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Re: Project X

Posted: Mon May 04, 2020 3:45 pm
by teazer
Ladies,
If you don't mind, please take your banter to another thread. Joking around is fine, but this is getting old when it spills over into a build thread.

Thanks

Re: Project X

Posted: Mon May 04, 2020 4:21 pm
by stevewharton
teazer wrote:Ladies,
If you don't mind, please take your banter to another thread. Joking around is fine, but this is getting old when it spills over into a build thread.

Thanks
Couldn't agree more!

Re: Project X

Posted: Wed May 06, 2020 8:44 pm
by madforitkev
So now I have had a chance to run it a bit with a set of old finely adjusted (hacked) Dencos, it was time to look at the custom (properly tuned) exhausts.

First step, confirmation of the current porting.
ports.JPG
Most dimensions are above, in addition.

Exhaust is now 57 wide (stock is 47 wide and 25.3 high)
Transfers I left at stock (37) wide and height (12mm)
Inlets now 27 wide and 32 high (stock is 28.5 high and 25 wide).

Because of the reed valves I also have ports in the piston skirts.

Remember I also have zero deck because of the squish (O ring) head, so all of my opening times have changed (as in the picture).

Anyway, luckily I know a genius with exhaust calculating software and the bottom line is to get the best power curve, I need to raise my transfers by 3mm. No probs will do that on the pre-paint strip.

So my exhaust will look like......

teazer2.jpg
......with a small compromise. I want to use tube headers to avoid segments and seam welds and that means s straight header (not a small cone as in the optimal calcs). But running the software again, I loose a small amount of power above 8k so I'm not worried about that and prefer the cosmetic improvement, Also I can apply a small swage to the out end of the header which might bring some of that power back. We will see.....

The power curve should look like this.....fingers crossed!!
Teazer.jpg
The stinger (tailpipe) will actually be slid in and welded 200mm down into the diffuser/belly to leave a small bit sticking out for a slide on silencer.

The header should finish up like this.....leaving a bit of extra length for adjustment....
IMG_2397.JPG
Time to go cone developing and welding.......

Re: Project X

Posted: Fri May 15, 2020 3:37 pm
by madforitkev
Got the new stainless steel headers back today.
IMG_2470.JPG
Plan is to still use the GT header clamp but add a dual radial O ring seal feature as the compression seals are a bit crap. If that works well I may even do away with the old seal and clamp and use quick release springs.

I also went back to the clocks.

Started with 1200 Bandit clocks and console.
download.jpg
download.jpg (8.02 KiB) Viewed 811 times
I wanted to be able to change electronics so had to design a split casing to get PCB's in and out.
IMG_2446.JPG
The black glass is the original glass with window tint inside. This obviously meant undoing the bezel crimp rings and resetting them again!
IMG_2447.JPG
The small gauge is now the GT gear indicator.Speed/revs on left. Fuel, temp and general OLED display on the right.

I will polish the newly machined domes up and get it all mounted next week.

Re: Project X

Posted: Fri Jun 26, 2020 2:27 pm
by yeadon_m
I’ve thoroughly enjoyed reading this right through in one go.
As an officially not very skilled at anything amateur, I’ve no idea how one person can plan & fabricate to the extent you have done. Like many here as well, I’m a purely analogue guy (except where it comes to the disciplines of new pharmaceutical R&D, where I occasionally surprise myself).
Bloody well done. Would love to see a YouTube “how the GT750FS was made” plus clips of it running / being ridden. All in due course, obv.
Cheers!
Mike

Re: Project X

Posted: Sun Jul 12, 2020 4:51 pm
by madforitkev
Appreciate the comments Mike. It has definitely been a labour of love and learning new skills.

I might try to a consolidated write up for one of the mags sometime.

Still stuff to do.

Final exhausts are at the welders now. Software is almost done. Then the fun begins......Carb tuning, dyno then take it all apart and bling it up.

Havent quite decided on the colour scheme yet....

Stay tuned.

Re: Project X

Posted: Thu Jul 30, 2020 12:00 pm
by madforitkev
Another small update (still waiting for exhausts!!).

So the clocks are all done.

For those that have followed this you will remember it involved;

1. Strip out Suzuki Bandit clocks
2. Make new bodies
3. Make new glass/bezel holders
4. Black coat the inside of the original glass
5. Design electronics and PCBs to include;
a. gear indicator (in middle)
b. Rev bar display (on left of left display)
c. Speedo digits display (on right of left)
d. Temp gauge (left of right display)
e. Fuel display (right of right display)
f. OLED data display (middle of right display), for; GPS (lat-Long), Speed (GPS), bearing, Water temp (in digits), fuel left and miles to go, Odometer - tripmeter, Battery level, engine revs in digits and clock
6. Write software
7. Make new back covers
8. Change main console display (High beam etc.) to LED's.
IMG-2990.jpg
All jolly good fun!!

Re: Project X

Posted: Thu Jul 30, 2020 12:45 pm
by Alan H
Very impressive. I'd like to see it 'in the flesh' so to speak.

Re: Project X

Posted: Thu Jul 30, 2020 5:00 pm
by madforitkev
That is definitely the plan!!

Once the exhaust are done then final tune up and strip, paint and rebuild.
The easy bit!!

Re: Project X

Posted: Fri Jul 31, 2020 9:57 am
by 2StrokeDreamer
Incredible.