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 Post subject: Re: Eeeeeeeeee FE
 Post Posted: Thu Apr 16, 2020 11:29 am 
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Knob Magnet
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Location: Catterick, North Yorkshire
latest bit or build turned up today, 3 way brake splitter block from Torques UK, will mean that i can keep the front end/bar area nice and clean

by running the brake line through the steering stem, got some 90deg adapters coming to fit this block, so the lines will exit rearwards to the calipers.

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 Post subject: Re: Eeeeeeeeee FE
 Post Posted: Fri Apr 17, 2020 7:30 pm 
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Knob Magnet
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today was upper front end test fit, fitted all the controls/switches/levers and hoses to make sure it would work like it had in my mind.

very happy with how it has gone together, looks very clean and un cluttered, only thing that might be a small niggle is the bar end indies!

due to the slope of the bars with the placement of the mirrors they might not be as open to the front as needed, might end up fitting some M-blaze buttons

somewhere on the front too. but until they are wired in it is all guess work on that score.

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 Post subject: Re: Eeeeeeeeee FE
 Post Posted: Tue Apr 21, 2020 1:27 pm 
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Knob Magnet
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Location: Catterick, North Yorkshire
after receiving my Motogadget M-blaze Pins I had a play around with some mounting ideas in my head, as i have a spare bottom yoke

it helps with picturing what i can get away with on the best yoke.

mounted down a bit and in line with the center bar would be nice and tidy i am thinking.

will need yoke drilling and a channel for the wire cutting, also need to cut the threads down on the M-blaze, but doable

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 Post subject: Re: Eeeeeeeeee FE
 Post Posted: Tue Apr 21, 2020 3:28 pm 
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Knob Magnet
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Location: Catterick, North Yorkshire
new chain and sprocket turned up today, gave chain a good clean off, de grease and test fit, looks to be more than enough chain/tyre/frame clearance with 190 tyre  & 530 chain

happy with that   :)

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 Post subject: Re: Eeeeeeeeee FE
 Post Posted: Wed Apr 22, 2020 4:28 pm 
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Knob Magnet
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doing my bit for social distancing :) made sure that i stayed at least 2m away from Mick whilst he did some "Essential" work on my frame, cheers mate.

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 Post subject: Re: Eeeeeeeeee FE
 Post Posted: Thu Apr 23, 2020 1:53 pm 
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Knob Magnet
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Pic of cam cover through from Brian at Centurion, looks the dogs  on with head tomorrow.

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 Post subject: Re: Eeeeeeeeee FE
 Post Posted: Thu Apr 23, 2020 6:34 pm 
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Knob Magnet
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got pics from Component Engineering of my two new made to order Ti engine rear mounting bolts, went round Taffs to get my M8 threaded frame inserts.

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 Post subject: Re: Eeeeeeeeee FE
 Post Posted: Sun Apr 26, 2020 9:49 pm 
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Knob Magnet
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sorted fitment of engine mounts and bolts today after getting spacers and frame inserts from Taff

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Then played around with the rear m/cylinder/hose attachment, ended up with the hose going down the back.

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 Post subject: Re: Eeeeeeeeee FE
 Post Posted: Mon Apr 27, 2020 12:23 pm 
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Knob Magnet
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More Ti goodness arrived in the post this morning :)

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 Post subject: Re: Eeeeeeeeee FE
 Post Posted: Tue Apr 28, 2020 2:11 pm 
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Knob Magnet
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Location: Catterick, North Yorkshire
work so far today has all been about test fitting the oil cooler and head cooler to gauge lock stop/cooler/wheel/exhaust clearances, Head cooler has been mounted directly to the main cooler mounting bracket (going to have Ducati rubber mounts)

cooler has lots of clearance from exhaust headers (using Yoshi Bandit headers) but dont see any problems as i am going to get Racefit to make me a system.

I like the idea of the two center header pipes staying inside the  down tubes and then the outside two passing behind the frame down tubes  and into the collector. will have to talk

to Jon on the idea.

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clearance of head cooler and yokes at full lock, (lock determined by fork to tank clearance)

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 Post subject: Re: Eeeeeeeeee FE
 Post Posted: Wed Apr 29, 2020 1:13 pm 
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Knob Magnet
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found an as new radiator fan from a CBR/CB, fan fits in the space between the down tubes very nicely, blades are a little deep, but i am sure that

i will be able to cut them down without too much effort, but looks to be a working answer to the problem.


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 Post subject: Re: Eeeeeeeeee FE
 Post Posted: Fri May 01, 2020 11:04 am 
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Knob Magnet
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Thanks to the feed back (good, bad or other wise) i have gleaned the information that i needed for fitment of the oil cooler fan, it would appear that every day is indeed a "Skool Day"

I have ordered a Spal Axial Fan, VA39-A101-45A, 12v (Pull) 5.5" (140mm) with the bigger of the two Ampage motors,

will be fitting it with a remote switch, unless i can find a temp switch to work at a high temp of the oil cooled motor (110-120deg +)

I will need to remove a bracket from under the steering head bracing to give me the required clearance  for the fan, and then get some mounting tabs welded on for it to fit to.

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 Post subject: Re: Eeeeeeeeee FE
 Post Posted: Fri May 01, 2020 1:07 pm 
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Knob Magnet
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Location: Catterick, North Yorkshire
just ordered one of these adjustable switches and AN10 adapter to go with it :)


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 Post subject: Re: Eeeeeeeeee FE
 Post Posted: Fri May 01, 2020 9:35 pm 
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Victor Meldrew
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Enjoying this thread. 8o

Just curious, why is there a separate smaller oil cooler ?

I'm assuming that the larger rad is also an oil cooler, on the same circuit ?

EDIT Googled it, found this:

Quote:
The normal way is to use the extra cooler as a head cooler - like the GSXR750RK had, linking the feed from top of cases, behind the barrels, to the new cooler and from there back to the cam cover - this reduces oil temperature before it goes to the hottest part of the engine.


Think I understand now.

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 Post subject: Re: Eeeeeeeeee FE
 Post Posted: Sat May 02, 2020 10:36 am 
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Knob Magnet
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That is correct Richard, Oil cooled Suzuki's loose a lot of power through heat build up in the head, putting a smaller "head" cooler helps this, some endurance teams actually swap the two over and have the large main cooler on the head circuit.

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 Post subject: Re: Eeeeeeeeee FE
 Post Posted: Sat May 02, 2020 6:05 pm 
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Knob Magnet
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had a play around with the oil cooler fixtures and fittings, happy now with how i will sort the pipework for both coolers

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test fit of fender and brake lines.

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ordered some more Ti bits and bobs whilst i was at it  :)

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 Post subject: Re: Eeeeeeeeee FE
 Post Posted: Sun May 03, 2020 9:10 pm 
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Knob Magnet
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Location: Catterick, North Yorkshire
As i am happy with the motor fitment and alloy mounting plates i had made, i have ordered some 8mm Ti GR5 plate to make some

finished items, need to find someone with a plasma cutter so they will have a "proper" finish/look once cut.

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 Post subject: Re: Eeeeeeeeee FE
 Post Posted: Wed May 06, 2020 12:25 pm 
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Knob Magnet
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not much done over the last couple of days, ordered some more bits and bobs, still waiting on bits back from 

coating, Brian said he had finished head and cam cover yesterday and will be getting packed up today.

need oil cooler brackets back from Taff, so i can sort mounting of fan (arrived yesterday) and then frame needs to go back down to Mick (Redsix) for

welding fan mounts, some small plates, pillion foot peg mountings and lock stops, still waiting on battery box, top has been machined, just needs other half doing.

awaiting word from Martek on Swing arm.

getting there slowly.

Onwards.

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 Post subject: Re: Eeeeeeeeee FE
 Post Posted: Wed May 06, 2020 4:21 pm 
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Knob Magnet
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Location: Catterick, North Yorkshire
managed to find a pucker Ohlins pre load adjuster bracket when i was browsing the web, came this afternoon,changed  out the bracket i made out of a fork clamp.

I know some will say "why"

but i wanted one for the build, if i could find one. now sorted

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 Post subject: Re: Eeeeeeeeee FE
 Post Posted: Thu May 07, 2020 12:21 pm 
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Knob Magnet
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Its the little bits that count, so i have been told, well in line with that thinking i had some more Ti goodness turned

up in the post today

thought has entered my head into getting a Ti shock spring, can get one made for a reasonable price, but was wandering if anyone had any links

or contacts for one to fit 57 x 160 x 130Nm?

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 Post subject: Re: Eeeeeeeeee FE
 Post Posted: Thu May 07, 2020 8:35 pm 
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Knob Magnet
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got the h/lamp done, M blaze pins mounted with alloy spacers, wire exiting through the rear, will drill some small holes through the webs on the rear of the lamp and feed the wire

through to where the harness plugs in.


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sorted the Ducati radiator mounts onto the oil cooler brackets,  will look at mounting the oil cooler tomorrow, going to use some rivnuts into the frame down tubes.

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 Post subject: Re: Eeeeeeeeee FE
 Post Posted: Thu May 07, 2020 8:58 pm 
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Knob Magnet
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Pics through from Brian at Centurion, head and cam cover sorted

clean and vapor blasted.

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then after coating, great job again


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 Post subject: Re: Eeeeeeeeee FE
 Post Posted: Fri May 08, 2020 4:07 pm 
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Knob Magnet
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Location: Catterick, North Yorkshire
very productive day so far, got oil cooler mounted to frame.

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then took frame out into the sun for some hot grinder action,

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cut the web away from the lower steering stem plating to give the required clearance

for the cooling fan, almost happy with its fitment, but might try to get it a little higher so it will sit almost central to the cooler.

once happy i will make a plate and get the bottom of the web welded up. and some tabs welded on to mount the fan.

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 Post subject: Re: Eeeeeeeeee FE
 Post Posted: Sat May 09, 2020 4:36 pm 
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Knob Magnet
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after sitting and thinking about the oil cooler/fan layout, and getting pictures of Blubbers EFE frame mod, i have changed the design,

it removes some of the webs from under the steering head, replaces it with a cross brace and allows the fan to sit higher on the cooler.

has the added advantage of allowing better air flow through the cooler matrix with the webs not blocking air flow.

so out with the grinder again.

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 Post subject: Re: Eeeeeeeeee FE
 Post Posted: Sun May 10, 2020 9:26 pm 
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Knob Magnet
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Location: Catterick, North Yorkshire
did some more cutting and grinding today, made some lock stop plates to weld to the lower head stock, small plate to patch a hole,

pillion peg mounting plates and finish off with making some brackets for the oil cooler fan to get welded.

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 Post subject: Re: Eeeeeeeeee FE
 Post Posted: Tue May 12, 2020 8:11 pm 
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Knob Magnet
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Location: Catterick, North Yorkshire
Quick trip down to Redsix for some thermal joining howkus powkus by Mick.

sorted the fitment of oil cooler fan, pillion pegs, lock stops, small plate and lower mid engine mount insert.

once i have the battery box sorted, i can plan the fitment of the electronics tray, which should be the end of the cutting/welding of the frame.

had a bit of a play with the rear shock, have ordered a next weight down spring, 130 down from the 140 i have now, got a 120 if i need to go further.

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 Post subject: Re: Eeeeeeeeee FE
 Post Posted: Wed May 13, 2020 8:00 pm 
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Knob Magnet
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finished off grinding off unwanted tabs, ruff bits and weld splats, and smoothing any bits i dont like.

sorted the lock stops, need a little bit more "adjustment" but almost there, then just need some stop bodies making.

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 Post subject: Re: Eeeeeeeeee FE
 Post Posted: Sat May 16, 2020 9:54 pm 
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Knob Magnet
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as i didnt have any plastigauge left to do the crank oil clearance checks, i dug the Yoshi valve spring kit out and set about fitting it.

well it turned into a rather different to the usual job, first off i had to get google translate on the job, as with all Yoshi bits the fitting instructions were in Japanese FFS.

even with translation it wasnt easy to understand, but i stumbled on and sort of found my way as i went.

seems that you have to A) measure the valve stem protrusion from the head, B) measure the spring seat thickness C) measure the spring retainer lip thickness,  D)then assemble the valve into the head and measure the amount of valve stem protruding above/below the spring retainer.

carry out the following equation X = A-B-C-D  (X is the spring compressed length measurement = 31.8mm +/_  0.2mm)

if X isnt within tolerance, then there is a bag full of 0.5 and 0.8 shims that will need fitting!

As it is The guy that did my valve job did a @#%$ brilliant job of cutting the valves in, they were almost the same depth across the whole head, so all the valves have gone in and do not require any shims as they are all within Factory spec,  

Result, well almost, as i was expecting to have to remove the valves after the measuring to fit shims, i haven't fitted any valve stem oil seals. so tomorrows job it to remove them all and fit some oil seals, before re fitting all the valve springs again :(

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 Post subject: Re: Eeeeeeeeee FE
 Post Posted: Sun May 17, 2020 6:13 pm 
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Knob Magnet
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today was a good day working on the head, removed all the valve springs and added the valve stem oil seals, then re fitted them,

but before going to far into it, I fitted a set of valves with stem seals and spring seats, then checked that the top spring seat had lots of clearance to the stem seal at full lift.

ended up with around 3mm of clearance, jobs a good un.

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re assembled all the other bits like rockers and adjusters.

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 Post subject: Re: Eeeeeeeeee FE
 Post Posted: Mon May 18, 2020 2:50 pm 
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Victor Meldrew
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Superb ! :clap

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 Post subject: Re: Eeeeeeeeee FE
 Post Posted: Mon May 18, 2020 3:26 pm 
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Knob Magnet
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Thank you Richard :o

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 Post subject: Re: Eeeeeeeeee FE
 Post Posted: Tue May 19, 2020 3:02 pm 
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Knob Magnet
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Location: Catterick, North Yorkshire
sent pics to water jet cutting place of what i need, in Yarm,

just waiting on quote for job :)

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 Post subject: Re: Eeeeeeeeee FE
 Post Posted: Wed May 20, 2020 4:15 pm 
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Knob Magnet
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Location: Catterick, North Yorkshire
Been over to SNT race engineering this afternoon, ooooooh i like what i saw, have left some bits for machining, and have asked for a price on some of there Billet loveliness,

look forward to hearing from /doing more business with them :)

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 Post subject: Re: Eeeeeeeeee FE
 Post Posted: Wed May 20, 2020 5:59 pm 
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Knob Magnet
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Delivery from the nice people at Robinsons Foundry, waiting on the plastigauge to get things sorted.

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 Post subject: Re: Eeeeeeeeee FE
 Post Posted: Thu May 21, 2020 7:21 pm 
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Knob Magnet
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Location: Catterick, North Yorkshire
I have been waiting on some S/steel springs to arrive, T hey came this afternoon, i needed them to try and hold the Tygon tubing in shape when i put a sharp bend in it.

got springs, wound 3 together, works a treat.

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 Post subject: Re: Eeeeeeeeee FE
 Post Posted: Fri May 22, 2020 9:29 pm 
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Knob Magnet
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Location: Catterick, North Yorkshire
never got a reply to my interest in some water cutting, or from another firm that does laser cutting???? you would think small firms dont need any work any more?

so i have talked to SNT about making me some brackets to their design used on the XR69 out of my Titanium plate  

going round to collect my Forks from them tomorrow sometime and drop the plates off.

plates will be like these but to my patterns 

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 Post subject: Re: Eeeeeeeeee FE
 Post Posted: Sat May 23, 2020 2:44 pm 
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Knob Magnet
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Location: Catterick, North Yorkshire
popped down to SNT to drop off the plates and collect my forks, great job on the calliper seats, removed 5mm from the calliper seating face, now the pads sit well below the outside edge of the disc and give me a small amount of adjust-ability for pad manufacturer differences.

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i will now get some 2mm spacers sorted to finish off with the pads around 1mm from the disc edge where i want them.

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 Post subject: Re: Eeeeeeeeee FE
 Post Posted: Sun May 24, 2020 6:35 pm 
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Knob Magnet
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Location: Catterick, North Yorkshire
sorted the res and hose on the clutch master cylinder.

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 Post subject: Re: Eeeeeeeeee FE
 Post Posted: Mon May 25, 2020 9:49 pm 
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Knob Magnet
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Location: Catterick, North Yorkshire
had a tinker around with the rear mud guard and reg plate fitment, i cut the mud guard down and made it fit the line of the rear lamp, needs cleaning up a

bit yet, but it isnt far off from what i am after,

i then cut a hole in it and mounted the plate bracket to the rear seat support, turned out great, keeps the reg plate under the tail and neat.

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 Post subject: Re: Eeeeeeeeee FE
 Post Posted: Tue May 26, 2020 3:27 pm 
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Knob Magnet
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Location: Catterick, North Yorkshire
did the indicator wires on the back of the head lamp by drilling through the cooling webs to keep the wires out of the way and hidden.
lined up the indicators and set them in place, wires now sit with the h/lamp loom in one cover round the steering stem.

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