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Guest

Project Kwikasfaki

Not sure if you guys want this project posted on the "S" series forum as it's a H2 special?

I'll start it but if you're not interested please say.

This is what I have so far:
Gary's drag bike H2 motor


A gsxr 400 frame and Aprilia swinger


Dymag alloy wheels



And here are the yokes I had made to order by "Billet Bike Bits"


garyb

you keep it on here cabbie me likey drunken
Guest

Hi
A other great build to look forward to wav


Sören
bubba2

Sweet bring it on.. drunken
scouse

looks like a cool project  icon_biggrin.gif

good luck

Gary T
Guest

Thought I'd make a start on the rolling chassis, there are two problems to get round:

1, the rear wheel is off a gsxr 1100 that uses a 20mm axle, the swing arm is off a YZF R6 that uses a 30mm axle, I'll need to make reducing bushes to fit the chain adjusters


2, the R6 swing arm is 25mm wider than the gsxr 400 frame, this will need a lot of fabrication, I intend to cut the pivot section off the R6 arm and weld on a gsxr 400 swing arm pivot section (I got a gsxr 400 swing arm with the frame)


The Kwaka 750 engine is a simple fit in the gsxr frame, just a few mounts to weld on.
Guest

Right, time to get this built.

I made the reducing bushes for the R6 swing arm


The forks are back from FireFox racing full rebuilt with Ohlins internals, re-valved and anodised etc etc



I got Brembo calipers, just need two adapter plates to mount the on.


Now I wasn't sure how to build this but I've thought for some time and decided to go with no light, no clocks or anything electrical, I got this box from the states to control the engine ignition etc so this is the wiring loom/harness


Looking good already, lol just need to get the swing arm in the frame then it easy from there.
BIG AL

looking good there cabbie, keep us update with more photos
Guest

I've spent the last two weeks working out how to fit the R6 swing arm in to the GSXR 400 frame, it's a little more of a challenge than I first thought, this has to be done right or the end build could turn out a disaster!

The plan was to cut the pivot section off the R6 swing arm and weld on a pivot section from a gsxr 400 swing arm, this seamed the easiest option BUT would have caused chain clearance issues etc.

This is the R6 swing arm pivot spindle


The large threaded section is the same as the gsxr 400 frame thread so It'll screw in to the frame ok, what I'll do is machine 10mm off each side of the inner frame so the swinger fits in, the R6 spindle is too long so I'll cut the end off and re-thread inside the spindle and use a bolt instead of a nut, the other end of the spindle will be trimmed to sit just inside the frame recess, sounds complicated but it'll work well.

The only problem is removing the 10mm of alloy from inside the frame to slide the swing arm in as it'll have to be done by hand, I'll make up a jig so each side is cut true.
Guest

Had some free time for the bike today.

The front Dymag is made for a gsxr 1100 that uses a 20mm spindle/axle, unfortunately I'm using gsxr 400 forks that use a 17mm spindle/axle, so, here are the front wheel spacers and bearings


What I've done is made new spacers with a 17mm bores and change the right hand bearing from a 6204 to a 6303 (same size bearing except the ID measurement)


Here's the new parts fitted, I just need two outer spacers now to fit the wheel.


I also made a reducing spacer for the rear caliper holder


The new carbs arrived too, blood moosive they are, lol

Guest

Had some seriously bad news today, the workshop I rent has been sold to a property developer and I'm out by next week, gutted, I've bought an 8'x6' shed but with the blade and S3 in it there ain't going to much room for building etc so project on hold for now.
Wolfie

That's a bugger Cabbie, sue the guy.

I'll have yer 400 then.
konky456

and il have ya blade all sorted eh ps must be cheap tho  :thumbright:
Guest

Loads of sympathy here for my workshop loss, bloody vultures.

So I thought I would get the swing arm fitted before I have to move out

Made an MDF jig and routed out the frame both sides by 10mm



Swing arm fitted, the spindle will need cutting down etc


The R6 shock linkage fitted straight to the frame! result there, just need to make two longer track rods


Here's the back end done, all the wheel spacers are made and the caliper holder is in


Bought some very nice bar risers too


I'm going to call my mate that has a very large spay shop, he might let me rent a corner to continue this build, fingers crossed
bluesmokebilly

If i had the space and lived nearer cabbie, you`d have no worries mate, fantasic work to watch and some great ideas for my s3 project , still in similar position, currently looking for house to buy, but must have space for workshop and storage, wife wants large kitchen and en suite what a waste !!! anyway good luck mate i`m sure you will sort somthing, cheers Billy
Guest

Wel the new site owner is having major issues with planning permission to develope the land so he said I could continue using the workshop, nice.

On to mounting the Brembos, these have come up just about as awkward as possible for mounting to the forks


What I always do in cases like this is make a template from MCF because MFD is cheap and easy to cut etc, here's the template



I make sure the piece is perfect in fit and appearance then send it away for CNC'ing out of 7075T6 alloy.


I'm using adjustable turnbuckles from a car steering system so set up the ride height, once the bike is finished and the rear suspension is set up right I'll make new alloy rods to replace the turnbuckles


I need a new top shock mount to hold the R6 shock, I've made a pattern from MDF for the CNC man to copy



And making sure it all fits before sending away


Next problem Opps I mean challenge.
I bought a very nice billet gsxr 1100 rear caliper hanger and a used gsxr 1100 caliper but the caliper weighed the same as a semi detached house so it went in the bin.

I bought a Brembo caliper to match the fronts, only problem is the Brembo won't fit the hanger


But with the caliper sitting on top of the hanger it's in the correct position for the disc so I'll just need a bridging plate, simples!
Nikfubar

Awsome build  Exclamation
Schurminater

Cabbie,just picked up on this build,very impressive work,and great detailing ,the MDF patterns are a great idea and though i,m sure they take time to make its an impressive way of pattern making and getting exactly what you want. Another great inspiring build good luck,wil be watching with interest  Exclamation
Guest

The project has been on the KTC website for months now, I didn't update here as I thought everyone uses both forums, here's some up to date pix for anyone not on the KTC site

It's getting pipes made next week my Mark Dent (the RD 500 specialist)






bridlad

man i love that bike.. yeah keep updating the progress on here please cos i dont go on that other site  Exclamation
Schurminater

Ditto!!! That truly is an amazing looking bike, Exclamation
malcolm

I absolutely hate specials, but you really, really have to applaud what Cabbie is building here. We had his S3 400 on the club stand at Stoneleigh and the Engineering is top class.
What I really want to see is him trying to hang on to the B*****d when it comes on the pipe  Very Happy  Very Happy  Very Happy
180kid

malcolm wrote:
I absolutely hate specials, but you really, really have to applaud what Cabbie is building here. We had his S3 400 on the club stand at Stoneleigh and the Engineering is top class.
What I really want to see is him trying to hang on to the B*****d when it comes on the pipe  Very Happy  Very Happy  Very Happy


thats funny Malc, dont think he even rides em'... Laughing  Confused
Guest

180kid I asure you I'll be putting many miles on this bike, ALL the paper work is done so no DVLA  shit this time, I'll even let you have a go!
180kid

cabbie wrote:
180kid I asure you I'll be putting many miles on this bike, ALL the paper work is done so no DVLA  shit this time, I'll even let you have a go!


cheers pal....i'll put the fuel in, Exclamation  Very Happy
trent

Special

Wow, that is fkin impressive..... Shocked
Rubbadub

whats the latest on this build cabbie, I have been missing your posts, have you had the pipes back yet?
Guest

Bike is at Mark's place having the pipes made, should have the bike back next week.
Rubbadub

bet u cant wait.... Mr. Green
Guest

Rubbadub wrote:
bet u cant wait.... Mr. Green


ERRRR yeah, lol  looking forward to kicking the motor over and hearing it fire up
Schurminater

Don,t forget to post us some pictures...... Exclamation
husson73

cabbie wrote:
Bike is at Mark's place having the pipes made, should have the bike back next week.
great Exclamation
Guest

It was a long wait but well worth it, Mark just sent this pic of the finished chambers, I can hear it ticking over already, will pick it up Friday evening.



Little vid
http://www.youtube.com/watch?v=tqMYvKfsO0E
olde coney

stunning Cabbie.....I'm hoping that you and the bike will be at the Norvern rally
kezsam1

cabbie this might be dumb of me but i am sure i saw somewhere you did another project but i cant find it anywhere the green and white 400. Help please!!!!! Shocked
Guest

kezsam1 wrote:
cabbie this might be dumb of me but i am sure i saw somewhere you did another project but i cant find it anywhere the green and white 400. Help please!!!!! Shocked


http://kawasakikhregister.myfastf...bout987.html&highlight=cabbie
kezsam1

thanks  Exclamation
Guest

So, you guys ready to see it?










There is still a few bits to do, the pipes need shortening at the back as vibration is an issue but this is how it will look









Schurminater

You know i,m sure we often take project work for granted sometimes by expecting tatty bikes to look a million dollars just by throwing heaps of cash at them and i guess it can be made a little bit easier for us today with the services and specialists available to us,though i know that is not entirely true and there is a much bigger picture and story involved with all projects.

However every now and then a bike comes along which stops you in your tracks and lets you marvel at the sheer vision,quality and the craftsmanship that has been applied and you can only stare and take it all in.
It may not be to everyones taste and there may be parts of it that I and you may not agree on but you cannot fail to notice  the Sheer Beauty and the bravery of producing one hell of a fine motorcycle and i for one Applaud you Cabbie.....Stunning Cool
bubba2

HEAR HEAR  Cool
delboy

WOW Exclamation  So will there be a show down at the OK Carrol with Ian Owen & the stelf Neutral Hope you can bring this baby to the 2011 Garden of England rally this year matey Cool
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