A Kiwi build from scratch

[kiwiguy]

HI all, been lurking around the forum for a bit, and finally got all my plans sorted, so now to build me a new scooter. Concept is Cafe' style V twin with new suspension and brakes etc. I am looking at around a 12-16 month build if I am being realistic, so no major rush! started my build by sourcing some suspension components. Found a good donor bike 2007 GSX-R 1000K7, so all the suspension and brakes are sorted.

 

[kiwiguy]

Found me an engine in Florida on EBay, a 2003 Sporster Evo only done 1400mile's! It's like new, so snapped that up and had that shipped to the other side of the world

 

[kiwiguy]

Then time to make some benches to work on, so some 10mm steel plate to make a bike table and a new welding table, all adjustable to get square and bolted to the floor

 

[kiwiguy]

And now the fun stuff! ;D making things from scratch, so first up a new head stock machined up so I can start on my frame

 

[kiwiguy]

Right-O then, a box full of bends, some length of pipe and a Mig welder. Start with whats floating around in my head and see what is actually realialistic. I would dearly like to run the Gixxer suspension front and rear, and use the mono shock and linkage set up, I think that will look trick as! 8) but a little worried about how long this is getting!

 

[kiwiguy]

Don't think this is going to cut the mustard . I'm already over 1500mm wheel base at 27 deg!! mmmmmmm time for plan B

 

[kiwiguy]

So I cant draw the front in any closer, so need to shorten the ass up. Thought about cutting and shortening the OE Gixxer swing-arm, possible but wouldn't save a lot. Sooo had a look around and found something that fixes a few of my problems in one hit, so back on E Bay I go. the wife aint going to be happy if she see's how much I'm buying off there! Buell swingarm!!! much shorter, right hand drive to take the chain AND has the built in oil tank inside, mint!!

 

[Augydog1]

subscribed. ;D

 

[kiwiguy]

Frame time

 

[kiwiguy]

More frame time

 

[kiwiguy]

The rough out nearly there. Then to re do it all over again once everything in the correct place.

 

[cqyqte]

Just a question, what does the motor weigh compared to the original motor that came with the rear suspension and front suspension? Looking at the ground clearance of the frame I would worry that the center of gravity is going to be very top heavy. And last comment the neck will need a bracing tube that should run from the top back down to between the top frame rails.

 

[kiwiguy]

HI cqyqte, the engine weight difference is about 30 kilos I would believe, never had the original 1000 motor when I got the bike. The ground clearance is going to be around the same as a Buell XB12 and I cannot see any other way of getting the engine any lower in the frame, as the engine case actually sits lower than the frame rails. I have set the engine at the height I wanted, then started the frame off that. Also, this part of the frame I am playing with at the moment is just to get the engine in to see what fits where. There will be more cutting before the last section of frame is made up. Cheers, Glen

 

[canyoncarver]

Great stuff. Nice skills. Following along.

 

[unclerob]

Nice project! I'm just starting a V twin café myself.....tempted to build my own frame as well but in the UK that either means pretending its the original one or telling the truth and being made to jump through all sorts of bureaucratic hoops!
I'm guessing you're planning this frame as a mock up and then when its all sorted build another? If that's so would it be worth taking the featherbed theme a bit further and alter the top rails slightly to take a Lyta tank?

 

[kiwiguy]

Nice project! I'm just starting a V twin café myself.....tempted to build my own frame as well but in the UK that either means pretending its the original one or telling the truth and being made to jump through all sorts of bureaucratic hoops!
I'm guessing you're planning this frame as a mock up and then when its all sorted build another? If that's so would it be worth taking the featherbed theme a bit further and alter the top rails slightly to take a Lyta tank?

With our laws here, it has to be of 'sound construction and must be welded by a certified welder'. Yeah, this frame is the mock, once I get everything where I need it to be, will bend a new frame from mild, make a jig off that one and redo in chromoly. There is still another main backbone going to go from the top of the headstock to where I am going to mount the shock mount for the rear. I have left enough room at the top to run a good size section. There will be some added braces as you said at the front, just no point putting them on at the present as it's only another thing I will have to cut off, but the finished product will do for sure.

 

[kiwiguy]

Right O then. Buell swing arm runs a 20mm pivot bolt, GSXR runs a hollow 22mm. Found that my old SP2 runs front wheel bearings the same size, how convenient! So ordered some new bearings, pulled the old ones out, removed the internal spacer, turned it down to take the larger bolt and reassemble with the new bearings. This went a lot easier than I could have hoped for!! Once I get all the alignment's corrected, I will turn down some spacers to set it up in the right place.

 

[Erskine]

I'm in ... keep it coming!

 

[Brodie]

yep

 

[kiwiguy]

I'm in ... keep it coming!

will do