DO THE TON

REGIONAL info on Meet-up, Burn-outs & other events => DTT United Kingdom => Topic started by: NoRiders on Jun 08, 2017, 13:27:42

Title: Latest project - Suzonda WTF200/2 in progress
Post by: NoRiders on Jun 08, 2017, 13:27:42
Hi (if anyone is actually reading the UK posts? :/ ) Thought I'd post a quick review of my latest project.

I'm working with what I have and trying to budget hard as I can't really justify another bike, but couldn't resist throwing parts I have or obtain uber cheaply together.

I fancy a 2smoker lightweight street tracker style ring a dingding bike.

I had the Honda frame, scored a cheap SB200 engine, then went to Kempton and bought the swingarm, forks, wheels and headlamp for a total of £75. Facebook turned up the CB200 tank for £72 delivered and I'm on my way heheh ;)

Here'tis.

(http://i77.photobucket.com/albums/j60/LemonBUG/20170607_164846_zpsgqx1rlng.jpg) (http://s77.photobucket.com/user/LemonBUG/media/20170607_164846_zpsgqx1rlng.jpg.html)
Title: Re: Latest project - Honduki WTF200/2 in progress
Post by: beachcomber on Jun 08, 2017, 13:50:58
Oh,oh. -  another gem in the making !
Title: Re: Latest project - Honduki WTF200/2 in progress
Post by: Maritime on Jun 08, 2017, 13:52:32
looks good so far
Title: Re: Latest project - Honduki WTF200/2 in progress
Post by: NoRiders on Jun 08, 2017, 14:41:39
Oh,oh. -  another gem in the making !

Thanx beachy......not too sure it'll turn out a gem.......cubic zirconia perhaps ;)
Title: Re: Latest project - Honduki WTF200/2 in progress
Post by: NoRiders on Jun 08, 2017, 17:08:11
looks good so far

I'm nearly there haha!
Title: Re: Latest project - Honduki WTF200/2 in progress
Post by: Alex jb on Jun 08, 2017, 17:12:23
That could be a good laugh to ride if it all comes together with the right trail and rake


Sent from my iPhone using Tapatalk
Title: Re: Latest project - Honduki WTF200/2 in progress
Post by: NoRiders on Jun 08, 2017, 18:12:53
That could be a good laugh to ride if it all comes together with the right trail and rake


Sent from my iPhone using Tapatalk

I hope so Alex ;D Still got to align the set up, including the swingarm/shock mounts to raise the rear a touch. The forks look to be fine in length and tyres will make a difference too.
Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: Popeye SXM on Jun 08, 2017, 22:57:45
I'm in, looks like you are having fun
Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: Titan performance on Jun 09, 2017, 16:34:33
You have my attention.........sounds fun !
Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: NoRiders on Jun 09, 2017, 16:41:09
I'm in, looks like you are having fun

I'm enjoying the parts sourcing and spec finding exercise. Lots more to think about compared to my previous CBX project....this needs much more detailed attention to make it work.
Keep'em peeled.
Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: NoRiders on Jun 09, 2017, 16:41:58
You have my attention.........sounds fun !

Thank you....yoo da man when it comes to Suzuki 2smokers I hear ;)

Next job....strip engine...yikes!!
Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: NoRiders on Jun 09, 2017, 16:42:58
Rear brake system turned up still connected, bled and working ha!

(http://i77.photobucket.com/albums/j60/LemonBUG/20170609_193350_zpss5mhuvuv.jpg) (http://s77.photobucket.com/user/LemonBUG/media/20170609_193350_zpss5mhuvuv.jpg.html)

Do I paint the caliper red, gold or silver?  :-\
Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: NoRiders on Jun 11, 2017, 22:01:36
The engine teardown begins :D

(http://i77.photobucket.com/albums/j60/LemonBUG/20170610_131836_zpszrkupymf.jpg) (http://s77.photobucket.com/user/LemonBUG/media/20170610_131836_zpszrkupymf.jpg.html)


(http://i77.photobucket.com/albums/j60/LemonBUG/20170610_133305_zpsl5vesmid.jpg) (http://s77.photobucket.com/user/LemonBUG/media/20170610_133305_zpsl5vesmid.jpg.html)


(http://i77.photobucket.com/albums/j60/LemonBUG/20170610_132418_zpsqi5ctrlg.jpg) (http://s77.photobucket.com/user/LemonBUG/media/20170610_132418_zpsqi5ctrlg.jpg.html)
Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: NoRiders on Jun 12, 2017, 18:26:25
Engine wedged in :D

(http://i77.photobucket.com/albums/j60/LemonBUG/20170612_181121_zpscmfyeve1.jpg) (http://s77.photobucket.com/user/LemonBUG/media/20170612_181121_zpscmfyeve1.jpg.html)
Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: Maritime on Jun 13, 2017, 09:10:59
OOOOH! I didn't know it was going to be a 2 smoke, I like it even more now.
Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: NoRiders on Jun 13, 2017, 19:39:41
OOOOH! I didn't know it was going to be a 2 smoke, I like it even more now.

*OooH YES :D





*said in a Yorkshire accent
Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: NoRiders on Jun 16, 2017, 06:32:46
Been buying agin...;)

(http://i77.photobucket.com/albums/j60/LemonBUG/GSX1100axle_zpslrgmuu2m.jpg) (http://s77.photobucket.com/user/LemonBUG/media/GSX1100axle_zpslrgmuu2m.jpg.html)

GSX1100 axle spindle with fittings.
SB200 clutch plates
Gudgeon pin circlips
NSR front axle spindle

I've decided the default is 'hope it fits?' on this build haha!
Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: NoRiders on Jun 29, 2017, 09:42:19
Been buying agin...;)

(http://i77.photobucket.com/albums/j60/LemonBUG/GSX1100axle_zpslrgmuu2m.jpg) (http://s77.photobucket.com/user/LemonBUG/media/GSX1100axle_zpslrgmuu2m.jpg.html)

GSX1100 axle spindle with fittings.


I've decided the default is 'hope it fits?' on this build haha!

After an hour on the bench wirewheel....:)

(http://i77.photobucket.com/albums/j60/LemonBUG/20170628_231331_zpskfjfsv1r.jpg) (http://s77.photobucket.com/user/LemonBUG/media/20170628_231331_zpskfjfsv1r.jpg.html)
Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: UK Mark on Jun 30, 2017, 18:36:32
What's the photo bucket thing about?  I can't see any pictures now  :(
Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: NoRiders on Jun 30, 2017, 19:18:59
(http://i77.photobucket.com/albums/j60/LemonBUG/20170628_231331_zpskfjfsv1r.jpg) (http://s77.photobucket.com/user/LemonBUG/media/20170628_231331_zpskfjfsv1r.jpg.html)
Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: NoRiders on Jun 30, 2017, 19:23:00
What's the photo bucket thing about?  I can't see any pictures now  :(

Not sure what's going on Mark...my photobucket account seems OK. I posted another image link but the same warning popped up??

The url photobucket.com/sp500 is a dead link??

I've reported the post to admin, let's see what they make of it? Any other posts/members affected I wonder?
Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: Tim on Jun 30, 2017, 19:29:15
Apparently a real problem.  I havent read all of it but i dont think i can do anything from my end.

https://www.ghacks.net/2017/06/30/photobucket-now-charges-399-for-third-party-hosted-images/
Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: UK Mark on Jul 01, 2017, 18:08:07
Just upload images from your phone, photobucket looks like it just committed suicide asking for that fee
Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: beachcomber on Jul 02, 2017, 08:06:22
Here's a little [ true ] story.

About 3 years ago [ been using PB for 8 ] I had some weirdness going on when I accessed the my PB account.

The next time I logged onto my computer [ 4 hours later? ], I found I had been hacked. :o

Coincidence surely - however when I checked around with some mates who use PB, they ALL had the same experience .............. like I said - coincidence ?

The problem is that not all of the forums I use have a facility to load pix direct from my PC [ don't use phones ].

So, anyone know of PB equivalent not related to Dick Turpin ? 8)
Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: Tune-A-Fishİ on Jul 02, 2017, 13:03:38
Yep photo bucket just phucked a lot of users.


Sent from my iPhone using DO THE TON
Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: NoRiders on Jul 03, 2017, 14:00:24
Imgur image hosting test copy.


(http://i.imgur.com/FokeWG4.jpg)
Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: NoRiders on Jul 13, 2017, 16:54:41
Small step forward. The NSR axle spindle actually fits the 'forks with no name'. The threaded end is to small but long enough to get a nut on the end of it. I'm happy with that, so long as no one spots a problem?

(http://i.imgur.com/vtLtrAP.jpg)

(http://i.imgur.com/JShIVLS.jpg)

Would anyone know/recognise this logo on the 36mm forks?

(http://i.imgur.com/L4st9wV.jpg)

(update) The forks are Paioli brand, nice quality Italian aftermarket and OEM manufacturer, well pleased to find that out.  :D

Cheers
Title: Latest project - Suzonda WTF200/2 in progress
Post by: farmer92 on Jul 13, 2017, 22:55:38
I'm not certain, but the threads might get bent around if they aren't threaded into the forks.
That side of the axle would then only be held in place by the friction of the nut, leaving room for some end play under loads.
Maybe only a mm or so, but its something to consider.

Unless the axle sits tight in the fork on a non threaded length, in which case just ignore me.


Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: NoRiders on Jul 14, 2017, 03:00:20
I'm not certain, but the threads might get bent around if they aren't threaded into the forks.
That side of the axle would then only be held in place by the friction of the nut, leaving room for some end play under loads.
Maybe only a mm or so, but its something to consider.

Unless the axle sits tight in the fork on a non threaded length, in which case just ignore me.

Yeah, that's why I am asking Farmer. The stepped spindle does sit snugly, and is clamped on the rightside. I could have the axle mount faced off 1-2mm to allow a deeper nut to torque it down correctly? Or have a replica spindle made up with the correct thread?
Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: farmer92 on Jul 14, 2017, 07:24:50
It's not the nut clamping properly that worries me.
If you only have threads sitting in the fork leg, i would be worried about them (threads) collapsing and the spindle having play.
You might not feel it by hand, but it will be there.
You might get away with putting some good thread locker or jb weld around the threads that only sit in the fork, but i would not leave it as is.

I wonder if there is a helicoil that could fit over the spindle and through the fork leg properly? That would be ideal.
Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: NoRiders on Jul 14, 2017, 14:19:05
It's not the nut clamping properly that worries me.
If you only have threads sitting in the fork leg, i would be worried about them (threads) collapsing and the spindle having play.
You might not feel it by hand, but it will be there.
You might get away with putting some good thread locker or jb weld around the threads that only sit in the fork, but i would not leave it as is.

I wonder if there is a helicoil that could fit over the spindle and through the fork leg properly? That would be ideal.

I see what you're saying, the stepped spindle has a threadless part that sits snugly in the l/s mount...then the threads start. So it's bedded solid on the l/s as if it were using the threads. I can check this by using a nut and see how it behaves. I need spacer/speedo drive now. 

I like the idea of a helicoil to reduce the thread down to fit the spindle I have, and then cap it with a nut/washer as well :)
Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: NoRiders on Sep 16, 2017, 13:52:11
Another blinding day rummaging around Kempton.

Here's the lastest haul for the WTF 200/2 project:

(https://i.imgur.com/iewUaNb.jpg)

Brand new ignition switch unit with keys = £1

20x330mm GS axle to modify = £2

Throttle with alloy switch gear - £1

Suzuki SB 200 gasket set = £20

Thick biker socks = £10

Spotted a good few further solutions to forthcoming requirements I think. Great day out and it only showered on us once :)
Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: unclerob on Sep 17, 2017, 05:15:40
I was at Kempton too Colin and almost bought something that would have been useful for you....it was a helicoil kit for repairing various sizes of drain plugs and might well have worked on your fork leg....he is nearly always there, mainly sells rubber/neophrene sheet etc but has a few tools as well....had 2 kits still there when I looked, red boxes, £15 a go....might be lucky next time!
Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: NoRiders on Sep 17, 2017, 08:01:13
I was at Kempton too Colin and almost bought something that would have been useful for you....it was a helicoil kit for repairing various sizes of drain plugs and might well have worked on your fork leg....he is nearly always there, mainly sells rubber/neophrene sheet etc but has a few tools as well....had 2 kits still there when I looked, red boxes, £15 a go....might be lucky next time!

Ah yeah, helicoil the axle threads to fit/fill out to suit the spindle I have...check! Concentrating on the arse end at the moment.

Were you trading?, we used the car park entry and I looked where you were when we met, but couldn't see you? Had a good mooch and my mate got nearly everything he was looking for :)

Your bikes are looking very smart.
Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: unclerob on Sep 18, 2017, 04:59:43
Thanks Colin.... no I was just buying stuff on Saturday...have a stand at Ardingly end of next month and trying to get things finished with a bit of time to spare!
Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: NoRiders on Oct 22, 2017, 18:17:39
Parts incoming....

(https://i.imgur.com/peLqJhC.jpg)
Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: NoRiders on Jul 06, 2018, 14:52:31
Hi gents, back on this after a house move mothballed the project.

Scored a pair of Microns that might beat into shape and fit?

(https://i.imgur.com/14HNEEl.jpg)

And bagged a bag of SB200 engine/gearbox bits....the engine has been apart so it just might be missing a few key items, hopefully these may come in handy ;)

(https://i.imgur.com/zcDiq21.jpg)

If it ends up looking even a bit like this BSA I'll be pleased.

(https://i.imgur.com/vuKrSrl.jpg)

More anon...thanks for checking in :)
Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: NoRiders on Jul 06, 2018, 19:13:16
Cleared the workbench with a sweep of my hand.....screwed a couple of melamine boards to extend the area. All set to get to work.

(https://i.imgur.com/nFzAEFw.jpg)

These are the stock 18mm carbs....anyone know if an upgrade is viable? I do have the tops and sliders...attached to the cables.

(https://i.imgur.com/HXNtMos.jpg)

I've been looking at the chinese (I know I know) 26mm+ carbs for not a lot. A mate fitted one to a souped up scooter which worked out very well.....any real life, tried it liked it reviews?
Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: farmer92 on Jul 06, 2018, 20:35:21
I used them
Recently on a 150cc gy6 buggy
They are ok
Use genuine mikuni/keihin brass if you can.
The chrome on the slides were subpar.
Other than that they do the job as well as expected.
Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: NoRiders on Jul 07, 2018, 11:55:48
I used them
Recently on a 150cc gy6 buggy
They are ok
Use genuine mikuni/keihin brass if you can.
The chrome on the slides were subpar.
Other than that they do the job as well as expected.

Thanks for that farmer....I'm certainly leaning towards them tbh. Liking the black versions too ;)
Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: NoRiders on Jul 09, 2018, 18:40:24
Small steps......clutch actuating mechanism cleaned and the connecting rod straightened as well as the cover plate.

(https://i.imgur.com/3GhklOr.jpg)

Also, checked the kickstart mechanism, turns the engine over a treat :) The conrods/bigends appear to be good with absolute minimal lateral movement and no discernible wear on the big end. I'll change the small ends as they're straight forward and cheap.
The crank turns over cleanly using either conrod, I can't detect any resistance of roughness in the rotation.
I'm gonna replace the main bearings and crank seals as a matter of course.

Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: NoRiders on Jul 14, 2018, 20:34:46
Talking to a fella on Facebook who produces custom decals and stickers. Roughing out what I had in mind for the tank....70's style, in GSX-R colours.

(https://i.imgur.com/LcQZY6i.jpg)

The tank will be painted appliance white (to match the wheels) and the blues will be decals including a 3d Suzonda badge possibly?

Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: beachcomber on Jul 15, 2018, 04:27:00
That looks good  ;)
Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: NoRiders on Jul 15, 2018, 08:27:46
That looks good  ;)

Ha...shoulda gone to spec savers!

(https://i.imgur.com/oftGR2b.jpg)

This version has had a bit more time on it, but the general jist is there, which I think works with the shape of the tank and the 70's look I'm after, thank you.
Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: NoRiders on Jul 15, 2018, 08:29:45
Bought this last night....

(https://i.imgur.com/U9BbYmb.jpg)

..barrel with carb intakes for the price of intakes alone....gotta be worth having a spare barrel, right?

Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: NoRiders on Jul 17, 2018, 12:35:18
I've just been quoted £80 cash for a rebore to match my supplied pistons. Ebay offer pistons for circa £25 (£50 for a pair including little ends, rings and circlips).
I'll need to take the barrel there to determine the existing bore and then decide on the oversize required, source them and have it done.....bit better than PJME at £170 including pistons & VAT. £40 is a saving towards the budget.
Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: pidjones on Jul 17, 2018, 15:36:29
Back in the 70's I really hated the sound of a bunch of two strokes together (even though I had an RD250, RD400, and Penton 125). They are so rare these days that I really miss their rasp.
Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: NoRiders on Jul 17, 2018, 21:30:31
Back in the 70's I really hated the sound of a bunch of two strokes together (even though I had an RD250, RD400, and Penton 125). They are so rare these days that I really miss their rasp.

That's what I wanted in my life a bit of ringa dingding, the Microns should help in that dept...:)

Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: NoRiders on Jul 18, 2018, 08:57:13
Happy I am.

A mate came good on a HPI check on the frame number and I now have the reg number GFC***S so I can gain a V5 in my name....yay!  :D
Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: NoRiders on Jul 20, 2018, 14:55:24
Part of the enjoyment of a project is the parts chasing. I spotted a reduced SB200 barrel on ebay. The price £30 was nearly the same as the carb inlets go for £25...so what the hell?

Turned up on time and in better order than I expected and inlets attached, so quids in :)

(https://i.imgur.com/eviYPkO.jpg)

I've got the inlets and the bores are in better shape than mine, so a quick hone, measure for new pistons or rings and it'll be good to go :)
Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: pidjones on Jul 21, 2018, 08:33:22
Measure the bores for roundness and if in spec you are gold! Wish I could find and old Yamaha 2 cyl 2 stroke for the next build.

I found a local one-man shop that reground the valve seats (total eight) for my GL1000 in 10 minutes for 10 dollars US. Walked in, asked if he could do it and work it in, he asked if I had them with me, I went to the truck and brought them in (might have helped that they were sparkly clean). He refused any more. Even reground an old intake and exhaust valve to check the seal.
Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: NoRiders on Jul 22, 2018, 10:44:22
Measure the bores for roundness and if in spec you are gold! Wish I could find and old Yamaha 2 cyl 2 stroke for the next build.

I found a local one-man shop that reground the valve seats (total eight) for my GL1000 in 10 minutes for 10 dollars US. Walked in, asked if he could do it and work it in, he asked if I had them with me, I went to the truck and brought them in (might have helped that they were sparkly clean). He refused any more. Even reground an old intake and exhaust valve to check the seal.

Good old boys are hard to find, nice one.

I chanced upon this 200 twin on a motorcycle Facebook group, found a good few other items that way, rather than venturing into the murky depths of fleabay and it rogues.

CB200 tank in good nick with chrome gas cap and trim £60.
Micron expansion chamber exhausts in good nick (needing a clean) with barrel clamps £80

Thanks for checking in
Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: NoRiders on Jul 23, 2018, 14:11:36
Honing kit incoming.....


(https://i.imgur.com/fn0wc0L.jpg)

I didn't buy the £8 kit as I thought this one might work better and last longer...anyone with experience?

My bargin barrel (as it's now known) looked nasty in the images, but that was protective wax, it cleaned up a bloody treat, better than my existing one. Possibly get away with a thorough honing instead of a rebore, which would be a complete result.
Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: NoRiders on Jul 24, 2018, 18:10:00
Loom incoming...

(https://i.imgur.com/Zn95A7g.jpg)

Ebay 'best offer' £26 delivered. Can't complain.

Thought it might come in handy at some point  :)

Boring post I know, but as I'm documenting the process this is required...thanks for putting up with it....interesting stuff will happen, I promise heheh.
Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: NoRiders on Jul 24, 2018, 19:49:58
Bought this last night....

(https://i.imgur.com/U9BbYmb.jpg)

..barrel with carb intakes for the price of intakes alone....gotta be worth having a spare barrel, right?

Update on this barrel. It did look nasty in this image, but it was protective wax and cleaned off to reveal bores in very good condition. Some light marks below the piston ring line but no noticeable wear.

(https://i.imgur.com/eviYPkO.jpg)

The carb inlets cleaned up real nice and I'll be using this barrel as the existing barrel had two stripped exhaust stud threads and needed a rebore.

So my £30 just might've saved me £170. + £25 for inlets ;)
Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: NoRiders on Jul 30, 2018, 19:25:54
Honing kit used tonight, barrel/bores looking OK I reckon. Not perfect but they should do if pistons measure up to fit.

Also, the loom has been trialed and all appears to be in order. Connected the major components such as regulator, spark box, coil pack, indicator relay.....I'm sure I (my son) can adapt to suit the 400/4 frame and bar controls too.

(https://i.imgur.com/OHx3kjx.jpg)


In other news...I've temp fitted the front disc to wheel and wheel to forks as I need a suitable caliper......anyone advise please?

Clearance between mount and disc = 20mm.

(https://i.imgur.com/sfRXhRx.jpg)

(https://i.imgur.com/F3jUg0J.jpg)

Mount to mount dimension - 60mm

(https://i.imgur.com/aMLpSrE.jpg)

I really like Yamaha calipers with the anodised star piston design, I wonder if they could be made to fit?
Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: NoRiders on Aug 01, 2018, 15:05:58
Blimey it very quiet in here these day...where is everyone....out riding? :)

A quick mock up of the Microns on the engine, just to see if they sit right....very pleased :)

(https://i.imgur.com/j1JqEeT.jpg)

(https://i.imgur.com/KwuSfkp.jpg)

(https://i.imgur.com/cROA5tT.jpg)

Judging by the lay out and length of the engine, that'll place the rear mounting tab somewhere close to the rear peg mount as a convenient location I reckon.

Liking the way they fit and look...fat expansion pipes in stove enamelled black will go nice with a glass blasted engine with black detailing.

Spoke to a local blaster & powdercoater today, £50 for each alloy wheel in appliance white, £80 to blast and powder the frame and the same for the tank too. The white will have a RAL number so I can have the plastic guards 2packed in the same shade of washing machine white ;)

Engine will be glass blasted which leaves a nice natural finish he tells me....liking the sound of that :)
Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: NoRiders on Aug 06, 2018, 11:10:10
The very nice people in DVLA have wrote me letter informing me that my copy V5 is incoming...yah!
Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: NoRiders on Aug 09, 2018, 19:02:11
Roll up roll up...get yer side panels...only £18 for three   ;)

(https://i.imgur.com/qXT88qO.jpg)


Honda 350 side panels with sharks gill vent a likes....me likes too. Hope they fit the frame haha!
Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: NoRiders on Aug 20, 2018, 14:46:38
All I'm sayin' is....it helps to have a mate who runs industrial power washing machines...;)

(https://i.imgur.com/PYC2YIL.jpg)

That must count as the easiest degrease I've ever done.

(https://i.imgur.com/B54pJD7.jpg)

Small steps....
Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: NoRiders on Aug 24, 2018, 06:37:39
Sourced a local (Witney, Oxfordshire) engineer who'll split and rebuild/true my crank with new seals and bearings....yay!

http://www.gardias-engine-services.co.uk/gallery1

Just need to order parts from Wemoto.
Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: beachcomber on Aug 24, 2018, 08:04:18
When I was using VW Beetle rear ends for my 356 Speedster replicas - I'd just get the rear end part I needed cut out and off to the lorry steam cleaners down the road. The gearboxes used to come back looking like new !

Nice pile of parts coming together there   8)
Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: NoRiders on Aug 24, 2018, 08:39:31
When I was using VW Beetle rear ends for my 356 Speedster replicas - I'd just get the rear end part I needed cut out and off to the lorry steam cleaners down the road. The gearboxes used to come back looking like new !

Nice pile of parts coming together there   8)

Haha...he's into aircooled VWs too and a handy mate to know ;)

The parts pile is growing....all I need to do now i simply bolt them together :)

Parts chasing is 50% of any project, I love it.
Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: NoRiders on Aug 27, 2018, 17:55:59
I finally got around to sorting my shithole out (till a work in progress but mucho better).....here's where the magic will happen :)

(https://i.imgur.com/sEGz0tW.jpg)

Polished the old CBX550 tank ready to sell....if you know anyone?
Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: NoRiders on Nov 19, 2018, 18:37:48
I spilled the guts of my 200 twin  ;)

Got it cleaned first.....always handy having a mamte who runs his own steamcleaning outfit.

(https://i.imgur.com/Oa78csY.jpg)

Turned out nice :)

(https://i.imgur.com/iLbWKDj.jpg)

Hit a slight snag....the cross head screw needed the correct 'persuading' to loosen.

(https://i.imgur.com/AvUNgJm.jpg)

Once that was sorted, the case split but put up a little fight....after 40+ years it came apart cleanly. Well, when I say cleanly, I don't mean clean.

(https://i.imgur.com/ndZXAiM.jpg)

Crank is now free, I'm dropping it into the 'shop this week to be stripped and fitted with new bearing and seals from Wemoto. I'll take the barrel and pistons in too have them measured for fit n tolerance. Hoping new rings and a good hone (which I have already had one pass over) should do it.

Whilst waiting to undo gear shift mechanism, I had a quick look at the carbs...

(https://i.imgur.com/xdTGoWK.jpg)

Bit grubby inside.

(https://i.imgur.com/VwBXmNG.jpg)

They'll clean up nicely I reckon.

So, headstock taper bearing ordered so I can pop the forks on to line up the axle spindle, spacers etc and find a suitable caliper. The forks are off a Malaguti XSM 50 super moto and the stock caliper is an AJP but it'll not suit the 320mm disc....hmmm....keep looking.

Got the frame out of the unit and into the garage so I can make progress on fitting the rear wheel/swingarm assembly......so I can align the drive sprocket and position the engine in the frame......according to my rough alignment it'll all line up a treat.

So, hopefully get to bolt this lot on :)

(https://i.imgur.com/peLqJhC.jpg)

Thanks for checking in.....I'll be updating more regularly as I'm revved up at the moment :)
Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: NoRiders on Nov 24, 2018, 20:01:44
In keeping with my 'use what I have' ethos, I think I've found my front guard....bit of jiggery pokery should have it looking right :)

(https://i.imgur.com/0BA2jFg.jpg)

oh yeah, and the garage is now 'live' !!

(https://i.imgur.com/xzit2yT.jpg)
Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: NoRiders on Nov 26, 2018, 17:42:18
For those of you still checking in....

The decal design for the CB200 tank....on a white tank.

(https://i.imgur.com/rkKZSBg.png)

Simple side panel design

(https://i.imgur.com/WB80SKz.png)

While messing with the frame and guards I think, as I'm not to keen to chop the frame, I just might take it down the flat tracker route. This would give me the tail unit to cover the stock seat subframe and stiffening bridge as well as allowing some bling that I quite like the look of ie: Anodised levers and accessories.

I think the tracker look will lend itself to the alloys and colour scheme too.

Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: NoRiders on Dec 02, 2018, 13:33:41
So, I'll be needing a longer fork stem then....:/

Spoke to my tame turner who can copy the Malaguti stem but add 15mm as it came up short when the taper bearings were installed which is a bummer, but just another obstacle to overcome.

I'll also need a 5mm spacer for the lower race as the bearing will sit too far inside the headstock and it may rub on the bottom yoke. The race has to be spaced 5mm from fully home which is about right.

He'll also make custom Delrin swingarm pivot bushes with one piece stainless steel liner as I couldn't find Metalastic steel/rubber bushes in the dimension required.
Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: NoRiders on Dec 08, 2018, 11:57:14
Brembos...nuff sed  8)

(https://i.imgur.com/C5hbfTa.jpg)
Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: NoRiders on Dec 10, 2018, 17:33:58
Swingarm trimmed to fit

(https://i.imgur.com/WwvBP9K.jpg)

Space for a wider tyre

(https://i.imgur.com/k7pTmMT.jpg)

Hagon slung on along with the rear wheel....linking the look :)

(https://i.imgur.com/5AaiEgF.jpg)
Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: NoRiders on Dec 13, 2018, 14:08:05
New fork stem in solid stainless = 20mm. :)

(https://i.imgur.com/E9IpGlW.jpg)
Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: NoRiders on Dec 18, 2018, 14:24:30
Decals incoming :)

(https://i.imgur.com/aJ8iWLE.jpg)
Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: NoRiders on Dec 21, 2018, 19:42:22
New fork stem in solid stainless = 20mm. :)

(https://i.imgur.com/E9IpGlW.jpg)

New stem installed.

(https://i.imgur.com/jttFfIJ.jpg)
Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: pitobread on Dec 21, 2018, 20:15:21
I saw those stickers posted in a facebook group I just joined,  neat build.
Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: NoRiders on Dec 21, 2018, 21:02:02
THANK you.

He's OK.  Worked with me from my rough outline to the finished product. He also supplies factory decals too.

Sent from my SM-J320FN using DO THE TON mobile app (http://'https://siteowners.tapatalk.com/byo/displayAndDownloadByoApp?rid=89466')

Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: NoRiders on Dec 22, 2018, 14:58:27
.....just might work as a flat tracker arse end on the Suzonda ;)

Something different from the usual perhaps?

(https://i.imgur.com/UF7QHuw.jpg)
Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: beachcomber on Dec 23, 2018, 18:25:54
I saw those stickers posted in a facebook group I just joined,  neat build.

That's great info - post it up in the UK suppliers section ?
Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: NoRiders on Dec 25, 2018, 06:31:36
That's great info - post it up in the UK suppliers section ?

Where's this UK suppliers section you speak of Beachy?

Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: NoRiders on Jan 01, 2019, 20:18:31
So, after a good few hours browsing various Honda model discs I think I might've found a workable alternative disc that meets the requirement.

A CBR250 could be it. The centre mounting looks likely to be the same as the NSR disc mount I reckon?

(https://i.imgur.com/kJCdkW6.jpg)

The NSR disc measure PCD 12mm hole to hole and the centre bore 10.5mm with what looks like a 5mm offset. I'm not too bothered about the diameter as that can be allowed for when mounting the Brembo.

(https://i.imgur.com/peLqJhC.jpg)

Don't suppose anyone has a definitive answer out there? Cheers Colin
Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: beachcomber on Jan 03, 2019, 06:27:07
Where's this UK suppliers section you speak of Beachy?



Under "Recommended - UK" - I'll try to change the title to make it clear !! A bit ambiguous.   
Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: unclerob on Jan 03, 2019, 06:37:28
If you've got problems with sourcing a disc Colin its worth talking to Nick at Allbike....he'll make a custom one to your spec for about the same price as a stock EBC one.....
http://www.allbikeengineering.co.uk/discs.php
Also, he makes fork stanchions as well.....good candidate for recommended list i think!!
Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: NoRiders on Jan 03, 2019, 17:52:56
Thanx for the refereral Unc, I'll bear him in mind.....I think I might've found an alternative disc off a 2010 CBR250.....just trying to get the breakers advertising them on ebay to run a measure over them for me....or even answer my messages and calls !! :/

I have also contacted EBC who have emailed me a template form to fill in and they'll come up with a match to my spec I hope.

This Brembo caliper had better be worth it haha!
Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: unclerob on Jan 04, 2019, 05:56:28
I've never had much luck with EBC but have one of their catalogues here if its of any use.....
Pic is of disc made for me by Allbike.....£70!
Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: NoRiders on Jan 04, 2019, 06:12:01
I've never had much luck with EBC but have one of their catalogues here if its of any use.....
Pic is of disc made for me by Allbike.....£70!

Wow, only £70! That looks like a lot of disc for the money. Thanks for the head's up.

I'm going to the next Kempton this January...are you?
Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: NoRiders on Jan 04, 2019, 06:39:47
CBR250 disc isn't suitable, shame.

But, thanks to Uncle Rob I'm now talking to Nick at Allbike about a solution. :)
Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: irk miller on Jan 04, 2019, 11:25:42
This dude needs to ship the US. 
Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: NoRiders on Jan 04, 2019, 11:39:17
I've never had much luck with EBC but have one of their catalogues here if its of any use.....
Pic is of disc made for me by Allbike.....£70!

Well, interesting convo with Nick...£280 will get me a custom disc which is waaay more than the £70 he did one for you for??!!

However, he's quoted for a 5-8mm spacer to allow the use of the NSR disc and centre it using shouldered mounting bolts....£40 quoted which is in budget I s'pose?

I'm to send him images so he can see what's required and figure a solution, which is cool :)

Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: NoRiders on Jan 04, 2019, 16:41:06
A simple google search for 120mm PCD Honda motorcycle disc turned up a CB750 SOHC front disc and/or GL1000 rear.

It was el cheapo on ebay, 55 ins to run and should be with me by next week.

(https://i.imgur.com/hKGLTX0.jpg)

Hope it fits? :)
Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: unclerob on Jan 06, 2019, 07:44:55
£280 seems a bit much Colin!! I just checked the receipt for the last one I had....it was actually £65....I've had quite a few the same though so probably he's all set up to make them....just press a couple of buttons and theres another one!
Haven't been to Kempton for a while now....will see how the weather is looking....last time I went it rained all morning.....very grim!
Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: NoRiders on Jan 07, 2019, 11:22:43
Decals are in.....better in the flesh than they look in the images...very pleased ;)

Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: NoRiders on Jan 11, 2019, 15:16:28
Update:

Swingarm needle roller bearing are in. (forgot the crush tube though....bugger).

(https://i.imgur.com/MvPXTB9.jpg)

Decided to clean up the main engine cases the traditional way.....srarting to look OK.....main drill died on me :(

(https://i.imgur.com/OaQX7sD.jpg)

Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: beachcomber on Jan 19, 2019, 08:08:53
Keep on keeping on ! 8)

Looking good, can't wait to see the finished project .... or at least a rolling engine / chassis !!
Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: NoRiders on Jan 19, 2019, 10:30:19
Keep on keeping on ! 8)

Looking good, can't wait to see the finished project .... or at least a rolling engine / chassis !!

Thanx Beachy....I' trying to keep motivated, my son's helping with daily checks on progress haha!

I have hit a few snags that need working out so it looks like slooow progress but it's mostly in hand.

Swingarm pivot will be a 2 or 3 piece bearing roller & crush tube turned out of stainless and should fit together as a one piece once in. Awaiting a swingarm bolt to get the i/d required.

Front disc is a challenge.....EBC custom build options next me thinks.

Seat unit will need serious chopping....I can see where I want it to go...;)

Engine cases cleaned ready for the rebuild....which I'm trrepadatious about if I'm honest.....just where do all the part go?? A ball bearing fell out of somehwere the other day...WTF??!! Where from I have no clue?

Thanks for checking in.....:)
Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: NoRiders on Jan 19, 2019, 20:46:39
This is a first...a part that just fits on :)

Having mislaid the CB350 side panels I bought......I've bitten the bullet and purchased a pair of 400/4 side panels, in pretty good nick, with only one small crack which can be repaired.

They'll do and will look smart in white with the decals I already have :)

(https://i.imgur.com/I7fs9rk.jpg)

Sorting barrel/head studs in readiness for the engine rebuild.

Keep checking in folks....
Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: NoRiders on Jan 21, 2019, 17:00:43
Finished cleaning the main engine cases and bought some VHT black.....think I'll go black for the centre cases and glass blasted side casings, barrel and head.

The black Microns will look smart alongside that combo I reckon.

Also, my lad popped in and we got a bit more mocked up....swingarm will work with the primary and drive sprocket lining up and the chain angle to the pivot will work we reckon.

Side panels, rear guard insert, swingarm and engine in place (awaiting engine mounting bolts to arrive). The Honda top mounts line up perfectly, I have a plan for the lower rear and will also make the top and lower front mounts........starting to look like a bike at last.

(https://i.imgur.com/QGnHpNf.jpg)

Bought some white/grey primer as I want to give the side panels a quick prep and blow over along with maybe grey on the frame to see how the colours work in real life. More anon....

Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: NoRiders on Jan 27, 2019, 15:38:52
Found sometime today....:)

Primed in white a side panel and grey primered the frame around it jsut to see how the white grey would look...me likey.

(https://i.imgur.com/6rbjW8A.jpg)

The scratch was caused by the seat unit...trial fitting ready for the chop.

1st cut is the deepest..

(https://i.imgur.com/rFRqw13.jpg)

A lot more fettling to tidy it up and get the lines right. Also, the arse end will be trimmed down too.

(https://i.imgur.com/bJXHhPw.jpg)

I took a leap and cut the seat mounts/lock off.....oooeerrr!

(https://i.imgur.com/hMzmwQb.jpg)

Received the extra barrel studs and clened them up.

Looking to use stainless shoulderred nuts on barrel/head.....will they be OK?

Thanx for checking in.
Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: NoRiders on Jan 28, 2019, 18:17:42
A job I'd been putting off to be honest.....repairing the hole in the float.

Needn't have worried, turned out OK....

(https://i.imgur.com/Zgs8aPn.jpg)

Also, had another go at cleaning the carbs using Wurth Carb Cleaner...good stuff but they also needed scotchbrite to remove a limescale like coating.

Pleased I left one carb intact to be a model should I forget how they go together.....

(https://i.imgur.com/DtZ7JGs.jpg)

However, through all the grime I noticed one jet missing from the clean carb, the small one next to the main jet....bugger, cannot find it....yet!

(https://i.imgur.com/s43vlJ6.jpg)

Anyone got one?
Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: NoRiders on Mar 21, 2019, 19:21:46
Hey....I've not gone away.

Been waiting for my tame turner to produce the goods....

(https://i.imgur.com/cVJZOY4.jpg)

Had a pair of needleroller bearing races that spigot into the modified crush tube, to form one piece centre, which has turned out well.
Also, he's made me a L306 s/s spindle bolt with open threads on each end so I can use stainless nylocs to pinch it up.

(https://i.imgur.com/xT9JNL8.jpg)

Meanwhile, towards the front end I've made a first attempt at mounting the Brembo.....getting there with my first attempt to get into my rough mock up. I'm trying to get my head around how the final adapter will look.
Any advice on what material to use? I'm thinking 4mm mild steel plate with spacers welded to it.

(https://i.imgur.com/O9gEP8g.jpg)

(https://i.imgur.com/IuuX7an.jpg)

(https://i.imgur.com/hWqfaB1.jpg)

Ignore that the caliper isn't aligned with the disc....it'd slipped on the loose bolts.

I need metric fine thread bolts.
Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: beachcomber on Mar 22, 2019, 07:59:14
Nice work as usual. 8)
Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: NoRiders on Apr 13, 2019, 14:30:30
Nice work as usual. 8)

Thanx beachy.

After a week away on a European farewell tour (heheh) I managed some time in the garage.

Wanted to finally sort the swingarm pivot.... I had to shave off another 1.5mm from the swingarm body to allow the 1mm PTFE washers to sit snugly.
I don't have access to a milling machine so a cutting disc and file did the job :)

(https://i.imgur.com/KeiOeiV.jpg)

I made PTFE washer/dust covers to protect the needle roller bearings from shit.
Bought a flat sheet of white PTFE and cut/shaped/drilled them into the size I needed. They fit between the pivot point, sitting larger than the inner bearing race so I can now tighten the swingarm spindle fully.

(https://i.imgur.com/r9B9Rrl.jpg)

Threading and mild steel tube arrived so I was able to fashion the front lower engine mount...ears/lugs will be welded to locate the engine casing once I jiggle the engine into position.

(https://i.imgur.com/4La7eKn.jpg)

Doesn't seem much, but the swingarm can now be installed so I can set the rear wheel in position...once it and the front forks arrive :)

(https://i.imgur.com/kq6dF3j.jpg)
Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: NoRiders on Apr 28, 2019, 17:57:44
Replacement NSR125 forks/wheel/caliper installed....just need new taper bearings. And another top yoke.

(https://i.imgur.com/mWhT9QC.jpg)

Sprocket/swingarm alignment working out OK I reckon.

(https://i.imgur.com/tObUOnT.jpg)

Getting closer to final mount position for the engine.....any ideas on engine inclination datum?

 (https://i.imgur.com/5pSzBJy.jpg)

That's all for now

Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: NoRiders on May 12, 2019, 19:51:03
It's rolling...:)

(https://i.imgur.com/jTwBhei.jpg)

Aligned the rear wheel using threading and extra nuts....I now know the size of the spacers.

(https://i.imgur.com/6WeNdjt.jpg?1)

(https://i.imgur.com/tOjLJ5Z.jpg)

Stage1 engine mount fabrication..

(https://i.imgur.com/fKaABXO.jpg)

Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: beachcomber on May 14, 2019, 17:54:02
One cool ride !!!!! 8) 8)
Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: NoRiders on May 20, 2019, 10:47:10
When you're at a VW event and score a tyre cheap. £10 bargain 110/70x17" Kingstone tracker style tread pattern should do the job of sunny runs down the coffee shop I reckon ;)

(https://i.imgur.com/5MNg8WB.jpg)

Also incoming: 3x25mm flat bar for enging mounts.
Headlight mounts.

Moving along....
Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: NoRiders on May 22, 2019, 06:54:10
Front disc cleaned up well enough :)

(https://i.imgur.com/zPABZMj.jpg)
Title: Re: Latest project - Suzonda WTF200/2 in progress
Post by: NoRiders on May 23, 2019, 10:49:25
GT200 5xspeed, electric start engine....incoming.  ;D

(https://i.imgur.com/xJOkGfk.jpg)