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  #121  
Old 28-04-2011, 05:54 PM
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Well local power company decided to kill our electricity supply today for maintenance or something. By half way through the day Iíd ran out of work related things to do without electricity. Weather was lousy too which left nothing to do but hide in garage n work on bikeÖÖÖ..Woohoo! lol

Thankfully I had a portable lighter fuelled soldering iron so was able to solder up extension wires for the ignition switch down to the side somewhere. Not mounted yet, but wiring for it done anyway. Also chopped back about a foot of wiring at front of bike to back behind frame rails and neatened up the mountain of wiring as much as possible as front ends pretty minimal now.

Light cowl mounted up, lights wired in, throttle/clutch cables connected, etc, etc. :-




Everything as neat as could get it.:-



Nice n clean view tho from bars. Be a wee bicycle speedo going on somewhere n couple of LED dash lights and thatís about it, but even then theyíll be hidden away somewhere.:-



Onto cleaning up caliper pistons and bodys, etc next. Pistons were sticky at mot test so clean em up inside n out. :-



Get front brake components bolted on n thatís front end more or less done for now. Leave rest of wee bits like indicators/dash lights, etc for now and start the rear end so can get it on its wheels again.
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  #122  
Old 02-05-2011, 05:07 PM
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Relatively quiet afternoon for me so popped pistons out of caliper bodys as far as would go and scrubbed them up removing all dirt, etc. Cleaned up sliding pins, etc, etc. Removed last of paint off bodys, back to bare alloy and just general good look over. Bolted back on and look pretty good and not sticking any more. All ready to roll brakes wise. :-



Moving onto back end now. Wee bits n bobs can wait at front till got it on its wheels which will make life a lot easier to move things around.

Started degreasing back end bits. :-



Need to take out each suspension bearing and free them off and grease them up. Main swingarm bearings are shot so will have to replace them. Others will be ok though with bit of tlc. Rest fo bits just need more degreasing/sanding/paint, etc.

Something to keep me busy in evenings for next week or so. lol
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  #123  
Old 24-06-2011, 04:39 PM
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Works been busy as hell n been lying under my daily driver hearse non-stop again sorting it out. Damn cam belt went few days back on me. Thankfully a non-contact engine tho. Phew. £9 for a new belt delivered n sorted.

Anyway have been doing bits n bobs at bike when got the odd bit of time here n there. The swingarm bearings I almost lost my temper with tbh. Damn things were rotten to the point they fell apart trying to tap them out and the outer edges were rotted to flaky white alloy inside from water/winter road salts. Nightmare of a job. Just wouldnt come out. Tried blowtorch, soaking them to no avail. Eventually had to chip away at the outer races inside swingarm with precision screwdrivers and a hammer for a week and a half of evenings trying to pry behind and gradually take the fragments out in pieces. Fookin PITA! Must have taken me good 20 hours plus in evenings to get buggers out then sand out chisel marks inside with dremmel tool to make smooth ready for new bearings. Not kidding about state of them!:-



Wheel bearings were fooked too. Notice the missing ball bearing in the cush drive! :-



All the shock, linkages, swingarm fittings, sidestand, etc cleaned up ready for back end to go together. :-



Swingarm plates painted up. Same metallic silver sheen/gunmetal black finish as front end parts. Lettering airbrushed on in nice modern font to match theme. :-



Hugger same finish, swingarm gloss black. :-



Wheel polished and painted up too. :-



Just need some spare cash for swingarm and wheel bearings so I can get back end bolted up and the bike back on its wheels.
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  #124  
Old 24-06-2011, 07:31 PM
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By eck thems fecked!
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  #125  
Old 24-06-2011, 08:13 PM
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It's not so much the before and after that will look so good, because it was a great looking bike before you started..

Its the total transformation, the quality of workmanship, and all the crap that you uncovered in the middle that is so amazing..

I bet it will break your heart when you sell it to start your next project..some lucky person is going to get a great one off bike.

John.
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  #126  
Old 25-06-2011, 03:37 PM
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Well big thanks to `DoomusZX6R` off the Riff Raff fighter forum. I was looking at over £115 for genuine Kawasaki bearings for both swingarm/rear wheel/cush drive. £80+ for reproduction ones. Doomus pointed me to a good online microfische which listed bearing codes for it all, and a good link to an online bearing supplier. Got the (3x) needle bearings and (1x) ball bearing for swingarm, and the (3x) ball bearings for the rear wheel/cush drive all delivered for £38! Just ordered them online so should be able to get back end back on as soon as arrive.

Definate result as can keep things moving along.
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  #127  
Old 25-06-2011, 03:41 PM
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Quote:
Originally Posted by John Hopkins View Post
I bet it will break your heart when you sell it to start your next project..some lucky person is going to get a great one off bike.

John.
Yer its gotta go bud. Turbo bandit is its replacement n extra garage space would be nice too. I'll miss it for sure as been up n down the country on it in all weathers for years n years. Never let me down at all. Be nice when its finished too.
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  #128  
Old 25-06-2011, 09:11 PM
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Can we be cheeky and ask where you got the bearings from? Sounds like you got a pretty good price there, mate.
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  #129  
Old 01-07-2011, 08:08 PM
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Couple hours tonight in garage cleaning up spacers and greasing everything up, etc. Got start on getting back end together.

Climbed over to work on the bike! Sure be glad when ninjas sold n got some free space to move and build in. lol. :-



Swingarm, chain and suspension components, etc all bolted up, along with sidestand, etc.:-




Looks not bad I think.:-




Few spacers n bits n bobs to clean up tomorrow n can get back wheel in there n sit it back on its wheels instead of suspended n chocked up on blocks. lol
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  #130  
Old 01-07-2011, 08:11 PM
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Quote:
Originally Posted by Grav View Post
Can we be cheeky and ask where you got the bearings from? Sounds like you got a pretty good price there, mate.
No probs bud. Got asked on 3 forums about them already.

I used kawasaki microfisches to find out bearing codes then went direct to a supplier.:-

http://simplybearings.co.uk/shop/

HTH
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  #131  
Old 05-07-2011, 06:17 PM
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Never got back wheel bits on over weekend. Weather was scorching so took advantage of it and sorted out my VW trike for its mainland MOT trip in next week or so. Also doodled over front wings n bonnet of my hearse. Need sanded n buffed up, but better than rust n dents of before. Had few highly religious locals point in horror at it already so job done. lol:-




Anyway on bike front got bits cleaned up/painted/greased tonight n back wheel in. Al back on rubber n sidestand again.:-



Next bits for cleanup n surgery.:-



Demolished the can tonight too.:-



Quick chop with grinder n got rid of dented section n made it bit more suitable for shortened seat unit, etc.:-



Get all bits polished up and endcan painted black next few evenings. Would have liked to have made my own endcan and various other bits for the bike. I need to draw the line somewhere though. End of the day Im not going to get a huge amount back for the bike when sell it so have to call a end to making lots of billet bits, etc, etc. Want to get it finished n gone so can use the money for windows for house, new garage roof, etc.

Going to rip my Harris apart after finish this bike and really go for it making one-off parts. Way beyond what I did with turbo bandit project. Save my time n materials for that build.
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  #132  
Old 07-07-2011, 04:35 PM
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Caught up with airbrushing work for first time in seemingly forever. Artwork needing customer approval before clear coating, several helmets on way in mail, etc, but nothing pressing to do today.

Got out of bed n started on bike bits which was a bit odd. Lol.

Productive day though. Sanded the endcan body, but waiting on primer delivery so cant paint it yet. Going to spray it gloss back though. Sanded and polished end fittings and straps which came up like chrome. Spent several hours out in sun wire brushing, sanding and then polishing stainless downpipes. Again came up like chrome after a few hours of hard work. About to order some exhaust gaskets off Egay for fitting, but all ready to bolt together anyway.:-



Stripped the rearsets and sanded/polished/painted all the bits. Also stripped the back caliper as piston was sticking. Just road salts n brake dust. Good clean out n put back together. Everything shiny n ready to bolt on tomorrow.:-



So yeah busy day at it, but got good weeks worth of `evenings after work` done so happy. Box of bits left to go on is looking very empty indeed. Going to keep at it flat out as long as I can though n make headway.
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  #133  
Old 07-07-2011, 07:03 PM
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Have you got shares in "Elbow Grease" cos you're getting through a fair old bit of it, mate.
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  #134  
Old 08-07-2011, 04:19 PM
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Nah I lactate it out of my left nipple bud. Summit to do. Dont drink or smoke or owt.
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  #135  
Old 08-07-2011, 04:20 PM
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Rearsets n few other bits n bobs back on today. Cut down rear brake reservoir hose as no subframe for it to bolt to now. Lol. Made a new alloy bracket to hold it and bled up the brake, etc, etc. Getting there.:-




Need idiot lights, ignition switch, etc, etc to finish off small bits. Waiting on exhaust gaskets coming in mail to get exhaust back on. Waiting on primer coming to paint endcan. Kinda at a standstill again so dragged out remainder of bodywork panels.:-



Few hours with sander and ready for primer too when gets here. :-



Tank will need paintstripper though. Iíll grab some next time down next village.

Turbo bandit sitting waiting on new plenum being made up by Emoe, trike sitting ready for its ferry ride over to mainland for its mot. Guess Iíll just have to actually ride this weekend instead of building. Lol. Go find some nice empty twisty mountain roads to fling my Harris about on. 
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  #136  
Old 21-07-2011, 03:38 PM
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Bit slow again Im afraid. Works through the roof so working days, evenings and weekends at minute airbrushing. Not a bad complaint by any means as pays the bills, but seriously short of spare time by the time I work/eat/sleep. lol

Had a bit of a mixup with exhaust gaskets = more waiting. Got right ones sorted and headers on though.:-



Only to find out that because I hadnít drilled n mounted the other swingarm plate when stripping the bike (because bike was tight against wall other way round at time) the plate wouldnít fit as ran right where headers sat. Can see in pic I blanked off original hole with allen bolt. No way panel was going to fit in there. Bugger. :-



Needed chopped back and repainted and swingarm redrilled/tapped for fixings, etc. PITA but one of those things.:-



Exhaust can I painted up in same colour with a wee Decepticon logo on end. Took me hours to get can back together as oval shape of sleeve just wouldnít line up with end caps. Must press fit the parts at factory or something. Patience n lots of hammering got it together at last. Drilled n riveted. Not perfect but certainly miles better than dented n scuffed like was before. Back end done. :-



Donít think endcan needs a support strap tbh. Downpipes are solid mounted to gearbox of engine at back and the stainless aftermarket dowpipes are really thickwall. Tried standing and jumping up and down on end where can bolts to and couldnít even wobble it with my fat arse. Lol. Endcan is all alloy and hollow too. Weighs nowt. Not like original flimsy tinfoil downpipes and elephant-dick exhaust can.

Also got fairing top and bottom panels sprayed up. Sitting ready for when needed anyway. Ignore bondage Pocahontas themed helmet in background thatís for a customer. Lol.

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  #137  
Old 21-07-2011, 09:17 PM
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Good to see the Decepticon on there, Harris
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  #138  
Old 08-01-2012, 05:59 PM
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Been out of the building game for a while. Felt a bit burnt out after the mammoth turbo bandit build and went back to just riding for a while. Between my trike n Harris sitting there to use:-



And my weirdola turbo bandit thing up n running:-



The temptation was far greater to get out and ride than sit in the garage building a bike which is getting sold as soon as finished. Not much motivation when know its not yours at the end of the build.

Feel refreshed for the break from building. Back into it now though as my pile of parts for the next bike build are stacking up, and got a 6` fiberglass tot-rod bodyshell on way too to build a miniature hotrod for the kids. Ninjas getting in the way of those projects so given me a bit of drive to get it done n gone so can get onto other projects.

In last week or so I finished off a few brackets, etc, and sprayed up the side panels. Got metallic silver tribalwork in background in same hue as on black parts. Some logo airbrushing, etc too. :-



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  #139  
Old 08-01-2012, 06:00 PM
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Continued..........



Got the 3 pieces of each panel bolted together and back on the bike.:-





Got the seat undertray sprayed up too ready to go back on.:-



Given the seat unit several reshapes and filler/primer sessions. Pretty much in shape now and ready for paintwork.:-



So yeah got a fair few bits done in not many days. More updates as get more stuff done, but want it done/sold asap as its holding me up with next project build now. Im fairly pushed for free time as airbrushing works just getting busier n busier, but Iíll do a bit each evening or something.
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  #140  
Old 09-01-2012, 10:04 AM
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I'm really looking forward to seeing this one finished.
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  #141  
Old 21-01-2012, 06:30 PM
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Last week of evenings and the other weekend were taken up making a new stainless steel exhaust system for my daily driver hearse. Bout 4.5 metres of thickwall stainless tubing n baffles from scratch, etc. PITA. Always something getting in the way of bike building. Lol. Still playing about with the baffles in it as loud enough to wake the dead. Pardon the pun. Lol

Anyway got some spare time back again for bike fiddling at last. Sure beats lying under a damn car in the pissing rain for days on end.

Did few oddís n sodís when had the chance. Got out today though n made this side mount numberplate bracket. Scrap steel offcuts leftover from doing car exhaust brackets.:-



Spot of weld, few holes and a light costing a mighty 60 pence! Lol. Bolts on behind wheel spindle nut/washer. Little rubber shrouded bolt stops it moving downwards under its own weight over bumps, etc. Shouldnít move anyway, but removes possibility. Still needs tidying up and painting gloss 2K black, but Iíll do that during week with work stuff. Also paint the light lens apart from small section underneath to light up plate. :-



Sits at a high enough angle to give good ground clearance. Far enough out that standard sized legal numberplate fits right on for motís. lol. Cheap n cheerfull. Should look alright once tidied n painted up. :-



Iíll get the alloy indicator, horn, idiot lights and ignition switch brackets made up this week in the evenings. Up town later this week so Iíll grab some wire, idiot lights, an ignition switch and possibly some rear lights too. Get everything wired in next weekend which should just leave little bits to do, and the seat unit/tank to spray up. Im prepping those bits along with work stuff tho so getting there now back on the case.

Sure feels good to be back in garage messing about tho.
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  #142  
Old 29-01-2012, 09:53 PM
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Productive weekend in n out of my garage crawling between the bikes like the Viet cong lol. Even got some spraying work done n few bits done on my daily driver hearse.

Side mount number plate setup tidied up and painted, etc. Wired in too.:-



Little idiot light console with flip cover ignition switch tucked down side of frame and fairing side panel. Need a blue and a green light to finish it off, but all wiring in place. Shop up town didnít have all the colours I needed so gonna have to get couple of Egay.:-



Front indicators and horn brackets made and wired in. All tucked away down sides at front behind fairing panels. Not perfect, but neat enough.:-



Couple more bits of wiring to do n few more piddly brackets, etc. Moving along at decent pace again tho. Seat unit is sitting in black basecoat so can get that airbrushed one evening this week. Tank is in bare metal ready for primer n filler work.

Need to buy back lights, couple idiot lights, rear brake light switch, battery, antifreeze, petrol. lol
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  #143  
Old 29-01-2012, 10:03 PM
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love this bike. cant remember where i first stumbld upon it. riff raff maybe?
keep it up jon its looking great
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  #144  
Old 30-06-2012, 04:12 PM
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Not updated for a while. Things have been stressfull here so slipped out of order of importance tbh.

Terminal illness in family to deal with which has been ripping my family to bits last 6 months or so. Add on top of that straight 70+ hour weeks with commission work n just couldnít find motivation to build/update about what Im doing.

Been trying to spend less time in garage and more time indoors to see us through it so progress has been slow.

Built this monkeybike sized fighter in meantime in house with my eldest to take his mind off things. All just junk old parts and some metal out of skips, etc. Fork springs made out of some old gsxr valve springs off Yantosh. Old damaged carbon fibre hugger chopped up for front muddy. Seat unit riveted up out of scrap metal. Bash plate out of stainless scrap. Handlebars out of old bandit ones chopped down 4Ē and risers made out of offcuts, etc, etc.

From this.:-



To this with lotta graft.:-





Gave me something to do indoors though and eldest is chuffed with it and looking to get some road legal tyres n daytime mot on it soon as almost 16.

Been chopping about my turbo bandit a hell of a lot too. Just waiting on Yantosh having some spare time for new headers to finish it off.:-




Get a proper forum update done somepoint on it.
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  #145  
Old 30-06-2012, 04:13 PM
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continued............



Back to ninja though and up n running now. Good wash/polish n bit of a fettle n job done I think. Feels extremely small and lightweight to ride.








Sad to see it going up for sale but got 2 other bikes n trike and this is lesser of them so has to go. Anyone want to buy it? Make me an offer.

Bike prices are through floor at minute so if doesnít fetch much then it`ll not be going anywhere. Not giving it away.
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