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mick2 19-09-2010 11:06 PM

bandit thingy
 
i picked up a gsx550 frame for a fiver complete with v5 on ebay awhile back, a wee bit later i picked up a bandit 600 engine and running gear. i could have got the frame and all but what fun would there have been in that?
engine was just too big to fit in the frame so it had a meeting with the angle grinder, i cut out the right hand side and made up blocks so it would become a removable section, like whats on the bandits and gsxr's etc. had to remove the engine mounts also and re profile below the headstock to make room for the cam chain tunnel. it sat for a bit then i managed to get some time on it this past couple of weeks.

made spacers for rear wheel and milled down caliper bracket
http://i192.photobucket.com/albums/z...h_BILD1501.jpg

used a gs500 sprocket carrier as its narrower than the bandit one, fitted bearings to take the smaller 17mm gsx spindle. spaced the bandit sprocket out by using the gsx sprocket as it was the perfect thickness, will remove a lot of it leaving just the centre.
http://i192.photobucket.com/albums/z...h_BILD1500.jpg

as mentioned earlier i had to cut the side from frame to get engine in. heres the rear of the section
http://i192.photobucket.com/albums/z...h_BILD1499.jpg

and here's the front. new engine mounts welded to removable section. bolts will be 10mm cap screws but only had 2 in garage hence the two hex heads.
http://i192.photobucket.com/albums/z...h_BILD1498.jpg

the gsx headstock is shorter than the bandit so i ground out the weld at bottom of yoke and pressed stem through enough. will weld it up fully when off the bike.
http://i192.photobucket.com/albums/z...h_BILD1497.jpg

left hand side new engine mounts. managed to keep the original bottom mounts and made up a suitable spacer.
http://i192.photobucket.com/albums/z...h_BILD1496.jpg

mick2 19-09-2010 11:06 PM

new rear mount for tank
http://i192.photobucket.com/albums/z...h_BILD1495.jpg

new front mounts fitted. had to buy new rubbers, shock horror.
http://i192.photobucket.com/albums/z...h_BILD1494.jpg

view from the rear with gs250 tank fitted
http://i192.photobucket.com/albums/z...h_BILD1504.jpg

its a roller! not a lot of room in that frame lol.
http://i192.photobucket.com/albums/z...h_BILD1502.jpg

nae danger of getting k&n's etc fitted on there as no where near enough room. got a couple of ideas so will see what transpires. engine had to be fitted slightly off centre to allow for chain run so carb for pot number two is sitting over the downtube a bit.
hope to have footrests and brake pedal etc done before i head over to ireland at weekend, we will see.

rob 20-09-2010 06:29 AM

Quote:

Originally Posted by mick2 (Post 595880)
nae danger of getting k&n's etc fitted on there as no where near enough room. got a couple of ideas so will see what transpires.

stainless steel tea strainers make good air filters, only 1 a pair from the pound shop.....

don't use perforated ally sheet, it fractures over time due to the inlet pulses, and dissapears into the motor. (voice of experience).

mick2 20-09-2010 07:37 AM

Quote:

Originally Posted by rob (Post 595884)
stainless steel tea strainers make good air filters, only 1 a pair from the pound shop.....

don't use perforated ally sheet, it fractures over time due to the inlet pulses, and dissapears into the motor. (voice of experience).

good tip there rob, time to go trawling the kitchenware dept's :)

Grav 20-09-2010 09:06 AM

That looks good so far, Mick. :)

mick2 15-10-2010 08:35 PM

was playing in the garage today. i bought a cheap acewell copy on ebay awhile back so decided to use it on the bandit.
took a worn bonnie piston and cut the top off
http://i192.photobucket.com/albums/z...h_BILD1522.jpg

milled out the inside deep enough to house speedo
http://i192.photobucket.com/albums/z...h_BILD1525.jpg

made a flat area and tapped the existing oil holes for bolting a plate to.
http://i192.photobucket.com/albums/z...h_BILD1524.jpg

made up a plate to bolt to piston and for the bolts on bottom of speedo to bolt to.
http://i192.photobucket.com/albums/z...h_BILD1523.jpg

speedo in piston
http://i192.photobucket.com/albums/z...h_BILD1526.jpg

mick2 15-10-2010 08:35 PM

made a bracket to bolt to engine casing
http://i192.photobucket.com/albums/z...h_BILD1527.jpg

welded bracket to underside of the plate.
http://i192.photobucket.com/albums/z...h_BILD1529.jpg

speedo mounted
http://i192.photobucket.com/albums/z...h_BILD1528.jpg

Strider 15-10-2010 09:35 PM

Love the speedo idea ... excellent :thumbsu:

Mistress Maker 16-10-2010 09:44 AM

excellent idea............and made swarf tooooo!!!!!!!!!

mick2 16-10-2010 11:15 AM

filters sorted oot for carbs. stainless tea strainers with the mesh cut oot :)
http://i192.photobucket.com/albums/z...h_BILD1533.jpg

fitted the mesh inside the carb rubbers that would have connected to the airbox.
http://i192.photobucket.com/albums/z...h_BILD1534.jpg

unsure whether to leave the rubbers that length or cut them back a bit, if kept that length then carb number two's rubber is squished a bit (you can just make it oot in the pic) but would only be noticeable when on yer knees :)

Grav 16-10-2010 01:55 PM

Most ingenious. :D

Biker Buster 18-10-2010 02:28 PM

Excellent stuff...

mick2 13-11-2010 09:39 PM

bit more done, footpeg brackets cut down to remove pillion pegs, subframe cut down and bent about and seat sitting roughly in place. will trim it a bit at front. started to knock up the frame to go under seat for support.

http://i192.photobucket.com/albums/z...h_BILD1549.jpg

http://i192.photobucket.com/albums/z...h_BILD1547.jpg

Nik 15-11-2010 01:14 PM

:cool: ..............

baldybongo 15-11-2010 03:59 PM

Looking good.:thumbu:

headless 21-11-2010 04:57 AM

i see you've made use o the tank :thumbu:

lookin good

mick2 21-11-2010 06:40 PM

Quote:

Originally Posted by headless (Post 599054)
i see you've made use o the tank :thumbu:

lookin good

aye, and been using the off cuts sheet metal you gave me also, thanks again for those.
hows your build doing?

headless 24-11-2010 02:59 AM

Quote:

Originally Posted by mick2 (Post 599068)
aye, and been using the off cuts sheet metal you gave me also, thanks again for those.
hows your build doing?

i've not done anything to mine cause i'm staying in lochee it the minute and wouldn't dream of putting the bike outside here so its all at a stop for now :(

p.s. if you need any more cut offs i could try get you some

mick2 24-11-2010 11:40 PM

off cuts always welcomed m8 :thumbu:

mick2 30-11-2010 08:10 PM

got a few more bits done

bent subframe about and chopped a chunk off the back, ground of a load of brackets and knocked up a frame for supporting the seat unit
http://i192.photobucket.com/albums/z...h_BILD1551.jpg

made a mount for rear light and boxed in rear of subframe, will be able to store the cdi and fuses etc in there.
http://i192.photobucket.com/albums/z...h_BILD1552.jpg

seat unit trimmed at front and in place, will trim again slightly at front once upholstery done
http://i192.photobucket.com/albums/z...h_BILD1553.jpg

1950's lucas repro tail light fits just fine in there i reckon
http://i192.photobucket.com/albums/z...h_BILD1554.jpg

made up a box for housing the battery, still got a couple of mounting lugs to weld on it.
http://i192.photobucket.com/albums/z...h_BILD1555.jpg

found a road sign knocked over in the field down the road, it would have been rude not to use it lol. still needs fine tuned just a rough cut out for now.
http://i192.photobucket.com/albums/z...h_BILD1556.jpg

mick2 13-02-2011 11:24 PM

not updated this for awhile as its been boring wee bits and wiring recently.
machined up some exhaust tips today so heres a wee update.

alloy exhaust tips with grooves cut in to tie in with the piston i used for speedo housing.
http://i192.photobucket.com/albums/z...h_BILD1630.jpg

http://i192.photobucket.com/albums/z...h_BILD1628.jpg

http://i192.photobucket.com/albums/z...h_BILD1627.jpg

finished all the wiring, managed to squeeze cdi, fusebox and relays in space under seat hump welding on tabs to use the original rubber mounts
http://i192.photobucket.com/albums/z...h_BILD1620.jpg

shortened a pair of headlamp brackets and fitted a 7" headlight from a honda cb900(eek)
found a 19" narrow mudguard in pile of bits and reduced radius to 17" thus widening it enough, its just sitting on tyre for now but fits the bandit brace fine so will be bolted to it.
http://i192.photobucket.com/albums/z...h_BILD1619.jpg

dazarooney 07-03-2011 07:18 PM

Looking good mick, keep the updates coming.

mick2 08-03-2011 12:08 AM

stripped it all doon today for powder and paint. few bits on the frame to weld that i couldnt get to with the motor etc in.
should be finished in april hopefully.


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