to make a skeletal guard for the front. Something like this with pulley wheels on view. -

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris031414.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris031414.jpg.html)

Bolted on. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris031415.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris031415.jpg.html)
http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris031416.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris031416.jpg.html)

Got all the shaft parts/bearings, etc gathered together for the belt driven magneto on the other side of crank so I’ll be starting on that next. A lot easier setup though so should be quicker to do as no oil inside that casing or anything and got it all worked out on paper as to how I’m doing it.

My turbo bandits been off the road for a couple of months over winter due to constant petrol tank leaks and rust debris in carbs, etc. Looks fine on outside but rotten inside and leaking seams, etc. Got sick of riding along paranoid about the drips of fuel hitting something hot so parked it up till sorted it properly. Bought a rough looking tank off ebay. Few dents but inside is like new, even with coating, etc. Spotless inside which is main thing. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris031417.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris031417.jpg.html)

Yantosh made me this fuel outlet and return up for it. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris031418.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris031418.jpg.html)

Getting it Tig’d onto the tank today by fishing boat builders up town. I’ll need to find time to get it fillered/painted up so Harris might have to take a back seat for a couple of weeks of evenings while do that. REALLY want back on the road now weathers starting to improve.

[Gix11]

Your idea of one month and "Don’t have a heck of a lot to show for it" amazes me mate. You've done more in that month than I've done in a year! Great post as always mate. Thanks.

[geesexar]

mind blowin jon

[Jon]

Your idea of one month and "Don’t have a heck of a lot to show for it" amazes me mate. You've done more in that month than I've done in a year! Great post as always mate. Thanks.

Just don't feel like it bud. House renovations are taking up every weekend and evening at mo. Having to snatch odd hour in garage at weird times of the night, etc to keep project moving. Don't want to fall into trap of it stalling. :/

[MDM]

Don't want to fall into trap of it stalling. :/

No chance of that happening mate, that trap is full of me and my projects...

[Jon]

No chance of that happening mate, that trap is full of me and my projects...

Easy done bud. Life gets in the way all the damn time. :/ Trying to jockey between DIY n bike stuff is a pita.

[ALBI]

love the alt bracket and drive mate ,well done !

[hyofighter]

jon top work as usual , have you got any pics of the shaft bearing and seal after you finished it ? I see the inside one but did you put a seal on the outside of the cover too

[Jon]

jon top work as usual , have you got any pics of the shaft bearing and seal after you finished it ? I see the inside one but did you put a seal on the outside of the cover too

Didnt take pics Im afraid. Inside I used 2mm rubber sheet off ebay and cut a gasket to suit myself. That sealed against oil seeping through. Shaft wise I just used a normal oil seal around the shaft. This sort of thing. Only £1-2 each online. -

5441

[Jon]

Well been another few weeks of battling with bike and house refurbishing. Got my replacement turbo bandit tank done and out of the way. Been out and about on it at every opportunity since tbh. Racking up a lot of miles and a lot of tanks of petrol. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris12051401.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris12051401.jpg.html)
http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris12051402.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris12051402.jpg.html)
http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris12051403.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris12051403.jpg.html)

Back to the Harris anyway. Ended up re-making parts several times over to get it all fitting together right. Bit of a nightmare getting it all to fit in space available. Started by stripping off and painting pickup/points casing black. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris12051404.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris12051404.jpg.html)

Made a pulley/shaft coupling for the crank using the original casing and a turned bearing housing. Shaft was made out of a long reach socket which engages on the end of the crankshaft nut whish is dowel-pinned to the crank so solid. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris12051405.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris12051405.jpg.html)
http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris12051406.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris12051406.jpg.html)

Used a stainless steel tea/coffee/sugar jar for the magneto type housing for the dynacoils. Drilled a few holes, etc. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris12051407.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris12051407.jpg.html)

Turned up a carrier to house 2x bearings. Shaft was made out of a section of an old wheel spindle. Fan was made out of some stainless scrap sheet. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris12051408.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris12051408.jpg.html)
http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris12051409.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris12051409.jpg.html)

Air is drawn in one end and blown out the other to keep the coils cool. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris12051410.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris12051410.jpg.html)

Dyna coils bolt to end cap. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris12051411.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris12051411.jpg.html)

A week or so of fettling and shaping with a file and losing my fingerprints sanding/polishing. Etc and job done. Carbon fibre guard to finish it off. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris12051412.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris12051412.jpg.html)
http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris12051413.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris12051413.jpg.html)
http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris12051414.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris12051414.jpg.html)

Bolted back on. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris12051415.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris12051415.jpg.html)
http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris12051416.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris12051416.jpg.html)

Carbon guard made up for other side to finish that off too.

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris12051417.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris12051417.jpg.html)

Where I’m up to. –

http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris12051418.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris12051418.jpg.html)
http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris12051419.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris12051419.jpg.html)
http://i61.photobucket.com/albums/h63/pitstop-paint/Album%202/Harris12051420.jpg (http://s61.photobucket.com/user/pitstop-paint/media/Album%202/Harris12051420.jpg.html)

Clutch cover to make next which should be a damn sight easier. Could have saved myself a couple of months of headaches and work just painting the engine casings black but reckon it’s been worth it now its done. Quick prod on kickstart and both belts spin away nicely. Should be nice when running though I’m bound to hang off the side watching them as I ride. lol

[Gix11]

Mate, I love your posts! Cheers Jon.

[Jon]

Nae probs.

[davo]

Awesome Jon. Best shed build ever. and those gloves...

[Jon]

Awesome Jon. Best shed build ever. and those gloves...

Need to protect my hands airbrushing for a living. Keeps the worst of the burns/cuts off. lol

[hooligan]

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

Liked Davo said, best shed build ever.