HollywoodMX's xv920/TR1 Cafe super-dupe!

[HollywoodMX]

Top end disassembled. Pistons off to Arias and cams off to megacycle for some custom high performance shiiiiiiit..

 

[mikeinnh]

Top end disassembled. Pistons off to Arias and cams off to megacycle for some custom high performance shiiiiiiit..

What's the nature of the work being done?

 

[HollywoodMX]

Re: Re: HollywoodMX's xv920/TR1 Cafe super-dupe!

What's the nature of the work being done?

High lift 495 cams focused on mid and top end.

Performance Springs with Ti retainers.

Custom high compression pistons 10.5 or 11. Either 93mm or 97. I haven't decided yet.

Raising the red line form 6500 to 8k to capitalize on the overall build further.

 

[andrewmac805]

Wow! Your bike is looking awesome! Now that's a good looking seat! And wheels, and tank, and exhaust, and suspension, and engine! Very nice! Can't wait to see it all together!

Sent from my SCH-I545 using Tapatalk

 

[HollywoodMX]

Thanks guys. I'm away on vacation for two weeks so not getting anything done but I had some parts nice parts waiting for me at the hotel made by the cognito guys that are forum vendor. Billet upper tree and longer gsxr steering stem.

I took advantage of shipping my piston and cams too while I'm in the US. The girlfriend was very patient about that. Lol.

When I get back I will be jobless as I search for a new contract. So I will be making accelerated progress.

 

[HollywoodMX]

Back from holidays and excited to make some progress. Some new parts to show.

 

[Djfob]

Feels like Christmas every time I get parts in the mail

 

[Finnigan]

Like those levers, what are they?

 

[HollywoodMX]

Feels like Christmas every time I get parts in the mail

Me too, except xmas is almost every week for me and my girlfriend gets jealous..lol

Like those levers, what are they?

Higher-priced knock offs from ebay. You have to be careful as there are multiple copies of this lever but only a few with higher precision than the others. Zoom in on the pics especially near the folding part and you will see some vendors have rougher edges and others have more precise edges. Also zoom in on the bolts as some have higher quality bolts.

 

[HollywoodMX]

So I promised a video of the making of the lower frames rather than posting all the pics. I put in a bit of effort on it so I hope it's enjoyable and edumacational. ;D

Enjoy!!

http://youtu.be/eyzhcG3BetY

 

[HollywoodMX]

Well well well. What do we have here from the postman..

 

[beachcomber]

Ah gotcha, why don't you put a washer for each bolt in between the sprocket and wheel?

Yep did that !!!!!!!!!!!!!! But I really want to get a decent shim spacer made up.

 

[HollywoodMX]

Well some interesting adventures today.

So for the rear wheel sprocket studs rubbing the swing arm, mark that as solved. I pulled out a couple studs and replaced them with R6 allan bolts and that solved that issue, it's close but not rubbing. Once my axle spacer is made I will be able to tell fully but I "might" need to grind the swingarm for tire rub but not 100% sure. When I hold it a certain way it doesn't rub.

I tackled the rear shock. WHOLLY That shock is HEAVY. The speed triple is a 1/4 of the weight it seems. I lucked out with some of it. The TR1 swing arm cross bolt fits perfect to the lower shock pivot hole, it just needs a spacers like the stock one. The top mount the speed triple pivot hole is smaller than the TR1 bolt and the reservoir bolt is hitting on the inside too. I decided to weld in a new mount that mounts horizontally, that way I can also solve the reservoir bolt issue. I found a scrap section of the stock subframe that will fill the role nicely. This will also get me some ride hight back as I will mount it closer 1" to rear wheel which will end up getting me a 1" higher that stock (speed triple is 14.5", stock is 15").

 

[HollywoodMX]

Oh SHEEEIIIIIT! She's broken!!... lol.

Also did a bit of cleaning of the new 980 cylinders for the machine shop.

 

[Rich Ard]

Finished the rear set pieces. Video will come once I'm back from vacation.

Those came out really well, Hollywood.

 

[HollywoodMX]

Those came out really well, Hollywood.

Thanks man, I plan on painting them with POR so I'm not worried about the blemishes here and there.
I was thinking yesterday as I was trying to install the speed triple shock, measuring engine details for the engine build up and battling with rear tire clearance; I was thinking FAK!!! I went a little crazy with this bike! There isn't a tonne of work to go compared to what’s conquered already in either execution or plan but I think I might have gone too far, I probably should have done the engine the following year. Oh well.

Progress? Well I dropped off most of the engine parts to a motor shop.

- engine work part 1 - trimming of the cylinder sleeve. DONE!
I didn’t want to split the cases in swapping cylinders to bore the case larger so I thought why not reduce the lower cylinder sleeve OD. So I got that done.

- custom rear axle tube (GXR1000 to TR1). DONE!
I wanted to use the TR1 swing arm cause I like it and I can weld shit onto it. This was my solution.

So what are the big items left?

GENERAL
- make custom mono shock spacers
- mount the mono shock 100%.
- swap stems. New cognito gsxr stem.
- finish the wiring. (fak!!)
- install gauges. (I’m thinking of reconditioning the stock tach because I can’t decide which one I want).
- install ignition.
- install new rectifier.
- install controls and misc wiring.
- make custom headlight mounts.
- make custom gauge bracket.
- clean up frame cutting and box in open areas.
- make new frame bracing. (I have a real cool idea for this.)
- close up the old frame airbox.
- make a custom rear fender.



ENGINE
- engine work part 1b – boring and hone.
- clean engine, polish x parts.
- Engine port & polish
- engine work part 3 - assemble new cylinders, cams and pistons.
- make the rear sets fully function with brake activation and rear reservoir mount.
- Create custom offset countershaft sprocket
- Install chain.
- fab a new front fender possibly from the old one.
- clean fcr carbs.
- design the fitment of the fcr carbs.
- drill out triple tree for various mounts
- Custom ignition key mount
- mount license plate holder
- create rear mini-fender.
- order custom brake lines.

PAINT
- paint frame. por.
- paint swingarm. por.
- new parts, subframe, lower frame, headlight mounts, etc. por.
- coat exhaust. ceramic paint.
- paint engine. por.
- paint gas tank. 2k paint.
- paint front fender. 2k paint.
- re-paint the mufflers. por.
- headlight bucket. por.

MISC
- probly 10 million other things I didn’t think about when I made this list.

 

[HollywoodMX]

So I was thinking about (gasp) plasti dipping my wheels...

Hear me out brothers!

The reason is I was actually wanted to protect them cause I am all nervous about scratches, dings, rock chips, etc.. and its reversible.

I was thinking of doing something like this with orange (the picks below are plastidip), keep in mind I am doing a gulf theme paint job with the blue as the primary, orange as the secondary and white and black as the....thirdary..lol.

Thoughts?

 

[johnu]

You mentioned your tyre rubbing on the swingarm, we get that all time with supermotos. One option depending how much rub you have is to just trim a couple of mm's off of the outside edge of the tyre, i've done this many times and it is easy to do with a woodworking plane. I know it sounds cowboyish but it works!

I know this is no help but I couldn't bring myself to paint over those beautiful wheels!!

 

[HollywoodMX]

You mentioned your tyre rubbing on the swingarm, we get that all time with supermotos. One option depending how much rub you have is to just trim a couple of mm's off of the outside edge of the tyre, i've done this many times and it is easy to do with a woodworking plane. I know it sounds cowboyish but it works!

I know this is no help but I couldn't bring myself to paint over those beautiful wheels!!

Ya it looks like I have about 2mm now with my new axle installed. So after the tires warm up it "may" rub. That's ok. I will grind down the swing arm tube there and weld a small dish in its place. No biggy.

As far as painting them.. Im just worried about them getting dinged up.. Maybe if I plasti-dip them a more subtle color like metallic black or dark metallic grey..

 

[Rich Ard]

I say go for it - worst thing that could happen is you have to do them again and you're out twenty bucks.