Hornet 900 project

[Dano919]

Hi all,
So it's time to start my thread for my build, thanks for all the welcomes when I intro'ed myself. Here goes....
The Bike
2007 CB900 Hornet that I picked up in late 2011 with 3000 k's on the clock. It was on con stock at a Honda dealer near work, I had a mate with many years experience working as a mech for dealers and then Honda in Melb (and an awesome enduro rider too) come with as he knows the principle and the salesman we dealt with. Picked it up for 5k, was pretty happy seeing even now the insurance value for it now is still 8k! Having said that there is evidence the previous owner had maybe found 900cc's a bit much to handle and slid it down the road into a curb, hence it being on consignment (I read between the lines a little I reckon they were spooked after insurance fixed it) Upside was lots of new bits on it and only small scratches under one side of the engine, and a slide dent in the rear rim, but nothing affecting performance and it runs like a bike with low k's so all good.
The plan
So we are building a house, 18mth old demanding attention and I reckon within the year we'll have another rugrat on the way so I am on a budget. Upside, I'm a mechanic, restored my first car a Torana from the ground up with Dad when I was 16 including full engine rebuild and all the welding/paint myself so I'm happy to take my time and hopefully I come up with some original and clever ideas. I plan to keep doing it in stages so I can get it back on the road now and then to actually enjoy it
My inspiration for this build includes but is not limited to some of the fairing styling from the BMW S1000rr, and this site has thrown up all sorts of ideas so it'll be a work in progress.
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[Dano919]

It as a while back now but the first thing I did was to put some new bars on the bike, fender eliminator, led indicators and remove the standard exhausts for a big single out the side to clean up the tail, which lightened things up as well. Through word of mouth I found a fellow named Ian who's a coded stainless welder who took the exhaust from 4 to 2 to 1 so I could fit the can out the side for only $200. Bargain, he even ordered the tube himself. I never got his last name, (kept his number somewhere), but I think he has an early XJ as a streetfighter bored out to 1300cc's with a full custom exhaust. Maybe he's on this forum???
Here's the pic, first qtr 2012:
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Just before Chrissy ordered a secondhand hot bodies belly pan, and a new pro-fiber race tail for BMW S1000rr, plus Sato racing rear sets. It all arrived just in time for the end of my hols, but I did start to mock up the belly pan. Lots of grinding and cutting and I am going to get real good at fibre glassing! This is a pic from weekend just gone:
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[fimpBIKES]

looks great, got some side-on pics for me to fap over later?

[Gix11]

Welcome aboard mate. Nice project.

[Cleverchap]

Good choice of base. Hornet should make a sweet fighter

[Dano919]

Fimp just for you I'll see if I can get a better angle!
Gix, thanks I think it'll come up pretty good
Clever yeah I think so, I don't feel too precious cutting into it either, so no holding back!

[Dano919]

Here's some more shots of the belly pan, rear sets and the tail. Lots of thinking about how to integrate the top of the belly pan into the radiator, obviously it's meant to have a front cowling attach to it. Also how aggressive to point the tail up - I'm think very aggressive! :cool:
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[Cruisecontrol]

Consider the seat angle though. Too steep and you will be balls deep in the tank before you know it.

[BANDITROD]

Welcome

[Dano919]

Ok so reality keeps getting in the way but I have made a little progress. Rearsets completely fitted and taken for a test run. Feels pretty good, different from stock obviously and I set them 30mm back and 30mm up (I think)
Lots of fiddly bits all well packaged, good instructions, loctite all included. BYO verniers and torque wrench
531653175318
So after I got home from my test ride I thought I had better hook into the tail mod, otherwise I'll not be riding when the weather gets cooler! So off came the tail, seat and under tray. Hmmm. Lots of wires and relays and computers and heat sink and stuff.....
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So then I mocked up the tail for some inspiration (below). Obviously no frame cutting....yet. Mindful of the advice about the seat, I do plan to keep the rider seat as is because that integrates nicely with the panels around the battery/airbox and the tank. I have two lines I could go with, the line in the panels the old tail followed, which would mean the new tail almost bolts straight on, or the lines that follow the front of the under tail, the hugger and the big single muffler, which is the line I prefer and requires cutting and sweeping up the rear frame and chopping the relevant plastics. Measure twice, think about it for a few days, measure again and cut once - I want this to look aggressive but no at odds with the rest of the bike.
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[Dano919]

And after some thought I have decided to give vinyl wrapping a shot. I'm inspired by the orange of the repsol race colors:
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So I found a decent sized off cut on fleabay, it's 3M Burnt Orange Gloss which is close. Not to everyone's tastes but my favourite colour is the matte black but not sure I could wrap my whole bike in it. And I would like the bike to stand out in orange.
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So the primary colour of the tail, tank, belly pan will be orange, matte black for the front fender and some matte black striping to tie it all in. Bought this for doing the striping:
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[ALBI]

Consider the seat angle though. Too steep and you will be balls deep in the tank before you know it.
Mate I've never agreed with anything you say but in this case ur spot on!

Don't go steep on seat as Dan said

[Dano919]

Haha yeah Albi, I need the two boys, the missus wants more kids!

[Dano919]

The cutting begins...
5333

[hyofighter]

now the fun begins

[xa-mont]

ahhh the cutting. the best part of all!

[Dano919]

It's been a few weeks but I finally got back to the bike for a couple of hours. The block of land we had a deposit on had its third delay on titles, now twelve months late, so after a nasty letter we got our deposit back. Fucking pricks couldn't plan a fuck in a brothel. At the same time we found an existing house we like and yes it has an extra double garage round the back, so I am set! Going to be slow going on the bike front till April though....
Back to the bike, the cutting got even more serious:
5374
The end I cut off I'm going to reuse by slitting it at the four corners of the tube to narrow the outside dimensions and then inserting it in the end of the frame, this means I can lap the joint and add strength to the join over a regular butt weld. More on that down the track, but here's the tail of the frame:
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And just to make things a little more difficult I found the frame is bent, which you can see in this photo, it doesn't line up to the wheel:
5376
I sort of thought it might be when I did my fender eliminator a couple of years back (I knew it had been dropped), but it was obvious before I cut the frame, about an inch to the right. Appear to be bent ever so slight at the back of the tank/front of seat which adds up to an inch all the way out at the end of the tail. Decided I'd do the work anyway, I can live with it, and when I come to do some other work to it like taking the engine out, I'll get the frame straightened.

[Dano919]

After a long time between posts, I've finally moved house. Got the bike round here with zip tie and a loud straight through exhaust
5849
Scored a $250 XT 250 for a cafe racer project with a twist project. For a rainy day
5850
Bike in the shed, and I'll stop talking, just pics:
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Next, modify the under seat in the pic below, or make a new one out of ali sheet
5865

[Dano919]

So after some careful trimming, I'm fairly happy with using the existing plastics under the seat. Began creating a cardboard template so I can cut some Ali sections to fill the gaps neatly.
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[wackyrider]

Bike's looking good mate.

But I think you need a photobucket account so that we can see the pics full size :D

[ALBI]

i see the look ur going for but is it possible to change and / or get seat redone so its moulded more to tail ?
to me " and it's just my opion" it look's like a after thought and you had to put it there ?? if you get my drift .

[Dano919]

Bike's looking good mate.

But I think you need a photobucket account so that we can see the pics full size :D
Photobucket account made :D

[Dano919]

i see the look ur going for but is it possible to change and / or get seat redone so its moulded more to tail ?
to me " and it's just my opion" it look's like a after thought and you had to put it there ?? if you get my drift .

Hi Albi, yes I hear you and I'm not 100% happy with the integration, however I am going to sort the rest of the build and will then likely go back. It's my first time doing a reupholstered seat. Ideally I would have something fibreglass made for that area and take more out from under the seat and yeah narrow the seat. Cheers for the feedback.

[Dano919]

http://i1265.photobucket.com/albums/jj513/since19781/Mobile%20Uploads/2014-06/467DCFB2-161C-4B52-AA49-BD4BA8260A01_zpsfipdfi7x.jpg (http://s1265.photobucket.com/user/since19781/media/Mobile%20Uploads/2014-06/467DCFB2-161C-4B52-AA49-BD4BA8260A01_zpsfipdfi7x.jpg.html)
Hopefully this photobucket thing works

[Gix11]

Now in widescreen!

[xa-mont]

nice looking arse there

[Dano919]

Some goodies arrived today, those familiar with fleabay may have seen these before
http://i1265.photobucket.com/albums/jj513/since19781/Mobile%20Uploads/2014-06/478B9849-F59B-4967-9E76-E9F0230601AD_zps2ytgqrpy.jpg (http://s1265.photobucket.com/user/since19781/media/Mobile%20Uploads/2014-06/478B9849-F59B-4967-9E76-E9F0230601AD_zps2ytgqrpy.jpg.html)
Some bolts and fixings because you can never have enough
http://i1265.photobucket.com/albums/jj513/since19781/Mobile%20Uploads/2014-06/204DE9BA-3A2B-4BF8-A20E-932C5BE1EC14_zpsxbl5rm2a.jpg (http://s1265.photobucket.com/user/since19781/media/Mobile%20Uploads/2014-06/204DE9BA-3A2B-4BF8-A20E-932C5BE1EC14_zpsxbl5rm2a.jpg.html)
Matt black wrap
http://i1265.photobucket.com/albums/jj513/since19781/Mobile%20Uploads/2014-06/C6AF9D63-FA80-4473-A2FD-87882EDCB222_zps6scbwvkt.jpg (http://s1265.photobucket.com/user/since19781/media/Mobile%20Uploads/2014-06/C6AF9D63-FA80-4473-A2FD-87882EDCB222_zps6scbwvkt.jpg.html)
A small tail light that will fit on my number plate holder. I want to eventually work out something light those radiantz led strips, so this'll do for now

[Dano919]

So I've spent a lot of time in a thinking pose out in the shed, and after reading a lot about fibreglass and watching a shit load of vids and looking at EXBENS posts (although I cAnt see the pics for some rean) I'm inspired to make a more integrated tail/seat/under tail. Albi was right on that in the end, thought I'd get it good enough but turns out once I had cut and moved and fiddled, I hated it. So the process begins to set up my mold. The missus is pissed though, she already thinks I'm spending too much time out there! Pics soon, and I'm going to post a question about people's regulator/rectifier relocations in the help section

[Dano919]

I picked up some goodies yesterday. Time to practice!
http://i1265.photobucket.com/albums/jj513/since19781/Mobile%20Uploads/2014-06/45181A15-D718-4393-A072-687BDB4AA699_zpsm3khypu3.jpg (http://s1265.photobucket.com/user/since19781/media/Mobile%20Uploads/2014-06/45181A15-D718-4393-A072-687BDB4AA699_zpsm3khypu3.jpg.html)

[aaa123]

Nice one, love the hornets. Had two 600 hornets. Was thinking of maybe using that led tail light as well.

Look forward to see how your fiber glassing turns out.

[Dano919]

So weekend just gone I did some fiberglassing
Made up my plug moulds for side covers and the seat - several coats of releas wax and a careful wipe down with PVA release agent
http://i1265.photobucket.com/albums/jj513/since19781/Mobile%20Uploads/2014-06/EA6A7828-668F-4C28-8528-CA280C505D87_zpsgh2frdrf.jpg (http://s1265.photobucket.com/user/since19781/media/Mobile%20Uploads/2014-06/EA6A7828-668F-4C28-8528-CA280C505D87_zpsgh2frdrf.jpg.html)
http://i1265.photobucket.com/albums/jj513/since19781/Mobile%20Uploads/2014-06/CB12E03C-1025-484B-9A5C-5B51B674E535_zps4oiovtan.jpg (http://s1265.photobucket.com/user/since19781/media/Mobile%20Uploads/2014-06/CB12E03C-1025-484B-9A5C-5B51B674E535_zps4oiovtan.jpg.html)
Cut my glass cloth, I used a weave that was recommended for the way it drapes
http://i1265.photobucket.com/albums/jj513/since19781/Mobile%20Uploads/2014-06/E5F25B60-92FF-4856-8DE2-F5DB2E0DC713_zps6gfxujbu.jpg (http://s1265.photobucket.com/user/since19781/media/Mobile%20Uploads/2014-06/E5F25B60-92FF-4856-8DE2-F5DB2E0DC713_zps6gfxujbu.jpg.html)
Scales put in a bag, didn't want to destroy the missus scales
http://i1265.photobucket.com/albums/jj513/since19781/Mobile%20Uploads/2014-06/E30FDD1B-12F7-46DA-A0D8-523465C81AE3_zpseykttwzh.jpg (http://s1265.photobucket.com/user/since19781/media/Mobile%20Uploads/2014-06/E30FDD1B-12F7-46DA-A0D8-523465C81AE3_zpseykttwzh.jpg.html)
After 30 minutes I had the side covers done
http://i1265.photobucket.com/albums/jj513/since19781/Mobile%20Uploads/2014-06/10A51DB9-0F11-43B3-A947-9A8721FF6BAB_zpsedzi8uz7.jpg (http://s1265.photobucket.com/user/since19781/media/Mobile%20Uploads/2014-06/10A51DB9-0F11-43B3-A947-9A8721FF6BAB_zpsedzi8uz7.jpg.html)
http://i1265.photobucket.com/albums/jj513/since19781/Mobile%20Uploads/2014-06/1D3EA8DD-ABAF-407C-9DB0-E22ED9CE93DC_zpsucvc3htd.jpg (http://s1265.photobucket.com/user/since19781/media/Mobile%20Uploads/2014-06/1D3EA8DD-ABAF-407C-9DB0-E22ED9CE93DC_zpsucvc3htd.jpg.html)
And after another 30 minutes the seat integrated to the race tail
http://i1265.photobucket.com/albums/jj513/since19781/Mobile%20Uploads/1650C60C-DF3C-4D44-8C01-099B300E77AA_zpsfvltwmth.jpg (http://s1265.photobucket.com/user/since19781/media/Mobile%20Uploads/1650C60C-DF3C-4D44-8C01-099B300E77AA_zpsfvltwmth.jpg.html)
http://i1265.photobucket.com/albums/jj513/since19781/Mobile%20Uploads/6ED0296C-ECCE-4B3E-A358-105925BEFF0E_zpsslpoebs1.jpg (http://s1265.photobucket.com/user/since19781/media/Mobile%20Uploads/6ED0296C-ECCE-4B3E-A358-105925BEFF0E_zpsslpoebs1.jpg.html)
http://i1265.photobucket.com/albums/jj513/since19781/Mobile%20Uploads/67B8B3C5-0FC5-4FD1-9643-67EE92B0AC8F_zpsjbtoj68m.jpg (http://s1265.photobucket.com/user/since19781/media/Mobile%20Uploads/67B8B3C5-0FC5-4FD1-9643-67EE92B0AC8F_zpsjbtoj68m.jpg.html)
So it wasn't the neatest job I've done, lots of resin and did not cut my fabric that neatly, and I ran down till the resin started to harden, but it's turned out smooth and I think neat enough to work with. Have managed to pull one side cover off its plug, so I know the release agents have worked.

[Gix11]

Have you joined that directly to the tail unit or were you just using it to get the shape? If you have joined it directly, what is the seat unit made from?

[Tony Nitrous]

Edit: stupid phone!

[Dano919]

Have you joined that directly to the tail unit or were you just using it to get the shape? If you have joined it directly, what is the seat unit made from?
I've joined it directly. The tail unit I believe is polyester resin over woven glass, I talked to the ppl at the shop about this and they recommended I use epoxy resin as it'll bond to polyester. I did a lot of cutting in as well and really exposed the fibres in the tail unit.

[Gix11]

Ok, should be alright then I guess. I thought for some mad moment that you had attached fibreglass to ABS. I use the word "attached" lightly in that sentence.

[Dano919]

Ah yeah I see what you're saying. I used the abs seat and foam as my plug mould, next stage is to remove it but leave key mounts in place, I can then build reinforcing into the underside of the seat, and it'll leave room underneath for electrics

[Dano919]

Plug removed, light grind back, and we have a seat that matches the bike.
http://i1265.photobucket.com/albums/jj513/since19781/Mobile%20Uploads/2014-07/9754C856-B095-472E-8F7B-DAEBC8F0E677_zps66spoduj.jpg (http://s1265.photobucket.com/user/since19781/media/Mobile%20Uploads/2014-07/9754C856-B095-472E-8F7B-DAEBC8F0E677_zps66spoduj.jpg.html)
http://i1265.photobucket.com/albums/jj513/since19781/Mobile%20Uploads/2014-07/3E97FAAF-3632-4E0E-BF41-AFEDBA7147EC_zpsi9cpv35b.jpg (http://s1265.photobucket.com/user/since19781/media/Mobile%20Uploads/2014-07/3E97FAAF-3632-4E0E-BF41-AFEDBA7147EC_zpsi9cpv35b.jpg.html)
http://i1265.photobucket.com/albums/jj513/since19781/Mobile%20Uploads/2014-07/E3658544-BC5A-4517-BD37-D42E2D85C2F0_zps6zbvdvro.jpg (http://s1265.photobucket.com/user/since19781/media/Mobile%20Uploads/2014-07/E3658544-BC5A-4517-BD37-D42E2D85C2F0_zps6zbvdvro.jpg.html)

[ozzy1100]

nice

[Bob]

looking good mate.

[Dano919]

Well, its been a while. so much has been going on in life that the bike has taken a bit of a back seat over the last 6 months, but I have slowly chipped away and with the arrival of the latest member of our family, a boy born just before December, I've taken 11 weeks long service leave and so things are moving much quicker. So heres a run down and some pics.

During December I finished tucking all the wiring, ECM, rectifier and coolant overflow up under the seat on a fiberglass tray I made myself. The tray also provides support to the rear of the seat so the tail/seat arrangement is supported in the middle as well as both ends.
http://i1265.photobucket.com/albums/jj513/since19781/68A89C48-6973-40A0-BF5B-4FF496CACA5A_zpsppozsbcs.jpg (http://s1265.photobucket.com/user/since19781/media/68A89C48-6973-40A0-BF5B-4FF496CACA5A_zpsppozsbcs.jpg.html)
Then a test of my wiring, the bike fired back into life after being off the road for a year. I then assembled and tested the lights etc.
http://i1265.photobucket.com/albums/jj513/since19781/C06F9CE5-45B0-49D4-940A-441D1AD0483E_zpsjoexhmqc.jpg (http://s1265.photobucket.com/user/since19781/media/C06F9CE5-45B0-49D4-940A-441D1AD0483E_zpsjoexhmqc.jpg.html)
EXBENS advice in making a saddle base was fantastic (Thankyou!) and a base was created in 'glass to fit a cheap seat foam I had.
http://i1265.photobucket.com/albums/jj513/since19781/EEE14C42-7231-4151-A545-818BC13BD980_zpsdzhauwuc.jpg (http://s1265.photobucket.com/user/since19781/media/EEE14C42-7231-4151-A545-818BC13BD980_zpsdzhauwuc.jpg.html)
Came up nice upolstered
http://i1265.photobucket.com/albums/jj513/since19781/8B28516F-4B6D-418A-B630-BBB99E7556BE_zpsxv23zcat.jpg (http://s1265.photobucket.com/user/since19781/media/8B28516F-4B6D-418A-B630-BBB99E7556BE_zpsxv23zcat.jpg.html)
Taken for a test ride, sans seat and muffler. It was great!
http://i1265.photobucket.com/albums/jj513/since19781/71B70BE2-B2B3-405F-885D-EA4B804E3AAD_zpsmgbrw8ol.jpg (http://s1265.photobucket.com/user/since19781/media/71B70BE2-B2B3-405F-885D-EA4B804E3AAD_zpsmgbrw8ol.jpg.html)

[Dano919]

Lets see if this vid works

http://i1265.photobucket.com/albums/jj513/since19781/th_6DE2D10A-58BB-429D-B2A3-A44C5990DDCD_zpsjqblqp2w.mp4 (http://i1265.photobucket.com/albums/jj513/since19781/6DE2D10A-58BB-429D-B2A3-A44C5990DDCD_zpsjqblqp2w.mp4)

After the ride I stripped it down again.
primer filler
http://i1265.photobucket.com/albums/jj513/since19781/94C24A6F-3FF5-4EA8-A0C3-4F444AD54125_zpswrtirbbl.jpg (http://s1265.photobucket.com/user/since19781/media/94C24A6F-3FF5-4EA8-A0C3-4F444AD54125_zpswrtirbbl.jpg.html)
Then some nice gloss black. I'm still going to vinyl wrap the tail so the paint is to create a good base. I did a little wrap test on the paint and its coming up well, certainly better than my paint job.
http://i1265.photobucket.com/albums/jj513/since19781/12A91787-A189-476B-B56A-E3FA25299A5A_zpshonssjiw.jpg (http://s1265.photobucket.com/user/since19781/media/12A91787-A189-476B-B56A-E3FA25299A5A_zpshonssjiw.jpg.html)
http://i1265.photobucket.com/albums/jj513/since19781/64E0D549-7E9D-4F2F-A891-6EAF22FE7AED_zps5fplsvqy.jpg (http://s1265.photobucket.com/user/since19781/media/64E0D549-7E9D-4F2F-A891-6EAF22FE7AED_zps5fplsvqy.jpg.html)
http://i1265.photobucket.com/albums/jj513/since19781/C3BFEFDA-E286-4204-9FAA-D0D722813369_zpskgqyyhkg.jpg (http://s1265.photobucket.com/user/since19781/media/C3BFEFDA-E286-4204-9FAA-D0D722813369_zpskgqyyhkg.jpg.html)

[ozzy1100]

Looking good

[Barra58]

^^^ as above, lookin good

[Gix11]

Nice work mate!

[BANDITROD]

Very nice mate well done

[whale]

Excellent skills with the wrap mate

Those labradors used to be white!

[Dano919]

vinyl wrap complete, saddle fitted
http://i1265.photobucket.com/albums/jj513/since19781/B51B9D81-E687-463C-9FC9-E5901C3C1A64_zpspjxfucpf.jpg (http://s1265.photobucket.com/user/since19781/media/B51B9D81-E687-463C-9FC9-E5901C3C1A64_zpspjxfucpf.jpg.html)
All fitted and ready to ride. Shortened the muffler as well. These shots I fitted the rear hugger
http://i1265.photobucket.com/albums/jj513/since19781/1EE3293E-5351-4015-BFBC-6A94635361C4_zpsvwihjcfh.jpg (http://s1265.photobucket.com/user/since19781/media/1EE3293E-5351-4015-BFBC-6A94635361C4_zpsvwihjcfh.jpg.html)
http://i1265.photobucket.com/albums/jj513/since19781/3C624C13-1826-45B9-B5F6-690929650898_zpsl9buhr8e.jpg (http://s1265.photobucket.com/user/since19781/media/3C624C13-1826-45B9-B5F6-690929650898_zpsl9buhr8e.jpg.html)
This time the hugger removed
http://i1265.photobucket.com/albums/jj513/since19781/7C80EE11-B6BE-4E30-B134-F433E71D35EC_zps7k1h6ldh.jpg (http://s1265.photobucket.com/user/since19781/media/7C80EE11-B6BE-4E30-B134-F433E71D35EC_zps7k1h6ldh.jpg.html)
http://i1265.photobucket.com/albums/jj513/since19781/image_zps2ghosf61.jpeg (http://s1265.photobucket.com/user/since19781/media/image_zps2ghosf61.jpeg.html)

[Bob]

Looks good mate, Like the tail.

[Large]

The pipe just says fuck you.

Me likey

[ozzy1100]

I likes the pipe as well, looks tuff

[hyofighter]

Nice work man looks the goods

[Dano919]

Thanks all, it's been good to get it to this stage. Now I just need to ride it a bit!

[M.V.]

Tail looks great mate, really transforms the old Hornet!

Is that a Dan Moto Jisu exhaust?

[Dano919]

Yes its a dan Moto and it was quite easy to shorten too.

[The Phantom]

Tough looking bike.