drzsimon
Tyrannosaurus Rex
Posts: 70
Bikes: GSXR 7/1216 turbo, Buell 1125, Buell XB9, Buell XB12, Yamaha Slider 70cc
Reg: Jun 15, 2013 19:13:15 GMT
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Post by drzsimon on Jan 3, 2014 16:59:33 GMT
Well, 10 minutes later I was in the garage... Sorry about the poor quality of the shots, camera phone and not a lot of lighting in the man-cave... Fired up the milling machine (Bosch drill, de-burrer and assortment of files. OldSkoolSuzukis need OldSkoolTools ) So, cutting the radius at the front is going to take some serious hacksaw/filing time, so I thought it'd be better to attack the slots and fit the extenders from the rear (as in wrong-way-round) as I can get the fit without touching the front radius. Here's the pics. Only taking small amounts off at a time. If you look carefully, you can still see the powdercoat on the top and bottom of the slot. Getting there... In! Cleaned the powder off the rear of the arm as I wanted alloy on alloy, not crumbly powder coat... Note drill, deburrer and file close to hand... No more updates until tomorrow - promise! Simon
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Post by danny4646 on Jan 3, 2014 18:04:15 GMT
Looks good mate, interested in them extenders, been watching some for a while now as a bolt on/off mod for when (and if!) I make it to do some drag runs, looks like there decent quality too
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Post by katana on Jan 4, 2014 13:37:40 GMT
Mounted that way you've taken a f**kin' chunk off the spindle width - will you still be able to get a wheel and sprocket carrier in there?
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Post by danm54 on Jan 4, 2014 13:51:49 GMT
I think he plans to turn them around once he's altered them to fit the right way.
Not sure I'd trust bolt ons though, I'd be happier with them jigged up and welded.
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drzsimon
Tyrannosaurus Rex
Posts: 70
Bikes: GSXR 7/1216 turbo, Buell 1125, Buell XB9, Buell XB12, Yamaha Slider 70cc
Reg: Jun 15, 2013 19:13:15 GMT
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Post by drzsimon on Jan 4, 2014 17:26:50 GMT
I think he plans to turn them around once he's altered them to fit the right way. Not sure I'd trust bolt ons though, I'd be happier with them jigged up and welded. Yep, they are only fitted that way round as I haven't trimmed the front yet. I think they will be jigged and welded, although they aren't supposed to be, I probably will nless they prove to be very secure and very strong...
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drzsimon
Tyrannosaurus Rex
Posts: 70
Bikes: GSXR 7/1216 turbo, Buell 1125, Buell XB9, Buell XB12, Yamaha Slider 70cc
Reg: Jun 15, 2013 19:13:15 GMT
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Post by drzsimon on Jan 5, 2014 17:45:31 GMT
Bits arrived from Robinsons Clutch plates good. watercooled headgasket bad... Shopping at Newark was fun, spent a bit; loads of stainless nuts and bolts, bit of M10 fine stuff, couple of metres of high pressure hose and decent clips, 2mm alloy sheet for the plenum sides and tube for plenum to head steadys. Also got a pair of bloody great circlip pliers so I can get the turbo cold side to pieces, clocked and a couple of 90's welded on Alloy solder looking thing is one of those *revolutionary* alloy welding kits, hoping to do some of the plenum and air pipes with it, used one a few years ago, Lumiweld kit I think it was then, worked really good, just needed a decent flame, and I've a BOC portack now so no problems there Moving on to the garage, thought I'd have a look at those Kawasaki swing arm extenders as it was white over and bloody cold. So, out with the hacksaw, file and a cup of coffee and away we go with alternative excersize! Not too many photos, once I get into the groove there's no stopping me! Lots of filing needed to square up my on-the-piss hacksawing lol Luckily, I always cut well north of the final line So, a couple of hours later and we have nice fitting bits. All the powder has been removed from the contact areas where the alloy touches and they certainly bolt up secure. Little bit of fettling on the caliper inner mount so it locates in the slot used for the axle adjuster. Wasn't one on the other side... With wheel in. Will need to get a Kwak spindle as the Gixx one is about 10mm too short Has extended the wheel back a fair way! Just a couple of shots showing the rough distance I've got to get spacers made up to. ...And the drive side. All in all, I think the conversion's been a success, even with having to buy a spindle I'll have still done this for less than £80 - which is £100 less than I was quoted for extenders machined up alone. Certainly worth thinking about if like me, you don't like (and can't afford) to follow the chequebook herd Thanks for looking. Simon
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drzsimon
Tyrannosaurus Rex
Posts: 70
Bikes: GSXR 7/1216 turbo, Buell 1125, Buell XB9, Buell XB12, Yamaha Slider 70cc
Reg: Jun 15, 2013 19:13:15 GMT
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Post by drzsimon on Jan 16, 2014 19:04:11 GMT
Been quiet on the bike front, doesn't mean nothing's been going on in the background, been buying loads of bites, hopefully covering every base now. So, to start... When I got the Busa pistons the rings and gudgeon pins were in nice bags, wasn't until I unwrapped bags I found a distinct lack of lube and a touch of surface rust. I decided to use the GSXR1127 ones as they were sweet, except when it came to fitting them I noticed they were longer than the Busa ones bite the bullet and spent £20-odd quid on some new ones. Put the two orig base gaskets and the 2mm spacer plate on with a smear of grease ready for the home-coming celebration of the barrels touching the crankcases again Got the piston rings gapped, spaced and fitted into the bores with millions of gallons of oil... I'll not go into the fucking nightmare getting the gudgeon pins and circlips onto the pistons while trying the balance the barrels blah, blah, blah... Didn't take any photos though... While I was at it I decided to get the valves in the head - which was great except the last retainer popped out at great speed and the two collets went into the depths of my garage never to be seen again Going to start the wiring tomorrow, going to do the alternator mod (as the wiring from the alternator looked like it had been a bit hot at some point Next up will be mounting the scavenge, sorting the wiring, fusebox, warning led's and if I can wire the pumps (fuel and scavenge) to be activated by the oil pressure light. We'll see... Not had many (any) replies, which probably means: (1) Everything is being done right (2) Nobody's interested (3) I'm doing it so wrong eveyone's following point (2) Anyway'z, I'll stick with it lol Thanks for looking Simon
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Post by katana on Jan 16, 2014 20:25:25 GMT
Please tell us you didn't put the 4 pistons in the barrels and then tried to drop them over the rods? No wonder you had a mare! Easiest way is pistons on rods inc pins and circlips, get 2 & 3 to TDC and drop barrels over, edging the rings in one at a time. Push barrels down half way and rotate crank till 1 & 4 are touching barrels and do the same with the rings,then push barrels completely down on to base gasket. No balancing as pistons will support barrels.
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Post by captain chaos on Jan 16, 2014 20:32:37 GMT
Please tell us you didn't put the 4 pistons in the barrels and then tried to drop them over the rods? No wonder you had a mare! Easiest way is pistons on rods inc pins and circlips, get 2 & 3 to TDC and drop barrels over, edging the rings in one at a time. Push barrels down half way and rotate crank till 1 & 4 are touching barrels and do the same with the rings,then push barrels completely down on to base gasket. No balancing as pistons will support barrels. what he says. Putting the pistons i the barrels first works easier if it's a single cilinder or a twin, not on an inline-4.
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drzsimon
Tyrannosaurus Rex
Posts: 70
Bikes: GSXR 7/1216 turbo, Buell 1125, Buell XB9, Buell XB12, Yamaha Slider 70cc
Reg: Jun 15, 2013 19:13:15 GMT
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Post by drzsimon on Jan 16, 2014 22:46:24 GMT
Please tell us you didn't put the 4 pistons in the barrels and then tried to drop them over the rods? No wonder you had a mare! Easiest way is pistons on rods inc pins and circlips, get 2 & 3 to TDC and drop barrels over, edging the rings in one at a time. Push barrels down half way and rotate crank till 1 & 4 are touching barrels and do the same with the rings,then push barrels completely down on to base gasket. No balancing as pistons will support barrels. what he says. Putting the pistons i the barrels first works easier if it's a single cilinder or a twin, not on an inline-4.
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drzsimon
Tyrannosaurus Rex
Posts: 70
Bikes: GSXR 7/1216 turbo, Buell 1125, Buell XB9, Buell XB12, Yamaha Slider 70cc
Reg: Jun 15, 2013 19:13:15 GMT
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Post by drzsimon on Jan 16, 2014 22:52:00 GMT
what he says. Putting the pistons i the barrels first works easier if it's a single cilinder or a twin, not on an inline-4. Yup, know that now. Been a looong time since I built a GSXR engine, too used to RD 2-smokes... Well, makes better reading than "I took it to (insert specialist) and gave them a cheque for (insert stoopid amount of money) Hopefully have a better day tomorrow, I also didn't go to work today so have to make the hours up next week so all in all it was lose-lose... In the background trying to spec out boost gauges and piping, but I refuse to go to the "big boys". I'm doing this on my own whether it works or not. Although I'd prefer "works" smileystick
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drzsimon
Tyrannosaurus Rex
Posts: 70
Bikes: GSXR 7/1216 turbo, Buell 1125, Buell XB9, Buell XB12, Yamaha Slider 70cc
Reg: Jun 15, 2013 19:13:15 GMT
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Post by drzsimon on Jan 19, 2014 11:46:57 GMT
Hello again, been a funny week, managed to get Thursday off work, hoping to bosh the hours in the garage but that fell over big style Had a fair bit of messing around with the Dyna 2K I got off another forum member. We're at a bit of a loss with it so thought I'd put it up here an see if anyone knows what the prob is. This bit's OK (except there's not the proper button for the rev limiter so don't know where the limit is at the mo) The problem seems to be here: The backplate has been drilled a few times but the main issue is the pickups protrude past the hole... ...Meaning it's too close to the crank to get the sensor in I've had it on, off, on, off and there's definitely something amiss somewhere. There's signs the old stator had been catching whatever it was fitted to before as well: Any ideas would be extremely welcome. At the moment it's in its box and I've put the stock one on, but I need a solution as I can't afford to piss money against the wall, I'm too involved pissing money for other shiny things as it is Got my 16mm to -an3 adaptor fitted in the oil gallery, and also got the fitting for the turbo as well. Forgot to photo it... Need to order the oil return and find somewhere to source turbo gaskets and a 3-bolt exhaust flange so I can get the two exhausts designed. Also got the file out and got the bracket fettled/fitted for the scavenge and the pipes/wiring routed: Popped the MTC extender on so I can get an idea where the return is going to enter the clutch housing (he said "enter" lol) While I'd got the files out, I decided to finish the adaptor brackets to lower the 'Busa aftermarket footrests I got off another momber as well. I've not actually done a fitting for this but the Gixx footrests don't fit my (older) legs anymore - far too cramped, so a 3" drop should be OK. I've a fair bit of adjustment if needed anyway, plus I could always drill more holes in the plates. I even (with the help of the file) got the original 750 rear master cylinder to fit the rearsets as well Couple of spacers for the brake rod and we're done! T'other side: Also been looking at intercoolers, went to Sheffield to look at some generic motorsports ones but they were all massive. Could do with some ideas please guys! Just putting another order in to Robinsons so (hopefully) transmission will be restored next Friday after I've worked extra hours to make up from last week Thanks for looking Simon
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Post by katana on Jan 19, 2014 18:17:08 GMT
Re - intercoolers, although I've got / had one on mine it was intended for 2 bar+ boost and 450+hp, but if you are not using that level of boost and / or for long periods of time, I have to admit they are pretty rather than functional! But this is what mine looked like....
This motor now wears a Dyna 2K and it fitted up no problem at all as did the one on my other Gixer motors - that backplate has been severely played with and i'm guessing it wasn't intended for an oil cooled lump?
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drzsimon
Tyrannosaurus Rex
Posts: 70
Bikes: GSXR 7/1216 turbo, Buell 1125, Buell XB9, Buell XB12, Yamaha Slider 70cc
Reg: Jun 15, 2013 19:13:15 GMT
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Post by drzsimon on Jan 19, 2014 19:33:20 GMT
Re - intercoolers, although I've got / had one on mine it was intended for 2 bar+ boost and 450+hp, but if you are not using that level of boost and / or for long periods of time, I have to admit they are pretty rather than functional! But this is what mine looked like....
This motor now wears a Dyna 2K and it fitted up no problem at all as did the one on my other Gixer motors - that backplate has been severely played with and i'm guessing it wasn't intended for an oil cooled lump? Thanks Katana, I'm building this for 1/4mile and top speed, I'm hoping to run 1bar with the engine mods I've carried out, target this year is 200mph. I'd assumed an intercooler was needed but armed with your information I'll continue with the build WITHOUT the intercooler. Yes, yours does look nice though I'll contact the seller and see what he'll do. I thought there was something a bit odd with it to be honest when I unpacked it - especially as it had come from a running bike, but I bought it at a very good price so I wasn't expecting brand new. Simon
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Post by CHR15 on Jan 19, 2014 20:06:35 GMT
out of interest katana, where did you get you ic core from?
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