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  #61  
Old 12-05-2014, 05:33 PM
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continued.....





Clutch cover to make next which should be a damn sight easier. Could have saved myself a couple of months of headaches and work just painting the engine casings black but reckon it’s been worth it now its done. Quick prod on kickstart and both belts spin away nicely. Should be nice when running though I’m bound to hang off the side watching them as I ride. lol
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  #62  
Old 12-05-2014, 06:31 PM
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Like all your work, it's looking great!!

John.
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  #63  
Old 12-05-2014, 06:47 PM
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Default stunner.

gonna be a stunner that one, lot of time and effort gone in. keep us posted.
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  #64  
Old 13-05-2014, 07:51 AM
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Cheers folks. Long old slog but getting there now I think. Looks bike shaped anyway.
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  #65  
Old 13-05-2014, 09:05 AM
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Should be nice when running though I’m bound to hang off the side watching them as I ride. lol

Be quite mesmeric I'd imagine..
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  #66  
Old 13-05-2014, 01:19 PM
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Looking better every day, John.
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  #67  
Old 18-06-2014, 04:32 PM
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Made these oil cooler line guides which bolt to old frame fairing points. Better than zip ties and in keeping with rest of bike. –




Ran out of things to do at this point pretty much as needed fairing to progress forwards but didn’t have the cash for it.

Got a bit of smoked lexan for the new clutch cover and had a go at engraving it with cheap dremmel copy and £3 ebay engraving bits. Not too bad for a first attempt. Kind of gives away the paintwork theme but then anyone that knows my mad max addiction would have guessed it was coming anyway. Lol. Not going for a straight goose replica though, more of an endurance racing team theme with a mad max tie in. Racing scheme with some photographic airbrush work in one band. Subtle compared to my turbo bandit build, but then anything would be compared to that. –




Even engraved on the oil level marks as the whole clutch cover is windowed now. –



Just waiting for a 16mm bit of alloy plate from Yantosh to make the spacer plate out of and can finish it off. –

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  #68  
Old 18-06-2014, 04:33 PM
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continued......

Finally got spare cash for the fairing (not screen yet though) and it was on 15% off sale so grabbed it. Arrived in one piece from Germany too. I was like a wee kid at xmas. Everything balanced roughly in position. So excited…



Then camea lot of evenings of alloy fabrication once again. Combined fairing bracket, battery tray and headlight mount. Overkill maybe but a lot of weight at a fair distance from the headstock mounting points. –



Bolted down. –



Curved section comes round tacho in middle of bars then a couple of stainless stays outwards to fairing. Got them at an angle so that once on the bike all you can see is the couple mm of thickness so nearly invisible when riding. –




Couple stainless brackets at rear edges to tuck it in and real nice fit to frame rails and round forks, etc. –

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  #69  
Old 18-06-2014, 04:33 PM
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Continued....


Going to have a carbon fibre dashboard tucked inside with the oil temp/pressure gauges and idiot lights sunk into it. The screen is going to be smoked like the clutch cover. –



Where I’m up to. All bolted up tight bodywork wise. –





Going to start repairing fibreglass on the seat unit and prepping up the panels. I’ll get the screen ordered and drilled/fitted also at somepoint so can move on with paintwork in between work paintwork.

Apart from clutch cover its basically paint and electrics now.
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  #70  
Old 20-07-2014, 02:01 PM
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Another busy few weeks here working on the bike every evening and weekend.

Got my wife and a passing courier driver to give me a hand lowering the bike down the ramp off the workbench and onto solid ground at last. Felt GREAT to sit on it properly at last. –







Was on a high till came out next day and found out the billet brake reservoir had leaked all over the frame damaging the paint/clearcoat. On my list to touch up. –

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  #71  
Old 20-07-2014, 02:02 PM
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continued....


Changed the reservoir to a normal one with billet shroud, etc but tbh I’m still not happy with the brake lever feel. Got offered a fancy GSXR1000 radial mastercylinder off a friend so going to get that on instead. Should firm up the lever feel substantially compared to the tiny bore of the old one. Bit more up to the job.

Been battling with the bodywork every evening/weekend for last couple of weeks. Taken several days just to get the 2-3 mm of rattlecan paint off the parts using thinners, scraper and a power washer. Nightmare!

Tank needed bit of fillerwork for a few small dings and re-shaping welds, etc. –



Seat unit was another matter. Gelcoat stress cracks, etc everywhere! Is 35-40 years old though so a bit worn out like me. Lol.




For the cracks I used a dremmel to grind down into the seat unit along them. –



Then I filled it all back in with fibreglass resin. –



I also reinforced the back of the panel in the damaged areas to give a bit more strength and filled in behind the side mounting holes, etc too. –

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Old 20-07-2014, 02:02 PM
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Continued.


A hell of a lot of hours filling/sanding/filling/sanding, etc and all panels as good as new. Refitted them to the bike today and got busy with the fineline tape marking things out. –






Aiming for something similar to this mockup. I’ve omitted the small silver stripe below the blue section now, but pretty much the same. Classic endurance racer meets Mad Max. –



Up the centre of the tank will be some very small scale B&W artwork of moive stills in a movie reel style layout. –



Going to take me 3-4 weeks to work through the artwork, etc as up to my eyeballs with work spraying as always. I’ll chip away at it one panel at a time though in my evenings/weekends.
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  #73  
Old 20-07-2014, 09:05 PM
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that looks fantastic ,i thought it was finished black with green stipes
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  #74  
Old 21-07-2014, 07:38 AM
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that looks fantastic ,i thought it was finished black with green stipes
Just laying things out with fineline tape. Reckon it'll work though once painted. Be summit a bit different.
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  #75  
Old 03-08-2014, 04:14 PM
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Made a start on paintwork. Bit limited with airbrushing at that scale as faces are same size as my thumbprint. Worked out not bad on the detailing though considering the tiny scale. Wanted to challenge myself with the scale though and see what was possible. –






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  #76  
Old 03-08-2014, 04:14 PM
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Continued.....







Heavy metallic silver (almost flake), pearls blue and metallic hint over the red/black too. -

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  #77  
Old 03-08-2014, 04:15 PM
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Continued....


Headlamps sprayed up too. Wiring soldered/heatshrinked inside, etc. Couple of carbon fibre lens protectors made up n sprayed with harris logo to match fairing. –




Bolted the bits on this afternoon. Screen balanced in place for now. Waiting on a hole reamer coming in mail to enlarge fairing holes a few mm and then I can get the screen drilled and bolted down. Got some big silver `MFP` decals coming in mail for screen too. –






Tank has silver on and a few coats of clear. Be sanding that back and getting the artwork done on the tank over next week or so. Going to get some wire and a battery ordered up too this week as got some of electrics parts here already such as blue LED dash gauges, idiot light led’s, etc. Can start hooking things up in evenings if get a chance.
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  #78  
Old 31-08-2014, 09:23 AM
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Hectic here. Only got 2 ½ weeks till the bike event I want to take it to. Going to be tight! Working on it every evening and weekend. Even sneaked a few days off work.

Drilling my screen and the damn thing cracked on the last hole! –



Don’t have time and money to wait for another one to be made and shipped over from germany, so came u with a plan. Prised open crack and superglued it solid. Sanded down both sides so flush then made some infil panels out of that super thick weave carbon fibre adhesive stuff and some smaller MFP decals that came with the larger ones. Neat enough and crack underneath is invisible and strong. –





Made a carbon fibre dash with LED idiot lights, blue led oil pressure/temp gauges and blue led engine `start` button. –



Made up a wiring loom. Got the battery through the mail and hooked up. Neat enough and everything works thankfully. Got a spark at plugs, etc too. Put blue led in the gsxr tacho too so matches. –



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  #79  
Old 31-08-2014, 09:23 AM
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Continued.....


Tank sprayed up. –









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  #80  
Old 31-08-2014, 09:24 AM
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Continued.....

Where I’m up to. The end is in sight………. –





Just clutch cover to make and the seat unit to airbrush. Battling with clutch cover just now as engine oil will be here any day in mail. Killed my trusty old £15 Argos jigsaw cutting out the 16mm alloy clutch cover spacer plate. –



Thankfully got it replaced under guarantee. Busy shaping/sanding it at moment. Another few evenings and have the clutch cover done and on the bike.

Really want to get engine fired up and see if the crank belt drives work and anti-dive front end, etc. No point hurrying with seat unit paintwork if these need more work or parts re-making. Won’t have time to do it for bike rally.

Fingers crossed!
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  #81  
Old 31-08-2014, 11:24 AM
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coming together well,don't think you need worry to much about you small scale airbrushing ...it looks amazing
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  #82  
Old 31-08-2014, 04:59 PM
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coming together well,don't think you need worry to much about you small scale airbrushing ...it looks amazing
Cheers. Yer seems like light at the end of the tunnel anyway. Got concerns about the anti dive front end and belt drives either side of crank. Worst case they need bits re-made/designed, etc. Nothing I can't do over another few weeks of fettling. All the hard work is done anyway I think.
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  #83  
Old 01-09-2014, 10:37 AM
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Damned shame about the the screen crack, but an excellent recovery.

Looking really, REALLY smart just now.
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  #84  
Old 15-10-2014, 04:29 PM
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Well where to start. Bike was meant to be finished ages ago and on its way to a rally on the Isle of Skye. Went to the rally……..on my turbo bandit….

Wind it back a month or two…….

Got clutch cover finished off and fitted. –



Got bike started up and running nicely. Thought I was on the finishing straight tbh. Was still cutting it close on getting it finished and to the rally but I was all go this end. Out in the shed till midnight every night after work getting the last bits worked through.

Then while on tickover the LHS belt drive decided to come apart jamming the engine and cutting it out. Feared the worst but after taking it apart I found the problem and spent a couple of evenings remaking parts so wouldn’t happen again.

Got it up n running again then the bike sitting on tickover made a light clicking noise and then cut out. Pushed the starter and only the LHS of crank was turning! FOOK!

Looked like the crank had sheared from the belt drive jamming up. Was the last straw really. I came in from shed dispondant to say the least and just emotionally/physically drained from working my ass off to the point of making myself sick and then this. Even considered selling it on as a project….

My wife came home from work and talked some sense into me and backed me fully in repairing it no matter what the cost. She knows how much this bike means to me. –



She also told me to take a break from it for a while so I did. Had a great blast about Skye on the bandit, great rally. Spent the last month or so working on house refurbishment, fitting windows and woodwork, etc. My wife then bought me a crank as a surprise to get me back into it. –



Got back out to shed last couple of days with a view to stripping out the engine and spending a few weeks/months rebuilding it and gradually saving up for gaskets, etc as I went along. Took plugs out and gently moved kickstart to see how bad things were while looking down plug holes with a torch. Fully expecting it to jam or some pistons not to be moving. Was kind of surprised to see all 4 pistons moving and the valves, etc opening/closing as normal. Nice clean piston bore walls, etc.
Was wondering if I had been so tired I had dreamt the snapped crankshaft! Lol. Plugs back in and jumped on kickstart. Pretty much bounces my 13-14 stone bodyweight off as high comp motor, but got it through few cycles and no weird noises at all, just the normal whump, whump.

Further investigation and found this! The woodruff key was snapped/ground down level with the crank tapered end as you can see. Also slight scores in rotor end in my hand to show it had been rubbing/slipping. –



Basically the rotor had come loose (hence clicking noise when rubbing) and snapped/ground the woodruff key down. When I hit the starter the rotor was turning but since not connected to the crankshaft then the RHS of crank wasn’t turning. The pulley on the LHS side was spinning as connected to the rotor.

Plugs out and grabbed tapered end of crank in my hand with a rag for grip. Can easily turn over engine by hand. Think I’ve been BLOODY lucky!

Belt drives have been thrown in scrap pile already. Sick of them and their problems. Want to go touring on the bike without hassles and had nothing but problems with them. Tbh the vision of them I had in my head didn’t match the reality once running. Had this spinny belt fixation which overruled my common sense. Made the bike wider, heavier and more complicated for no good reason. Good break from building has made me realise it’s a hell of a lot better without them. More in keeping with the overall bike. Lighter, neater, and more focussed on handling/performance. Wasted a lot of time making parts to throw them in the scrap pile. Hey ho, lesson learnt. Had to try it to find out it wasn’t right for me or the bike. The crank I bought I got for a really good price so can get my money back or a profit even.

So where am I now with it. Well here really. -



Belt drives removed. Waiting on new woodruff key arriving and can get both ends of crank, etc bolted back on. Need to modify the LHS cover to make it oil tight and re-make the RHS cover too. Going to make casings that match the clutch cover as I’m really happy with that. Neat and modern/smooth looking. Going to make 2 matching casings with engraved windowed covers so ties together.

Need to remount the coils and reg/rec under tank and change wiring about to suit. Finish spraying the seat unit and generally get it finished off. Going to spend my efforts detailing things more, making a few more parts, etc and trying to make it a much tidier build. Back on it now an hour or so a night and treating it as relaxation rather than fixating on it. No timescale set at all. If takes me a couple of months then so be it.
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  #85  
Old 16-10-2014, 08:36 AM
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Was one of the spinney beltey things not driving the alternator? and the other starter motor?
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  #86  
Old 16-10-2014, 01:13 PM
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Quote:
Originally Posted by Biker Buster View Post
Was one of the spinney beltey things not driving the alternator? and the other starter motor?
Can convert it back to original setup bud. Going for some smoked lexan windowed coveres engraved like the clutch one. Bit more sublte and lightweight. Narrower better ground clearance bike is much better on my roads anyway. Need some handling round here.
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  #87  
Old 16-10-2014, 01:54 PM
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Glad it's not as bad as first feared, John.
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  #88  
Old 16-10-2014, 02:04 PM
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Can convert it back to original setup bud. Going for some smoked lexan windowed coveres engraved like the clutch one. Bit more sublte and lightweight. Narrower better ground clearance bike is much better on my roads anyway. Need some handling round here.
Ah Sweet, lookin' forward tae seein' it.
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  #89  
Old 16-10-2014, 06:36 PM
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good to see you stuck with it,it will be worth it
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  #90  
Old 09-11-2014, 05:52 PM
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New woodruff key came through so got alternator rotor bolted back on with a new bolt and plenty of permanent threadlock. Lol.

Recycled a bit of the old belt drives with a bit of trimming to act as base for the LHS engine cover window. Got it welded on up town (50 miles) by a small place that does fishing boat hulls, etc. Pricely sum of £5 for 5 minutes of tig work. –



Bit of a repaint and some smoked lexan windows engraved with my dremmel and had a couple of nice `KWAKA` engine covers to cover up the belt drive holes. –



Got the seat unit finished off at last. Been a hard slog of fibreglass/filler/paint but think it was worth saving as a one-off and love the shape of it. Kept my `comfy` seat. Back seat cowl has hidden fixings so nice n neat. –







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