XR11/73

[garry55]

You're certainly making good use of that grinder / cutting wheel Garry :-)

too much for my home grinder - it's died a death, having been shown too much graft. Serves me right for buying a cheapo one - the Bosch grinders at work can handle it though!

I'm actually hoping to add material to the frame some time soon.

[garry55]

A liitle progress.......

as I am waiting on the frame being welded, I thought I would spend some idle time pursuing the radiator idea I've been thinking about. See what you think...............

Below is a picture of a standard-fit GSXR400 front fairing bracket, complete with headlamps.



as I am not running the bike with lights, these were removed and a small, aluminium radiator sourced from my local bike shop that was of a similar size to the bracket.



it's off a Piaggio 2-stroke scooter - nice and light and compact. Maybe too compact? We shall see.............

next up, I removed the original headlamp mounting brackets and made some new lower mounts, drilled to take some rubber bushings



these take the radiator's lower locating pegs, like so......



then, with the radiator in situ, I could shape the top mounts....



next up - welding. I know it's not to craftsman standard, but I'm only just learning the dark (light?) art of welding so it's actually pretty good for me.......and it's cheap!



the radiator, mounted to the bracket.







I don't have, as yet, a front fairing (or anything to attach it to at present :( ) but if you were to remove the headlamps from the pic of the GSXR400 below, all you would see on my bike would be a radiator.
And the front wheel. And the forks. But not the mirrors. Oh no - not the mirrors.............

[garry55]

and as I still had a bit of spare time, I addressed the top yoke

this has no place on a race bike, so I cut off the ignition switch mount.........



and the instrument cluster mountings........



then set about removing the ugly casting marks.........



much filing later, it's de-seamed and ready for the shot cabinet to remove the un-wanted shine......



and emerges resembling a "works" lookalike magnesium top clamp.......







I know - totally meaningless - but it passed away a few hours.

the bottom yoke needs doing now.................

[mark.read3]

Superb, can't wait to see the end result.

[garry55]

onward.....................

[garry55]

the "G-Plan" diet commences............

some serious exercise required to tackle the excess girth





not running any lights, so won't be needing this......





thats better - now I can re-locate the ignition from the other side into here (and no- I didn't smash the casing - it was like that when I bought the motor - honest guv)



only problem now is that the crank protrudes outside the casing



spacer required, methinks.......more bloody fabrication.

[garry55]

it's amazing what a bit of pondering can achieve - and it's legal too...........

as the generator cover is damaged, it is only fit for the scrap bin - but not without donating a vital part.

Apply some careful hacksaw wielding



the spacer



fitted



result :D



just a cover to make and weld on and thats done - 3" lost already - diet going well 8-)

[oldjapanesebikes]

Nice !

Just wondering - will you need to cut a keyway in the right side end shaft to ensure the timing for the self generating system you will be installing can't move around ? Or do you plan to rely on the taper ?

[garry55]

good point Ian - I have contacted the manufacturers to ask exactly that question !
I will let you know their response.

[oldjapanesebikes]

I was curious as I was looking at possibly putting the ignition on the right side of a project I have in mind, and use a GS alternator on the left side as I'd still need full lights etc. Still in the research phase !

And will the self gen system put out enough juice to power a brake light ? Or do you need them under your day time running classification over there ?