Phoenix Fighter

swest wrote: Sounds good. Will you have some plastic mock ups to test sizing? MAN it's got to cost a bundle. If it weren't for that, I was thinking you could beef up around the top and use those extenders. I'm sure it's better the way you're doing it. Like to see pics of the progress.
Question; Weren't the early Honda top triple clamps sand cast? I read they did that until they knew if the bikes would sell or not then the tooled up molds. That's why I suggested casting the top clamp.
Steve

Sandcasting might be alright if the triple was flat but with the nearly 2" of drop I need all the strength I can get. The cost will only be in materials as i am getting the drawing and tooling labor for free.

As for the proto type, yes, there will be a 3D printed version first for fitment. I may have someone else mill it the first time as my brother wants to mill it in his garage but I would have to wait a few months. I don't want to wait months to get on the bike as that would put me in the Arizona summer. I may just turn a couple of fork tube extenders in the lath to get me by.

That's a good plan my friend. Maybe a couple sleeves to go on the outsides of the tubes for more strength. That way you can enjoy all the hard work you have into it.
Steve

swest wrote: That's a good plan my friend. Maybe a couple sleeves to go on the outsides of the tubes for more strength. That way you can enjoy all the hard work you have into it.
Steve

With a pinch bolt on the bottom

Top and bottom, that way you can have a little space for adjustment of the steering head.
Steve

I also get to use the stock stem and bearings.

Are they in the front end you were planning on using? Cool
Steve

swest wrote: Are they in the front end you were planning on using? Cool
Steve

No, it's a bearing conversion kit from All Balls Bearings and the GSXR stem. That is why I went with this front end, at the time I didn't want to do machine work. I have learned a lot building this bike.

You're a trail blazer and the ones like you. I sure we all are learning from this.
Steve

I'm using same forks as you...93 gsxr1100 forks . When I mock up mine ( see sig pic) I had almost 4" clearance with the exhaust on.
I'm using all balls conversion bearing kit

spdygon wrote: I'm using same forks as you...93 gsxr1100 forks . When I mock up mine ( see sig pic) I had almost 4" clearance with the exhaust on.
I'm using all balls conversion bearing kit

Mine are 92 GSXR 750's, I have been told the 1100's were longer.

spdygon wrote: I'm using same forks as you...93 gsxr1100 forks . When I mock up mine ( see sig pic) I had almost 4" clearance with the exhaust on.
I'm using all balls conversion bearing kit

Do you, or anyone else know if 91-92 GSXR forks are longer than the 750's?

4inches is about 10cm. Thats about what I have with the ZX9R forks and thats with the bike standing at rest.No paddock stand and no rider.
That is not a lot and (for me) not enough.
I was talking with my local bike shop owner about this today. Fork extensions or dropped triple tree? Im still undecided.With fork extensions,you have a weak spot,with dropped upper yoke you have a weak area,unless you drop the bottom yoke as well,in which case you have an empty bank account!For the money,he reckoned the extensions would be good enough.
I was also thinking about heavier springs in the forks but he thought that wouldnt work because the springs are rated to the weight of the bike. I pointed out that the ZXR springs (in your case GSXR springs) would be rated to the weight of a ZXR (GSXR) which would be a lot lighter than a 1980s KZ so,it should be possible to fit heavier springs without losing effectiveness in the front suspension (probably improving it). Heavier springs would,in theory, lift the front end,though I dont know by how much.Then again,every little bit helps!
Im just running this around in my mind at the minute as I have a ton of other things to sort out first but I need to sit down and figure this all out. First thing is to set up the sag properly ,as the bike is.Take some proper measurements and go from there.