The Junker gsxr

[-Dex-]

Well, uni starts in a week and a half so I thought Id better remove the finger and get this piece of shit ready for daily riding duties as commuting by car would take far too long, not to mention parking, fuel, traffic etc. etc.

The victim is an 87 (I think?) Gsxr750 with several million kms on the clock in generally shitty condition. Sorry, I dont have any pics of it as I bought it but you'll get the idea.

As I said, this is NOT going to be a show bike, or even a decent build [:o)] but I thought I may as well share my progress.
Time and money are extremely tight so its going to be very ghetto and bare bones but it should do the job to get me to uni and back during he week and maybe a bit of rear wheel work on the weekends;).

Feel free to chime in with any comments, criticisms, ideas, and "I cant believe you're actually going to ride that booty fabbed peice of shit on the road" type posts. :D


Anyway, enough jibber jabber. On with the show...

[-Dex-]

I had these lying around and they seemed like as good a place to start as any.

http://i13.photobucket.com/albums/a296/v840/RG250%20build/The%20Junker/P2100009.jpg

I also bought some risers off egay.

[-Dex-]

Next, I removed the top triple clamp and started measuring. When I was happy, the pedestal drill was called into action and I got into it.

http://i13.photobucket.com/albums/a296/v840/RG250%20build/The%20Junker/P2100011.jpg

And from the under side.

http://i13.photobucket.com/albums/a296/v840/RG250%20build/The%20Junker/P2100012.jpg

[-Dex-]

After reading up on her as much as I could on whther to drill the top clamp, weld the top clamp, or buy a ready made top clamp from Stu or Ben, I decided to go down the ready made route. Unfortunately my wallet was being a tightarse and stopped me, so I went the drilling route instead.

If I had more cash, I would not hesitate to buy from Ben or Stu. I think this will be strong enough but I think both those guys top clamps look so much nicer. Anyway.

I added some 6mm steel plates underneath. When I pull all this apart again for painting (after rego), I plan on weding a brace between the two plates for added strength.

http://i13.photobucket.com/albums/a296/v840/RG250%20build/The%20Junker/P2100013.jpg

I also used hi-tensile bolts rather than the allen-head bolts supplied with the risers. I dnt have any scientific reason other than I didnt like the "looks" of the standard ones.

http://i13.photobucket.com/albums/a296/v840/RG250%20build/The%20Junker/P2110016.jpg

Sorry about the dark photos, my garage is small and dingy.

[-Dex-]

Bars bolted and loctited into position.

http://i13.photobucket.com/albums/a296/v840/RG250%20build/The%20Junker/P2110020.jpg

From the front.

http://i13.photobucket.com/albums/a296/v840/RG250%20build/The%20Junker/P1270005.jpg

I then put all the switchgear back in place.

http://i13.photobucket.com/albums/a296/v840/RG250%20build/The%20Junker/P2110022.jpg

[-Dex-]

I also have this to go on the front.

http://i13.photobucket.com/albums/a296/v840/RG250%20build/The%20Junker/P2230032.jpg

To be honest, the jury is still out on this. Im not too sure if I like it or not. I'll run it for now at least until rego but I may change it at a later date. I may change my mind when its painted. It sticks out like dogs balls at the moment.

[-Dex-]

If anyone cares, the costs to date: $930

Im hoping to keep it under $2K regoed.....

[-Dex-]

Next up, I removed the seat, tank, battery tray and basically got the subframe ready for its date with the grinder.

Now you see it.....
http://i13.photobucket.com/albums/a296/v840/RG250%20build/The%20Junker/P2240034.jpg



....Now you dont!

http://i13.photobucket.com/albums/a296/v840/RG250%20build/The%20Junker/P2240035.jpg

[03gixxerpilot]

dose that include the bike

[-Dex-]

And thats how its sitting right now. Im getting it to EXBEN's workshop later in the week to get some tabs welded on so that I can make up a bolt on subframe.

After thats all done, I have to make a seat for it, wire it all up, mount front light and guages, fix seized rear caliper, rego, get to riding.

http://i13.photobucket.com/albums/a296/v840/RG250%20build/The%20Junker/P2240036.jpg

[-Dex-]

Yeah mate, the bike was $900 and the headlight was $30.

Im actually into it little bit less than that as I bought it with most of the fairing which I sold for $150.

Its definitely going to be budget.

[03gixxerpilot]

nice, what plans do you have for the tail what are you using.

[Seifer]

Oh cheap and nasty build. Love it!

[-Dex-]

Um well, Im not really sure. I have a kwaka636 tail or a later model gixxer tail. They're pretty much the same but Im leaning toward the Kawasaki as it already has a brake light, mudguard (only for rego), and rear seat whereas the suzuki is only the plastics. If I had more time Id prolly go the suzuki to keep it in the family but for now at least I think I'll just go the 636.

[03gixxerpilot]

go for the 636 tail unit as they are nice looking, and better still you got most of the parts there. fighterising a bike is about what looks good and not so much about keeping it in the family

[-Dex-]

Yep, cheap and nasty, just like its owner.


03gixxerpilot, you're right dude but I hate building shit to a schedule. I like being able to agonise over every decision and detail, not throw it all up in the air and hope it lands in the form of a streetfighter. Like you say though, I'll use what I have. I can always rebuild it later on when I have time and money.

[03gixxerpilot]

part of building streetfighters, rebuilding them till we are happy with them

[Gix11]

Dex. Couple of things mate. The drill holes in the triple are not level from side to side. I know that's petty but it leads on to my next bit, you have bolted your risers to the 6mm plate at the bottom yea, but the plates themselves are not attached to the clamp right? Nor do they have any kind of spacers between the plate and the bottom of the clap where the holes are? Is that right? If this is right, although they feel tight in your garage as soon as you get out on the road those bottom plates are going to shift mate, and so are your bars. Even more so because they are not straight (my original point). This will lead to them eventually shearing the bolts mate and you having the bars come off which isn't attractive. Can I suggest you do away with the plates and bolt it directly to the triple clamp mate? This way there will be no movement and it will be a lot safer. If that is not possible because the holes are too close to the edges (as I have just noticed) Maybe you could find some billet aluminium or similar that is the same width as the gap from the clapm to the plate and drill two holes in it and cut the ends off to make a support for the bolts. Do you get what i mean? Alternatively, if you're going to see Ben anyway, can you pint out my concern for him to check? Don't want you coming unstuck mate and I just want to make sure that's all.

Other than that, keep up the good work mate.

[-Dex-]

Gix, after reading what you wrote (about 12 times till I got it [:o)] ) I think I know what you're saying.

You're saying that the bolts need lateral support so they cannot move around in the hollow area of the clamp right? To be honest I didnt even take that into consideration as I thought that they would be tight enough on there own.
Im not sure what you mean by the holes not being level though? I measured and re-measured with a micrometer before drilling and I thought they were sweet. Are you seeing something that Ive completely missed? I did do it at about 3am so it wouldnt suprise me.

Like I alluded to, I did it this way as needed to be done quickly but if its going to crap out like you say I will definitely change it up. This is my first proper bike build so Im in unchartered territory here :D

Thanks heaps for the heads up mate, its much appreciated.

[Cruisecontrol]

quote:Originally posted by -Dex-


are you seeing something that Ive completely missed? I did do it at about 3am so it wouldnt suprise me.



http://www.streetfighters.com.au/forum/upload/39244507195531.jpg


Just looking at the symetry of the top yoke indicates that things are a little amiss with the holes.
I considered drilling myself but thought safety is one thing I shouldn't skimp on.
Otherwise, love the build. :D

i think thats a 86...wack up the 1st few frame numbers. with that offset yolk your bike will steer tight and fast thru rights but you'll fight it thru lefts.excellent for clockwise race tracks...
ya havn't really damaged the casting stringers too much so it should be right.

...and foto number 7, man you seriously just won the cleanest shed floor contest,is there a fuckin bike in there somewhere?

[-Dex-]

Fuck. Now you point it out I see what you mean. Might see if I can get another top clamp and have another crack at it. Yet another reason why working on my bike shouldnt be a mixer for my JD. I cant believe I missed that, Im such a retard.

Davo mate, that is clean! My parents and brother all emmigrated OS a couple of years ago and before they left they dumped ALL their shit in my garage "for a couple of weeks". Fuckers.
That, and the fact that I have two other builds going on simultaneously sort of clogs things up. No excuses but, it is a shithole.:D
I'll tidy it up eventually. Maybe.

[Zed14]

get set of clamps with one mounting bolt and get a set of 1100 clamps.

[fimpBIKES]

if your going to see ben, and the clamps and top yoke are aluminium

just give him 20 bucks or whatever to weld the fuckers on, it'll be worth not having to worry about it mid-corner!


built should be SWEET, love how your not fucking about
you only paid $30 for one of those headlights? i paid about 100 a few weeks back!

[-Dex-]

Yeah fimp I'll talk to him and see what he says.

Gix and Cruisecontrol have got me thinking that I shouldnt muck around when it comes to safety though so Im seriously considering gettin a top clamp off Stu or Ben. Tax return should be coming so I really have no excuse to be a tightarse. Pffft who pays bills on time anyway?

[scotty mac]

i used a similar head light but with the halogen bulbs(thanks rod).
i removed the oringinal lights n mounted a single beem spot light in it using ally brackets.

http://www.streetfighters.com.au/forum/upload/53668290085982.jpg

[Gix11]

Hey Dex, yea, you got my drift but you just said it much clearer than I did!:

"the bolts need lateral support so they cannot move around in the hollow area of the clamp"

That's exactly it.

Cruise pointed out what i meant about not in line also.

The 1100 clmap is wider and that is the one I drilled.

If you're really fucked for money just now and you have the same diametre forks legs I have this kicking around in my shed to get you on the road if you want it?: http://www.streetfighters.com.au/forum/topic.asp?TOPIC_ID=6608 - looks pus but does the job. It was the first conversion I did over here when I had no time to take it off the road.

[-Dex-]

Hell yeah man. How much you chasing for them?

[Gix11]

What size fork tops do you have mate. Let me check to see if they fit first. If they do we'll sort it out then.

[pesh]

good work m8 , and on a tooiggght budget .. how's it guna go with the rear subframe chopped off .. will u need an engineers report ..? as its part of the frame and it has been changed . i know i copped that here in melbourne .. keep up the good work and keep them pics coming

[kookaburra]

good job dex great to see you having a go
and top job gix and everyone else great to see some support instead of assholes dragging some one down like so many other sites

[Bear]

I'm with Kooka - it's great to see so much support from relative strangers. Nothing to be prescious about.

Soldier on, Dex. :)

[-Dex-]

Thanks fellas, thats one of the reasons i love this site.

Gix, Im not at home at the moment so I cant check but from memory they're around 33~34mm fork diameter I think. Will be home later this evening, will check then for sure.

[Gix11]

No worries mate. 34 sounds famialiar. I'll wait for your reply.

[-Dex-]

Hey dude, just checked and its actually 40mm diameter.

[Gix11]

I fucked up as well. I knew it had a 3 and a 4 in it. It's 43mm. Oh well. Sorry mate, close though hey?

[-Dex-]

>< This close! Thanks again for the offer though mate.

[-Dex-]

Small update.

Nothing much has happened this week as Ive been flat out with work, but I did manage to bolt on a 4inch longer brake line......
http://i13.photobucket.com/albums/a296/v840/RG250%20build/The%20Junker/P2260037.jpg



.....and some mirrors

http://i13.photobucket.com/albums/a296/v840/RG250%20build/The%20Junker/P2260038.jpg

Nothing earth shattering but two less things on the to-do list.

[-Dex-]

Okay, another update.

Got it back from Ben today with the subframe tabs welded to the main frame.

http://i13.photobucket.com/albums/a296/v840/RG250%20build/The%20Junker/P3040047.jpg

Check out those welds! mmmmmmmmm tig.......



He also fixed up the clusterfuck that was my top clamp. He welded everything back up and re-drilled it. Much better now. Ive also promised myself never to drink and work on the bike again. [8)]

http://i13.photobucket.com/albums/a296/v840/RG250%20build/The%20Junker/P3040048.jpg

[-Dex-]

So I had planned to get a 636 subframe from a wreckers to save a bit of time and effort, but the $700 they quoted me seemed excessive. Like I said to Ben, Im not sure if the guy I spoke to was having a bad day or something but fuck that.

So anyway, I guess its on with the original plan and make one myself. Two whole cuts with the dropsaw and two holes with the drill later I had the beginnings of my main bars. I sat the tail on there to get some perspective.

http://i13.photobucket.com/albums/a296/v840/RG250%20build/The%20Junker/P3040043.jpg

http://i13.photobucket.com/albums/a296/v840/RG250%20build/The%20Junker/P3040042.jpg

[-Dex-]

And that's where Im at for today. Tomorrow Im planning on rattle canning the tail, tank and light to try and get a bit of uniformity happening and hopefully getting the subframe sorted. As usual, I'll post pics.

Just one more to give you an idea of the mess Im working in. Im this close to chucking everything! :(

http://i13.photobucket.com/albums/a296/v840/RG250%20build/The%20Junker/P3040045.jpg

[Weaselman]

mate thats a fab budget build. Really happy to see such good results on a shoestring.

Keeping it real

[03gixxerpilot]

Dex that is coming along VERY nicely, looking good.

keep the pics coming

[Jockney Rebel]

nice work dex mate..... get up here

[Cruisecontrol]

Looking good.

What is the caper with your fork travel? It looks like they will bottom out if you hit a lane marker...

[Gix11]

That's what it is! I knew something looked strange but couldn't put my finger on it. Well done Dan. What is the go there Dex? Are they the original fork sthat came with the bike and have you ridden it like that?

By the way, still like what you're doing mate. Good on ya.

[Darn]

Nice job there Dex, stuff the $700 for the wreckers. go the home built subframe.

http://www.streetfighters.com.au/forum/upload/716552827249401.jpg

[-Dex-]

Thanks Darn, thats the sort of thing Im looking at. Nice job there mate. Very nice.

Gix & Cruisecontrol, the forks need rebuilding badly. They are pretty much cactus. I have ridden it round the block, but not on a proper trip. It will be getting sorted before I start riding though. Im tossing up between rebuilding this one or getting another complete front end to bolt in.

The braking system also needs some fairly urgent attention too. I'll be getting a rear caliper rebuild done and a new rear master cylinder in the next week or so as well as a new front lever/master combo.

It seems that for every one thing you fix, you find two more things that need work hey. Oh well, thats the nature of the beast I spose.

[kookaburra]

thats a good pic up there Si if your seeing the same thing i am ?

Dex from the bottom of your bottom fork clamp to the top of your fork leg there is not much room for travel before the forks hit the clamp or is there some thing i am missing ?

[fimpBIKES]

shit $700 for just the subframe?!?!?


whole r6 rear was less than that a month or two ago
i think you definitely got quoted by a prick!


knock it up yourself mate, the steel in mine (looks like yours, 25 SHS?) cost about $2 ;)

[scotty mac]

hey dex that subby that darn made has adjustable lower bars so ya can raise the tail up or down. something like that would look sweet with that tail.

[descendingfear]

Very nice. Going to look good when completed.

[pesh]

ya should go for the shorty tail look , i reckon it would look sweet as on this

[-Dex-]

UPDATE

Well, I missed my start of term deadline by a country mile :(
but I have been making a little bit of progress.
I started welding up my subframe, but just after this shot was taken I ran out of gas.:(
I dont have time to go and get any more till mid next week which sort of fucks me up but you have to roll with these punches.
http://i13.photobucket.com/albums/a296/v840/RG250%20build/The%20Junker/P3100070.jpg

I also started making up a seat following Exben's advice from here.
No where near as nice/professional as his but it'll do me......at least until I get sick of it and make another one. [:p]
http://i13.photobucket.com/albums/a296/v840/RG250%20build/The%20Junker/P3070058.jpg

[-Dex-]

Also painted the headlight and tank.

Before:
http://i13.photobucket.com/albums/a296/v840/RG250%20build/The%20Junker/P3070056.jpg

After:
http://i13.photobucket.com/albums/a296/v840/RG250%20build/The%20Junker/P3070060.jpg

And the tank:
http://i13.photobucket.com/albums/a296/v840/RG250%20build/The%20Junker/P3070064.jpg

I toyed around with the idea of adding flames to the tank (you can make out the tape in the above picture) but after spraying it looked truly, truly shit so I just painted over them. :D

[-Dex-]

Anyway, getting ever closer to completion. With uni underway my time is severely limited on this thing but Im still aiming to finish it as soon as possible.
http://i13.photobucket.com/albums/a296/v840/RG250%20build/The%20Junker/P3140073.jpg

http://i13.photobucket.com/albums/a296/v840/RG250%20build/The%20Junker/P3140077.jpg

Still to do:
Finish subby.
Final sand seat and cover.
Fork rebuild (probably need new springs).
Rear brake MC/Caliper change (have replacement parts ready to go).
Front MC/lever.
Figure out mounting for guages.
Wiring tidy-up.
Fix anything else tha breaks along the way. [B)]

[-Dex-]

Ps thanks for the kind words guys! Keeps me motivated!

Pesh, what do you mean by "shorty tail look"? Like a single seater or something? Cause Ive been having similar thoughts myself :)

[pesh]

chop that shit down man .. bring the plastic in so it meets up with ur tank ,, it will look the bomb .. its what i did with my old gsxr , it was sweet as , with plenty of seat left

[pesh]

m8 im shit with photo shop but ya get my drift

http://www.streetfighters.com.au/forum/upload/34829958559488.jpg

[BANDITROD]

This is what mark is talking about dude it would be heaps sweeter and wouldnt cost anymore either btw you are doing a great job man
http://www.streetfighters.com.au/forum/upload/34829727876069.jpg

[BANDITROD]

shit you beat me to it peshh

[oldskool]

Nice to see another slabby in town , what state do you linger in?

[-Dex-]

Hmmm you might be on to something there pesh. Will be looking into that for sure.

Im in Shitney oldskool, its a fair way from Barbados but if you are ever in Nsw Im always keen to go for a blat. ;)

[pesh]

hahaha beat ya to it rod .. yeah thats definately what im sayin , and it will still leave ya heaps of seat

[Fish]

dex I'm well inspired mate. keep up the good work. you bringing it up for AFR? will it be ready by then?

[-Dex-]

UPDATE

Im still plugging away at this whore. Uni is eating up most of my time so Im just getting little bits and pieces done. The trend seems to be: I fix or modify something, and in the process of working on that one thing, I notice another three things need attention. Oh well, name of the game I guess.

Anyway, I decided against re-using the stock clocks as i would need to custom mount them anyway, and then wire up idiot lights etc, so in the end I just said fuck it and got one of these instead.

http://i13.photobucket.com/albums/a296/v840/RG250%20build/The%20Junker/acewell.jpg

I also found a dirty big crack in my airbox (sorry forgot to take a pic) so I decided to cut it out and replace with pods.
I thought the air filter was still in good nick when i pulled it out so I may hang on to it, never know when it will come in handy. What do you guys reckon? Still good or what?

http://i13.photobucket.com/albums/a296/v840/RG250%20build/The%20Junker/fuctfilter.jpg

[-Dex-]

I also came up with an idea to get my battery out from underneath my seat and relocate it up underneath my tank (in the newly liberated area where my airbox used to sit). More on that idea later but here's some pics of what i came up with.

Starting off the box.

http://i13.photobucket.com/albums/a296/v840/RG250%20build/The%20Junker/bbstart.jpg

Mocked in position
http://i13.photobucket.com/albums/a296/v840/RG250%20build/The%20Junker/P4040081.jpg

Nuvva angle
http://i13.photobucket.com/albums/a296/v840/RG250%20build/The%20Junker/P4040083.jpg

[-Dex-]

Ive got heaps more pics of the battery box build but I dont think its particularly intersting so I'll leave them out of this thread. This is how it ended up anyway.

http://i13.photobucket.com/albums/a296/v840/RG250%20build/The%20Junker/P4170097.jpg

Now, after I did all that and got it sitting in there sweet, I decided, as I often do, to change it up and get an R1 battery on its side up under the tail. I didnt like it under the tank, as unlikely as it is, Id be constantly worry about the battery shorting against the tank and KABOOM! Yeah, probably stupid but Ive never professed to be otherwise.[B)]

I also got the subby pretty much finished.

http://i13.photobucket.com/albums/a296/v840/RG250%20build/The%20Junker/P4200102.jpg

[-Dex-]

Here you can see the bracket I made for the ignition switch which Im relocating here to make way for the Acewell.

http://i13.photobucket.com/albums/a296/v840/RG250%20build/The%20Junker/P4140089.jpg

I also started work on a headlight/indicator/Acewell mount

http://i13.photobucket.com/albums/a296/v840/RG250%20build/The%20Junker/P4200101.jpg

Which is where Im up to. Like I said, nothing too exciting but little things take up most of the time hey. The more I look at it, the less I like the subframe so I may modify it or cut it up completely and start again. Im also not at all happy with the job I did on my seat so Im thinking of redoing it with a wooden base (for ease of use) and some new foam. Im also tossing around in my head the idea of some neoprene to cover it with.

As always fellas, advice, criticisms and ideas are all welcomed.
Cheers,
Dex.

[-Dex-]

By the way, thanks for all the help and kind words already in this thread. You guys keep me inspired with the amazing work you all do on your bikes.

[xb9r]

Awesome work there mate, love budget builds they always get me thinking keep them updates coming I hope thats not a roach in the last photo could explain the tripple clamp fuck up hehehehehe

[-Dex-]

No shit I didnt notice that! HaHaHa its definitely not mine! I dont smoke!!

I only have lack of sleep, alcomohol, and ineptitude to blame for the clamp

[fimpBIKES]

great work!
R1 battery in the tail is going to be better in the wet anyways

keep us updated ;)

[pappas]

That's a thick gauge steel for the headlight bracket, any reason your going so thick? I'm assuming it's what you had laying around but would be very heavy. Yes?

[-Dex-]

Cheers Fimp, will do.


Yeah pappas, its just made from offcuts I had laying around. The box sections are 2mm wall and the flat bar is 4mm. It weighs around 1.2kg. including extra gusseting that isnt pictured.

I do realise its way overkill and not exactly practical but Im not too worried as Im changing the light up in the not to distant future anyway which will mean a lighter bracket. I got the current light cheap off egay and it doesnt look horrible (even though I dont like it) and I want to get it regoed and riding as Im going insane not having a bike to ride.

Once rego is out of the way, Im planning on redoing the subby with heim joints, new bars, new light, pull engine out to give it and the frame a fresh coat of paint, paint rims, shorten can and relocate under the frame, new levers and reservoirs, rearsets, etc etc. Its a fair way off being 100% but yeah, rego is the immediate goal.

[-Dex-]

Just to add to that last post.

Before rego I have to:
Redo the seat. My first effort would probably get through rego ok but every time I look at it it bugs me so fuck it, its going.
Sort wiring, which Im in the process of doing (I fucking HATE wiring).
Sort Acewell.
Get exhaust mounted properly.
Give it a general tidy up/clean.
Few other little odd jobs.

Then I just have to find a dodgy mechanic who does blue slips for beer. If anyone knows one in Northern Sydney, hook me up! ;)

[Cruisecontrol]

I went to one in Hornsby that knows nothing about bikes. He checked the lights and tyres...

Broady Automotive Repairs
Unit 1, 4 Leighton Pl Hornsby NSW 2077
ph: (02) 9476 8300