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 Post Posted: Tue Dec 27, 2016 10:44 pm 
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Just out of interest what (as it is) does that plate weigh?

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 Post Posted: Wed Dec 28, 2016 10:59 pm 
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Knob Magnet
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Biggabit wrote:
Just out of interest what (as it is) does that plate weigh?


it is 7.5 Lb's :eek but it will be much much lighter when i have finished with it :)

did some more to the suspension, drilled, tapped and fitted the top shock bracket, after drilling and tapping the second set of side mounting bolts

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i think the lower link it sat where it needs to be, just the lower mounting plates to make and weld in place.

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 Post Posted: Sat Dec 31, 2016 4:16 pm 
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as the weather wasnt bad, I got the frame out and went to work with the grinder! removed anything not needed and cleaned up some welds and imperfections, frame looks good, so only bit that needs replacing will be the lower frame loop that had rusted through.

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 Post Posted: Sun Jan 01, 2017 11:51 am 
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Victor Meldrew
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Any worries about frame distorting when that tube gets welded in ?

Maybe get an alignment check once its all done ?

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 Post Posted: Sun Jan 01, 2017 4:07 pm 
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richard pitman wrote:
Any worries about frame distorting when that tube gets welded in ?

Maybe get an alignment check once its all done ?


there was no twisting or distorting of the frame when the tube was cut out Richard, Im going to make sure that
the swing arm and suspension mounting plate are bolted in nice and tight before any welding is done.

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 Post Posted: Mon Jan 02, 2017 1:43 am 
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had a play around with the top mount (lowered it slightly) and made some cardboard templates for the lower linkage mounts

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did a bit more by moving the top mount out a bit, allowing me to put the link at a slightly steeper angle

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shimmed out the top mount to give me a bit more shock clearance on the swing arm

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will end up with a lower mount welded on something like this

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 Post Posted: Tue Jan 03, 2017 2:52 pm 
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As i have a set of Keihin FCR carbs that came off my hornet sat around doing nothing, i have
looked into fitting them to the bandit motor, they will need spacing to fit and the inlet spigots are
too large for the bandit inlet rubbers.
i contacted Allens and they want £300 for a re space and new inlet spigots :eek :eek
can get the same done in Holland for £244, but i cant see why i cant do it myself, just a case of new
spacer bars and throttle linkage, throttle linkage looks the biggest part of the job, but cant see it being a huge problem.
the inlet rubbers off the GSX600F head i have are bigger than the bandit ones, and the inlet spigots would only need a small amount machined off
for them to fit.
Taff is on with making the lower shock linkage brackets, I will make a proper spacer plate for the top mount soon, then i hope to get the wheels on so i can wheel it back and forth to the welders when needed.

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 Post Posted: Tue Jan 03, 2017 6:27 pm 
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370steve wrote:
As i have a set of Keihin FCR carbs that came off my hornet sat around doing nothing, i have
looked into fitting them to the bandit motor, they will need spacing to fit and the inlet spigots are
too large for the bandit inlet rubbers.
i contacted Allens and they want £300 for a re space and new inlet spigots :eek :eek
can get the same done in Holland for £244, but i cant see why i cant do it myself, just a case of new
spacer bars and throttle linkage, throttle linkage looks the biggest part of the job, but cant see it being a huge problem.
the inlet rubbers off the GSX600F head i have are bigger than the bandit ones, and the inlet spigots would only need a small amount machined off
for them to fit.
Taff is on with making the lower shock linkage brackets, I will make a proper spacer plate for the top mount soon, then i hope to get the wheels on so i can wheel it back and forth to the welders when needed.


Well I for one have every confidence in you successfully respacing the carbs and will look forward to reading about it here :)

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 Post Posted: Tue Jan 03, 2017 8:30 pm 
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have made a 6mm spacer plate for the top mount.

Image
Image

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 Post Posted: Sat Jan 07, 2017 6:36 pm 
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got the metal i was waiting for today so got on with making the new lower frame rail, first thing was to make some slugs to fit at either end of the removed section, made sure they fitted into the new frame section first, then into the old frame

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once i was happy i did a fit

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the rear caliper and hanger also turned up today so did a test fit of the wheel into the swinger. looks good, but
might need to center the wheel slightly, or move the swing arm over around 5mm, rear sprocket carrier might need machining also.

Image

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 Post Posted: Sun Jan 08, 2017 9:08 pm 
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to balance things out when i am working on the bench, i have fitted the front stem bearings to allow me to fit the yokes and forks,
this puts a bit of weight on the front end and stops it tipping backwards.

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with everything in place at the back, i checked the wheel for centralization, would appear that it is sat 7mm to the right, so i will
get 7mm taken off the left hand spacer and get a thicker spacer made up for the right hand side.
going to have to take some metal off the sprocket carrier, but at a first glance i dont think that i will need too much taking off, 10mm tops
might just end up fitting a 520 chain and sprockets to keep clearances to a max, as it isnt going to be the most powerful of bikes on the road.

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 Post Posted: Tue Jan 10, 2017 9:33 pm 
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have taken the rear wheel off, measured the sprocket carrier and swing arm spacers.
looks like it is not going to be a hard job getting everything centered.
going to take 9mm of the sprocket carrier face, this will also mean shortening the sprocket bolts and putting some thread further down their shafts,
I will need to take 7mm off one swing arm spacer and increase the other by the same amount.
as soon as i have the bottom frame rail sorted and the lower linkage mounts on I will get the engine into the frame and attempt to get everything
lined up.

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 Post Posted: Fri Jan 13, 2017 8:22 pm 
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today i cut the plate down to the size it will be, still need to get it machined to the correct profile.
i will make some small spacers to go between the plate and frame down tubes.
fitted some nice s/steel bolts to the shock mount.

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then had a play around with where i will fit the foot pegs, think this will be a good starting place.

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Image

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 Post Posted: Sat Jan 14, 2017 8:19 pm 
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got the lower shock link brackets back from Taff, well pleased with them, I have done a quick
test fit and all is good.
i havent got time to do anything else tonight as i am off out for a meal, but
I will get some pics up as soon as i get a chance some time tomorrow.

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 Post Posted: Sun Jan 15, 2017 1:09 pm 
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Pics of lower linkage mounts, they are only ruff at the ends and will be cut and sorted before
getting them welded.

Image
Image

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 Post Posted: Sun Jan 15, 2017 2:21 pm 
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Nice :clap

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 Post Posted: Sun Jan 15, 2017 2:53 pm 
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Wow - this is starting to look really good :D :clap


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 Post Posted: Sun Jan 15, 2017 11:18 pm 
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cheers guys :)

cleaned up the mounts and cut down a bolt so i could get them lined up.
now marked up ready for tacking in place.
have ordered some Ti and some S/steel bolts for the end fitment.

Image
Image

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 Post Posted: Tue Jan 17, 2017 11:02 am 
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frame is now ready and booked for some welding tomorrow afternoon, (lower frame loop replacement, lower linkage mount, some tube re enforcement)
made some spacer plates for the shock mount plate.
once i have this done i will start on getting the engine in and some frame bracing made up for the next session of welding to be done.

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 Post Posted: Tue Jan 17, 2017 10:24 pm 
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made the strengthener tubes for the top of the shock mount plate, just need to drill the cross member and insert some
crush tubes for the two mounting bolts.

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Image

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 Post Posted: Thu Jan 19, 2017 12:19 pm 
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Knob Magnet
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should pick the frame up this afternoon, might do a test fit of wheels if i get time.

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 Post Posted: Thu Jan 19, 2017 11:45 pm 
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good days work, got the frame back and cleaned up the weld on the lower frame tube.

Image


then put everything together (shock without spring) so i could test the suspension for free movement and correct range of movement.

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once i was happy with it i replaced the spring and got it on its wheels

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will get it back to bits so i can get some more welding done before getting the engine in

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 Post Posted: Sun Jan 22, 2017 11:23 pm 
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Knob Magnet
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more work done on the frame, cut some more strengthening tubes for the head stock
made and inserted some crush tubes into the cross piece for the top of the shock mounting plate. I
will cut them down once welded in place.
welders again soon.

Image
Image
Image

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 Post Posted: Mon Jan 23, 2017 9:43 pm 
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took the cross bar support to the welders today, hope to get it back tomorrow so i can get it
mounted and bolted in place before wheeling the bike round to get all the supports that have been done so far welded.
also went and ordered some hi quality rose joints, half nuts & S/steel bar, to make some adjustable length turn buckles for the suspension.

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 Post Posted: Mon Jan 23, 2017 11:33 pm 
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Love it - some proper engineering skills going on here! :clap :D


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 Post Posted: Mon Jan 23, 2017 11:39 pm 
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Knob Magnet
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cheers Hoon :angel

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 Post Posted: Tue Jan 24, 2017 10:50 pm 
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got the cross support back from the welders, cut off the excess, cleaned it up ready
for fitting to alloy shock mounting plate.

Image

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 Post Posted: Wed Jan 25, 2017 10:52 pm 
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fitted the cross bar with the bracing tubes ready for welding in place.

Image
Image
Image

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 Post Posted: Fri Jan 27, 2017 11:29 am 
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Last night i went to visit Taff with the next lot of machining requests that i have,
need him to remove some metal from the sprocket seat on the carrier, remove some metal from one swing arm spacer and
re make the other with a thicker seat face. i have also now got the bits i need to make an adjustable set of suspension link rods to replace the stock
flat plate ones. i have some rose joints and some stainless steel bar that Taff is going to make into a turn buckle for me.
whilst there i got to see the progress on my yokes for the GS1157 (looking good).
frame is going back to the welders this afternoon for bracing tubes & lower shock linkage mounts to be fixed,
now i am happy with the test fitments.
having removed the shock linkage from the bike, i thought i would give it a check over, i knew the bearings needed replacing, but when i did the test
of the suspension after fitting the lower mount, the suspension seemed a bit rigid, this was traced to a seized linkage bearing!!!!!
so bearings will be getting ordered as and when i get round to it.

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 Post Posted: Fri Jan 27, 2017 11:51 pm 
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welder was snowed under this afternoon so didnt get any tubes fixed in place, instead i
sorted some more bracing to get done when i can get some welding done.

Image
Image

I have ordered some new bearings for the suspension linkage, set about removing the old shot bearings, got
the two end ones out no probs, but the two central ones have put up a bit of resistance to moving, i have left them soaking in penetrating oil to see
what happens tomorrow.

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 Post Posted: Sat Jan 28, 2017 2:57 pm 
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Knob Magnet
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I am glad that i have what can only be described as "the best utility tool ever" in my tool collection.
to some it might only be called a Dremel, but it has got me out of a lot of problems up till now.
today it worked wonders at cutting through the outer bearing shells that i couldnt get to budge.

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once i had them cut through, they came out with very little persuasion. i then removed all the casting marks and gave the link
a good clean up ready for either paint or powder coat.

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Image

package from the US arrived today with my seat catch and hinges, so got them fitted.

Image

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 Post Posted: Sun Jan 29, 2017 7:00 pm 
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Knob Magnet
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as i mentioned not too long ago, I am going to have a go at re spacing my FCR carbs, as also mentioned was the fact that
it was quote for the job to cost £300,
wellllllllllllll, 15 minuets with my allen keys and i am like this, didnt take much thinking about, now i have done it once, i am
sure it wont take more than 10 mins to do next time. parts wont have cost more than a few quid, so dont see how they can justify
asking £300 for doing it FFS

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was only six M5 socket head bolts holding the carbs together, the throttle slides needed the small grub screw and nut undoing so i could slide the carbs off the throttle bar,

Image

the spacer tubes will be easy to make, the fuel "T" pieces will work at the larger
spacing i will be doing, so wont need replacing.
will also need some slightly longer fuel hose to go between the carb bottoms.
main thing that will need replacing is the throttle bar, but as it is standard GSXR 600/750/1100 spacing i think
i should be able to get one off the shelf somewhere.

Image
Image

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 Post Posted: Sun Jan 29, 2017 7:47 pm 
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Quote:
main thing that will need replacing is the throttle bar, but as it is standard GSXR 600/750/1100 spacing i think
i should be able to get one off the shelf somewhere.


... and thems throttle bars only cost £200 :rollin

Excellent work Steve can't wait to see those carbs fitted :clap

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 Post Posted: Sun Jan 29, 2017 7:56 pm 
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Knob Magnet
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Biggabit wrote:
Quote:
... and thems throttle bars only cost £200 :rollin



Saved myself £100 then lol :lol :lol

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 Post Posted: Mon Jan 30, 2017 11:01 pm 
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Knob Magnet
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as i was picking up my yokes from Taff I left him the sprocket carrier for the removal of 8mm
of metal from the sprocket seat.
and i asked about making some spacers for the FCR carbs, spacers on their way.

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 Post Posted: Tue Jan 31, 2017 11:45 pm 
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took the frame round to the welders, got just about everything sorted, just footpeg and engine mount inserts along with
the lock stops.
whilst with the welder he asked me what engine i was fitting
told him it was a bandit 6,
then he says he has a complete one sat in his garden if i wanted it!!!!
so i am picking it up Sat, even if it dont run, I will be able
to use some of it, what i dont use i will put on the Bay of Evil, win win :)

Image
Image

took the carbs to work and gave them a good going over in the kero bath

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 Post Posted: Fri Feb 03, 2017 10:30 pm 
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Knob Magnet
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Got the sprocket carrier back from machining, 8mm off the sprocket face.


Image


got to cut down the sprocket bolts yet, but sprocket now as close as i think i need it without being too close


Image

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 Post Posted: Sun Feb 05, 2017 5:19 pm 
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Knob Magnet
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picked up the "Parts bin" yesterday, will be able to use a few bits for sure, had thought about
trying to get it sorted and back on the road, but not sure it is worth the time and effort, still
need to decide.

also came with a box with lots of bits

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Image

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 Post Posted: Sun Feb 05, 2017 7:44 pm 
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What a stroke of luck. That'd be a great parts bike. I may know somebody who'd take it in one lump if you felt able to do that.


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 Post Posted: Sun Feb 05, 2017 8:19 pm 
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Victor Meldrew
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Blimey !

That would fetch a fair few hundred quid on Ebay, if prices asked for some of the crap out there is anything to go by.

Check out 'Project Finder' in Practical Sportsbikes ...

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