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The RC30 fairing has big vent holes on the sides that I didn't really like for this build, plus it was a weak spot that had caused the gel coat to crack. I decided to fill them in. I built some aluminum panels to fill the holes, and I'll glass these in when it gets warmer outside. Spring is...

One last major component is half done. I finished the front half of the 4 onto 1 collector, and got the link pipe assembled. Right now I have this D&D muffler fitted, and it could run with this, but I really want to do the curved aluminum muffler like the original race bikes. I haven't...

Well, 2024 has been a s**t show so far. Hurt my back moving snow, got sick for a month, and had a total computer melt down. But, I've still been plugging away at the project. I'm reached the tipping point of the 80/20 rule, where the last 20% takes 80% of the time. Fairing - I resurected an RC30...

Finished the fender mounting, and the dashboard setup.

Front fender fitted and nearly mounted. Fender and arched brace hand formed aluminum.

Christmas eve progress. I finished the mount for the rear master cylinder and reservoir. I also "finished" the gauges/dash. The black 3d printed cover over the speedometer will be replaced with a machined aluminum part. The 5 grommets will hold LED's for the turn signals/high beam/neutral/oil...

On the original racers the sear is mounted up above the frame rails I didn't really like this so I lowered the seat to cover the frame rails. This was all good until I actually sat down on the the seat. With the rearsets I was going to use it felt like my knees were up into my armpits. I spaced...

The CBR600F4 fork were finished in a really rough cast texture, where as the RCB race bikes had smooth for legs. Doing the brake side was a P.I.T.A, but using a combination of the lathe, an air belt sander, and much manual sanding I finally got it smooth. The non brake side was much easier as I...

After much searching I finally found the tank rubbers that I was looking for. I could find them for a good price, but the shipping to Canada was crazy, or I could find good shipping but the price was 2-3 times more than the cheaper ones. I finally found some from Mead Speed in the UK that were...

Well, 4 years have passed, and I am finally back on this build. Hope to have it running this summer if I can stay focused. I braced the frame over the summer.

Hey Eric, no build thread on the last 400F, it's top secret ;-) I'll email you some pictures.

Hey Eric, Progress is slow right now. We're enjoying some beautiful weather right now, and I'm out riding/tweaking/tuning my last 400F project. I'm just putting the finishing touches on the buck to do the fairing, so I'll post that in the next week or so.

I am only keeping the windscreen. I'll use the uppermost 2" or so of the fairing as a pattern to start building the aluminum fairing. Look back to the very beginning of the thread, you will see a CAD model of the fairing. The end result will hopefully be very close to the original RCB upper.

I made up a quick temporary bracket to start the process of building the fairing. Needed to check bar clearance.

I am going to try to make RCB half fairing from aluminum. I needed a windshield to start from so I didn't have to try to make something fit afterwards. I was going to use one from an NS400 since I have an NS windshield and fairing mounted on another bike, and I was going to use that as a...

Overall view of the bike so far. I don't like the look of the CBR600F4 fender, so I think I'll have to make one to fit.

I thought I'd take a shot of the tank template that I made before I threw it out. If you can make it out of cardboard, it will be easier to make in aluminum. If you can't make it in cardboard without creasing or tearing the cardboard, then that means you are going to have to stretch/shrink the...

Someone commented that I had way more equipment than the average builder, so I decided to make this rear caliper bracket by hand. (Well, truth be told I did use a drill press and a band saw. But, as a youngster, I made lots of parts like this with a hacksaw, angle grinder, and hand drill. With...

Finally got back to doing some more work on this project. I built a painting stand to paint the wheels. The stand makes it really easy to spin the wheel and get even paint coverage. Much easier than hanging them. The yellow is an aluminum primer.

Finally got some time to work on this project again. I got the tank pieces fitted and ready to be tacked together. (hopefully this week). And, my fuel filler arrived! I had a choice if this 80mm one or a larger 105mm one. I picked the small one, but now I wish I had picked the larger one. Oh...