The Build begins.....well sort of !

[cadman342001]

Progress so far ..... not much

1. Order loads of bits off fleabay - CHECK ! Have about 25 packages on the way, mainly from the US. Missus is waitin on a waterproof kindle cover from amazon, she's gonna get excited and disappointed 25 times in the next week or two ! "we got a card from the PO ! must be my cover!"...."er, no love it's for me"

2. Strip bike in extreme heat and humidity inside a large oven, I mean tin shed (have a wall fan, but being cheap chinese shite from bunnings the swivel action packed up after 5 mins so now I either have to keep adjusting it to where I'm standing or leave it in one place and stand in front of it for a minute every time I walk round the front of the bike!) - CHECK !

3. Sit and twiddle my thumbs, anxiously checking tracking details that basically tell you nothing - CHECK !

The build is all planned, even down to the paint job, gonna be more of a bolt bits on from other bikes ( ie make them fit with a grinder and a hammer ) rather than actually making parts for it I reckon cos I'm not that good with my hands and don't have the gear. I'm going to concentrate on making the parts fit and concentrate on doing a good job of any small brackets etc. that I have to fab up.

Pics -

Tank and a seat and she's good to go !

http://i4.photobucket.com/albums/y126/cadman342001/DSC_0001.jpg



Waiting on socket tool to remove swinger pivot bolt. Rad is actually off now too. Probs remove engine next (bloody Boxing Day and my B'day tomorrow means it'll have to wait until friday before I can get onto that) - then when forks and swing arm arrive I can make up a rolling chassis to ensure it all fits before anything gets painted.

http://i4.photobucket.com/albums/y126/cadman342001/DSC_0004.jpg

Andy

[stiffsimon]

Happy birthday mate. Looking forward to see how your project develops

[Redmohawk]

Popular bike atm , be interesting to see how we all go about it.

[RevHead]

hey Red wonder if Andy has a spare airbox.

[cadman342001]

Thanks chaps and no sorry I don't have a spare. Just lots of scraped body panels ! and soon stock swinger, forks, front wheel, seats, subframe etc etc :)

[Redmohawk]

Where my toy is going it wont need no air box Pete.

[cadman342001]

OK so here's the plan / parts list -


Swingarm - 06 Aprilia RSV - will be painted all or part in satin black


Forks - 07 yam R1 (black)


Front brakes - 04 gixxer thou tokico radial calipers, they are black but may paint them gold.


Front wheel - new 07 R1 wheel off e-gay from china. Similar spokes to std back wheel, same colour ie black. Mayber go with either red pinstripe one wheel and green the other or a double wheel stripe of green and red. or paint them another colour. (see paint job plans below)


Front discs - new, egay, china. $175 pr for 07-08 R1, with gold centres.


Headlight - 07/08 R1 new $99 off e-gay china. Also looking into green / red CCFLs.


Nose fairing / fairing stay - same as above but from HK. White ABS plastic. 07-08 R1, air scoops under/side of lights.


Screen - black/dark tint DB for R1 (obviously)


Clocks - Koso RX-2N go stylee with white face


Rear seats / cowl / subframe - 06 R1 including underseat cans - standard but with race baffles. It's blue but will be painted white.


Rear sets - gold anodised off e-gay from china $153 for Fireblade.


Frame - Fireblade - painted satin black


Black alloy risers and gold pro-taper bars.


Belly pan using trimmed down std lower fairings.


Engine - clean it, might paint cylinders and or top end.



Paint job - it's gonna be white with 2 parallel stripes from front to back, 1 green, 1 red (a Castrol Honda reference), thinking of calling it GTX919RR ! Only concern is that the forks/wheels/frame/swinger and engine are all similar in colour ie too dark. So may have to do wheels white? gold ? one thing I'm not doing is 1 red, 1 green. made that mistake before on gsx750es pepsi colours. ie 1 blue 1 red, never looked right.


All painting will be diy rattle can jobby by moi (at least until i **** it up and then have to get a professional to do it again !). Worked at bike paint shop once for a while so know the level of prep required for a good finish.


At the mo can only see having to make a bracket/spacer to mate R1 fairing stay to the frame mounts and grind 10mm off the frame to get the Prilla swinger to fit and sort out mounting bolt for the rear of the tank.


I know it's not exactly a traditional streetfighter in the strictest sense, and sure it's mainly bolting on stuff off other bikes (mainly R1 but I have had 4 of them albeit older models and I have always reckoned the yam to be the prettiest of the litre bikes) rather than making them but I don't have the equipment, skill or patience for that.


What do you reckon ? opinions welcome




Andy

[ALBI]

hmmmm may be interesting build

[wackyrider]

Been keen to see how it turns out, except for sticking the R1 fairings on.


Fairings are gay!!!! :D

[Chase]

^^ +1 on the fairings, and get yourself some decent discs if you intend to ride it, instead of the ebay Chinese crap - you'll find flat ones work better.

[cadman342001]

We'll see -

May lose the R1 nose fairing and use just the lights, depends how it looks

If the discs warp I'll get some OE ones

[cadman342001]

Okay............so, back to MY build..:rolleyes:


Stripped the rest of the bike totally...


1st up, had to make a socket tool to remove swingarm nut: 27mm socket with 5mm gaps at quadrants (leaving 4 raised sections @ 10mm each). Bit of a botch job using the grinder with a metal cutting disc on got me this:


http://i4.photobucket.com/albums/y126/cadman342001/DSC_0037.jpg


Then had to make one for the 21mm hex nut in the swingarm pivot area. Big arse old bolt with a nut the appropriate size forced onto it. Worked a treat.


http://i4.photobucket.com/albums/y126/cadman342001/DSC_0038.jpg


So, once stripped I got the motor on the bench and started cleaning - degreasing, so much crap on the front I got the wire brush going in the drill, cleaned it up, removed and or masked off stuff (carrier bags over things behind the casings makes an easy masker) and primed it with hi-temp metal primer. Came out really nice I thought.


Satin black will be the go for the top coat, unfortunately the cans say it should be left for 7 days to cure so will paint it next weekend.


Not like I don't have plenty to do in the meantime plus lots of bits should start arriving next week.


Pics:


http://i4.photobucket.com/albums/y126/cadman342001/DSC_0063.jpg


http://s4.photobucket.com/albums/y126/cadman342001/?action=view&current=DSC_0059.jpg


http://i4.photobucket.com/albums/y126/cadman342001/DSC_0065.jpg


Primed -


http://i4.photobucket.com/albums/y126/cadman342001/DSC_0066.jpg


http://i4.photobucket.com/albums/y126/cadman342001/DSC_0068.jpg


http://i4.photobucket.com/albums/y126/cadman342001/DSC_0069.jpg


http://i4.photobucket.com/albums/y126/cadman342001/DSC_0071.jpg


Here's the stuff I'll be using for the top coat:


http://i4.photobucket.com/albums/y126/cadman342001/DSC_0073.jpg


Had some weird numbers on the motor, anyone any idea what this is about ? :


OR4 ?


http://i4.photobucket.com/albums/y126/cadman342001/DSC_0056.jpg


and A.J.H. 22 ?


http://i4.photobucket.com/albums/y126/cadman342001/DSC_0057.jpg


Andy

[RevHead]

prob a motor from a wrecker or breaker,hey Andy what primer you using

[Redmohawk]

prob a motor from a wrecker or breaker

Maybe My cbr900 has "AG 0" in very similar looking yellow paint marker pen in the same spots.

[RevHead]

Maybe My cbr900 has "AG 0" in very similar looking yellow paint marker pen in the same spots.it could be a mark from the factory ,from the guy who assembled the bike or motor

[cadman342001]

The clocks have got 83k kms on them so could be it's not the original motor.

I'm using Dupli-Color Engine Primer (DE1612) same stuff as the paint but primer recommended by Dupli-color if using on bare metal. I figured the 7 day thing was for colder climates and that 3 days in a hot tin shed in North QLD would be enough so painted it yesterday. Came out nice.

http://i4.photobucket.com/albums/y126/cadman342001/DSC_0074-1.jpg

http://i4.photobucket.com/albums/y126/cadman342001/DSC_0075-1.jpg

[Jinx]

Looking good cadman. Its going to be a very interesting build.

[cadman342001]

Thanks Jinx, watch this space !

[BANDITROD]

alot of bike donks have those markings from factory and its looking good cadman

[cadman342001]

alot of bike donks have those markings from factory and its looking good cadman

Ah right, not like I care if it' the original donk or not anyways although the clocks do say 83k kms so maybe I should ! Seems plenty fast, a bit dodgy on the box in 2nd sometimes but hoping (praying) it's just play in the linkage and that the new rearsets will fix that up. Does make a ticking noise when cold, goes away when i pull the clutch in or raise the tickover. Any ideas?

7 parcels to pick up from the PO in the morning (out of about 20 odd total) - it's xmas has come again ;)

[Redmohawk]

Clutch slap due to fingers wearing into basket, Comon enough no real concern.

[cadman342001]

thanks mate, good to know

[cadman342001]

Got the frame and RSV swing arm done - rattle can satin black.


Prepped and primered up the tank and tail.


Put motor back in painted numerous brackets etc satin black.


Just waitin on R1 lower triple tree clamp to arrive and can then get front end on


http://i4.photobucket.com/albums/y126/cadman342001/DSC_0081.jpg


http://i4.photobucket.com/albums/y126/cadman342001/DSC_0084.jpg


http://i4.photobucket.com/albums/y126/cadman342001/DSC_0087.jpg


http://i4.photobucket.com/albums/y126/cadman342001/DSC_0088.jpg


http://i4.photobucket.com/albums/y126/cadman342001/DSC_0080.jpg




Got to finalise the brackets for the R1 subbie, need to make sure it's correct or build in some adjustment if necessary, std rear shock in at the mo, waitin on sachs one off RSVR.
Anyone tell me what I need to do to the rear fireblade wheel to make it fit the Priller one ? I'm thinkin new bearings with bigger inner hole but same OD ?


Oh and can anyone tell me what the little brass tube is in middle just below the inlet ports ? I snapped mine off - managed to get the snapped bit out thank god.


Andy

[BANDITROD]

looking good mate as for the little brass thingy id say its something to do with the cooling system

[Redmohawk]

You said brass so I'm assuming its the little one on Number 1 cyl (its a vacume conection, usally plugged for riding) the one marked 2 is for a hose to the water pump. I see there is a hole tapped into a boss under number 3 cyl , I've not seen one there before but the CBR motors have lots of differences some in the same models. I'd bet its eather a mounting lug to hold a retainer for a hose, or it may go into the water jacket (less likely).

3291

[cadman342001]

Cheers. It is the one under pot #3, have been told it's for vacuum to fuel tap which does seem to be correct from the pics I took when dismantling it (obviously the tank was off at that point but it has a small dia black tube on it). So i'm assuming it needs to be connected and will have to get a new one or see if there is enough thread left on it and araldite it back in ! ;)

[Redmohawk]

You will prob find your local hydrolic supplys "enzed" etc will have something that will fit as a replacement in brass. Prob set you back $5. Take the old one in for thread identification , prob 5 or 6 mm fine metric at a guess.

[cadman342001]

Thanks mate, will do..........when i find it !

Meantime...............

http://i4.photobucket.com/albums/y126/cadman342001/DSC_0106.jpg

I have been told that R1 triple clamps go straight in? the stem doesn't look long enough to me. they are 07s.

Do I remove the old races from the tapered bearings of the honda stem ?

[K6Thou]

What's the difference in the stem diameter and length between the two ? can you press the stem out of the R1 clamp, and into the honda one providing it's the same length ?

Looking good by the way....

[Redmohawk]

Thanks mate, will do..........when i find it !

Meantime...............

http://i4.photobucket.com/albums/y126/cadman342001/DSC_0106.jpg

I have been told that R1 triple clamps go straight in? the stem doesn't look long enough to me. they are 07s.

Do I remove the old races from the tapered bearings of the honda stem ?


From what I've been told R1 forks with 929/954 tripples are the go for a better handeling front end and USD , later R1 front if you want radial brakes as well. Personally I think radial brake front ends are more wank than anything (but a radial master with conventional forks brakes could be a cheap way to improve the stopping power with a lite touch of the hand)

[cadman342001]

Yeah, but don't people also say USD forks are no better than normal forks ?

Either way, I like wank ! so I've got 06s with radial calipers to go on. Good tip on the 929/954 triples though so thanks for that, I'll look into it.

This weekend's progress -

Rear wheel painted by moi this weekend, came out pretty good ? rattle can satin black.
Minter 2010 Sachs shock installed.


Just need some spacers making for the shock / linkages.
stem swap and spacer for triple clamps so I can get that front end on.
Brackets for subby and rearsets spacers/brackets making up.




In the meantime here's a few pic -


http://i4.photobucket.com/albums/y126/cadman342001/_MG_1243.jpg


http://i4.photobucket.com/albums/y126/cadman342001/_MG_1244.jpg


http://i4.photobucket.com/albums/y126/cadman342001/_MG_1245.jpg


http://i4.photobucket.com/albums/y126/cadman342001/_MG_1246.jpg


http://i4.photobucket.com/albums/y126/cadman342001/_MG_1247.jpg


http://i4.photobucket.com/albums/y126/cadman342001/_MG_1258.jpg


http://i4.photobucket.com/albums/y126/cadman342001/_MG_1259.jpg


http://i4.photobucket.com/albums/y126/cadman342001/_MG_1260.jpg


http://i4.photobucket.com/albums/y126/cadman342001/_MG_1261.jpg


http://i4.photobucket.com/albums/y126/cadman342001/_MG_1262.jpg


http://i4.photobucket.com/albums/y126/cadman342001/_MG_1264.jpg


http://i4.photobucket.com/albums/y126/cadman342001/_MG_1265.jpg


http://i4.photobucket.com/albums/y126/cadman342001/_MG_1266.jpg


http://i4.photobucket.com/albums/y126/cadman342001/_MG_1267.jpg

[ozzy1100]

nice build .
looks like a small prob with the steams tho lol you have both that makes it a lot more easy

[kartras]

Nice going mate on the build. Keep it up. Looks good so far ...

[cadman342001]

nice build .
looks like a small prob with the steams tho lol you have both that makes it a lot more easy

Yeah, same dia at the bottom so will get it swapped, smaller dia at the top so will make a spacer. No biggy. (other than the R1 one looks nicer), 10mm shorter. Ordered a new set of blade head bearings today too.

I tell you what as well, the blade one is like twice as heavy ! hoping the extra weight is all in the triple clamp and not the stem. Must be made of pig iron !

Andy

[cadman342001]

Nice going mate on the build. Keep it up. Looks good so far ...

Cheers bud, fingers crossed I don't fuck it up by being impatient as usual !

Andy

[BANDITROD]

you will have to grind the weld off the stock blade stem or it wont budge

[ozzy1100]

Yeah, same dia at the bottom so will get it swapped, smaller dia at the top so will make a spacer. No biggy. (other than the R1 one looks nicer), 10mm shorter. Ordered a new set of blade head bearings today too.

I tell you what as well, the blade one is like twice as heavy ! hoping the extra weight is all in the triple clamp and not the stem. Must be made of pig iron !


Andy
most of weight dif is in steem but dont worry about it
you are lucky if both bottom dia the same makes it very simple
I have done a few now and just use both to measure and draw a new steam to suit
I would still feel better if you used a mic to make shore the crush is right but should be, most jap stuff is.
I do like the way you going about the build

[cadman342001]

I would still feel better if you used a mic to make shore the crush is right but should be, most jap stuff is. I do like the way you going about the build

Thanks Ozzy. Also, I have no idea what you're talking about ! mic ? crush ? I'll be getting an engineering shop to do it as I don't have a 20t hydraulic press !

[cadman342001]

you will have to grind the weld off the stock blade stem or it wont budge

thanks mate, good to know. I did suspect it was welded when I looked at it but wasn't 100% sure.

[ozzy1100]

Thanks Ozzy. Also, I have no idea what you're talking about ! mic ? crush ? I'll be getting an engineering shop to do it as I don't have a 20t hydraulic press !

best you do get some 1 else to do then :-) mind you I do mine all with a super cheep 6 tone press works fine.
btw mic just means Micrometer and is just a tool you use to measure to 0.01 of a mm
and crush is just a common term for interference fit ( the shaft is bigger than the hole so when pushed in it dont fall out)
I just like to sound smarter than i really am :-)

[BOBBY]

Danmoto rearsets?
I need some new controls on mine. They look good.

Rims came up mint ;-)

Not too sure on that front fairing setup your going with but that's just my opinion. If you like it who gives a toss.
You'll love that radial front end if you have experienced the standard brakes.

Keep up the good work mate.

[Gix11]

Shit, we've never had photos like that before. You take an SLR to the shed?

[cadman342001]

Danmoto rearsets?
I need some new controls on mine. They look good.

Rims came up mint ;-)

Not too sure on that front fairing setup your going with but that's just my opinion. If you like it who gives a toss.
You'll love that radial front end if you have experienced the standard brakes.

Keep up the good work mate.

Cheers bud. I may or may not use the front fairing, not sure yet. Thought about just mounting the lights but the new triumph streetfighter has done something similar. We'll see, I have only seen 1 or 2 fighter style lights that I like and they're over $300.

Yeah never had radials before, just blue spots on R1 which were pretty good and my gixxer 750s always had good brakes. The blade ones seemed ok, esp after I gave them a clean to free up the pistons in them (just before I took it apart of course !)

The reasets are branded Ahashi.

[cadman342001]

Shit, we've never had photos like that before. You take an SLR to the shed?

Haha, yes mate I did. Sick of my phone's camera producing shitty pics (usually very good but anything in the shed with bright light coming in through the door played havoc with the metering, not enough DR obviously on the tiny sensor.)

Just sold my D700 to pay for the build, left with Canon 5D Mk1 or as they call them now 5D Classic ! I was taking pics of stuff for evilbay so thought while I was at it I might as well.

Andy

[cadman342001]

oh and btw - Dropped the stems / bottom clamps off at an engineering place today, pick them up tomorrow.

[Gix11]

5D, nice. Don't be shy to keep using it mate, great to see good photos in a topic!

[cadman342001]

A few update pics for ya. Brackets for rearsets and subby made, painted, finished, fitted.

Been waiting for stem swap, bearings etc in the post.

Triples painting -



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Tank securing bolt - used the end of the cbr subby and original boss



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http://i4.photobucket.com/albums/y126/cadman342001/DSC_0116.jpg







Rearsets fitted inc bracket -



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http://i4.photobucket.com/albums/y126/cadman342001/DSC_0117.jpg







Using R1 tank trim -



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http://i4.photobucket.com/albums/y126/cadman342001/DSC_0115.jpg







Rear wheel in, just need nut for axle -



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http://i4.photobucket.com/albums/y126/cadman342001/DSC_0113.jpg







Risers and front end is next -



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Andy

[Jinx]

Looking good Andy and its only taken 4 weeks so far.

[BOBBY]

Very impressed mate
Kinda makes me want to strip and paint mine.

[RevHead]

looking good ,the tail looks a little long ,have you got any more pictures from a side view

[cadman342001]

Just the angle mate -

http://i4.photobucket.com/albums/y126/cadman342001/_MG_0097.jpg

http://i4.photobucket.com/albums/y126/cadman342001/_MG_0128copy.jpg

http://i4.photobucket.com/albums/y126/cadman342001/_MG_0096.jpg

[RevHead]

now that looks scmick! good work

[Bob]

Fuck thats nice, good work mate

[hyofighter]

nice , liking the front gaurd

[Shum]

nice , liking the front gaurd

That whole front end setup looks great

[cadman342001]

Thanks. I'm likin it too, so far. I've ditched the R1 front lights/fairing idea and am thinking of not using the R1 cans, at least not just yet, gonna go with a slash cut with a welded in baffle I think.

[MattyDucati]

That looks mint!

[wackyrider]

That is looking wicked mate. Loving it

[cadman342001]

Here's the latest addition to the build. A bit exxy to say the least but me like it !



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http://i4.photobucket.com/albums/y126/cadman342001/20130213_071113-1_zps51278ca3.jpg


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and......

Caliper bolts - stainless, ebay uk, 8 pounds

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Headlight - wanted one these all along, put off by the price, got this cheaper.



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[wackyrider]

Keen to see the headlight mounted as I can't really picture it on the bike

[BOBBY]

That headlight looks sick just sitting there. Hopefully it goes with the rest of it.
I can kinda imagine it. Mine has stacked dominators which almost sit at the same angle.

[cadman342001]

That headlight looks sick just sitting there. Hopefully it goes with the rest of it.
I can kinda imagine it. Mine has stacked dominators which almost sit at the same angle.

Like I say, shame that it's almost entirely hidden on the 999 isn't it ?

Not dissimilar to the MadAss or the Hesa Fire lights either.

Always thought it would make a good fighter light but only time will tell. Question is - satin black or gold ? or some combination of both !?!

[FIGHTERMC]

satin black i would think....
bike is turning out very very nice indeed.

[cadman342001]

Thanks mate

[cadman342001]

So, now that I have the front tyre on I was able to put the front wheel on and
the calipers on so that's that done now.

While I wait for the headlight I
want to -

1. Finish redoing the wiring / new gauges
2. sort out rear
brake caliper/chain/alignment and make any spacers needed
3. paint and refit
radiator and hoses - I will be replacing the hoses with a red samco kit when
funds permit
4. Make / weld exhaust baffle, paint and refit exhaust.

http://i4.photobucket.com/albums/y126/cadman342001/20130215_073139_zps0f252f1d.jpg

My mate at work just did me a quick n dirty of the stripes i want. They would be down the centreline of the bike though - up the middle of the front mudguard, on the tank and then on the tail/solo seat cowl.

http://i4.photobucket.com/albums/y126/cadman342001/20130215_073139redgreen_zps51c80eaa.jpg

[Gix11]

Fuck that's tidy! Nice work mate.

I reckon you should do the light unit in black so it doesn't stand out too much on the front. It would be subtle, just like whatever is on the shelf behind the bike in the photo pretending to be a light unit.

[BOBBY]

I'm with the bossman. Headlight would be best in black. Maybe even the front fender.

[cadman342001]

Fuck that's tidy! Nice work mate.

I reckon you should do the light unit in black so it doesn't stand out too much on the front. It would be subtle, just like whatever is on the shelf behind the bike in the photo pretending to be a light unit.

Ha ! you mean the R1 lights and nose fairing. They're facing the wall, ashamed that they're no longer part of the project :p

[cadman342001]

I'm with the bossman. Headlight would be best in black. Maybe even the front fender.

Black it is then. Front fender - the one that was black when I got it that I painted white ? Yeah, thought about it, even thought about doing some of it black and some white but I like the white. for now !

[MattyDucati]

bikes lookin great bloke!

[cadman342001]

Thanks mayyyyyyyyyyyyte

[kev@vcm]

Have just read this thread right through cadman and all I can say is this is a kickass bike mate well done to you , can't wait to see the finished product

[Bob]

That nice mate, look tidy and neat. Nice job