CSR1000 Project Build

Yeah,one of the reasons I decided against powder coat! Anyway,called in at the alu center after work today so I have some 3mm plate for an undertray and the 10mm slab for the clutch conversion. Looks like Ill be having an 'alutastic' weekend

Hey! 1 Year since I started my 'CSR1000 Project Build'.
Happy Birthday to me !!

Good day today Pt1;
I got the undertray cut and dry mounted.Very happy with it. Cut with a jigsaw,bent with a homemade bender (see Youtube),sand the edges to take the sharpness off. It slid right into the original mounts then a couple of 6mm bolts and Bob's your uncle.







Sorted

Good day today Pt2;
Started on the Hydraulic clutch conversion.
First,I laid out the original cover on a piece of 9mm MDF. I dropped the screws through the holes and whacked them with a tapometer.Then I drew a rough outline.


Next,I copied that onto a piece of cardboard and tried it out on the bike to make sure it lined up


Cut out the MDF and fit that


Not too worried about the distance from the engine yet.That'll come later.


For now,its about getting all the holes lined up and in the right place


This is the slave cylinder Ill be mounting.Its from an early ZX9R


Thats as far as I got. I need my hole drills and theyre in work.Ill get them tonight.
When the holes are all drilled.Ill work on getting a nicer fitting outline . Ill maybe do another piece of MDF to get it all a bit cleaner before transferring it to the alu plate.
Anyway,a good day.Finally some progress. Like I said, One year on the build. I was hoping to have the engine in by now but that aint happening yet.

Fantastic, Davido. Really nice job so far. I did the same thing with cardboard. I like your idea using the MDF. I have to make some mods to my template then I will transfer them to MDF. I opted for a slave cylinder off of a GSXR, only because it has 2 mounting wholes instead of three, makes drilling wholes for it easier. Keep those pics coming. What are you using for a master cylinder? Also off the ZX9?

Yes,the whole thing came from swapping the front end for a ZX9R. With the newer brakes on that I needed a matching mastercylinder,. Then of course the handelbars would be lopsided with the old cable operated clutch so I had to go with the hydraulic one.(Yes ,also ZX9R)
The MDF is good as you get a more solid thing to work from,and its a similar thickness. My biggest worry was the pushrod would be off center which would bugger everything up but it seems good.
I checked my hole drills tonight and I dont have the right diameter (I need 42mm) to sink the slave cylinder in. Ill try and get one tomorrow.

Davido,
I was doing some research for a Clutch Master Cylinder and notice the year of ZX9 you are using for parts has a MC reservoir attached to the lever. The angle that the MC reservoir was designed to sit on clubmans not on upright handle bars. This may cause air bubbles in the line. Just something to verify won't be an issue.

Hmmm! Ok,well something else to think about. I did buy straight bars (actually,I think i they were the first thing I bought on this project ,To kill the cruiser!!) but Ive also been having these strange perverted thoughts about clip ons!!! So Im not sure which way Im going to go. I have the straight bars,so Ill work with them for now.
So many details come up that you cant forsee everything. My attitude now is just to plow on . I noticed the gearchange rearset that I mounted is mighty close to the side stand. Is that going to cause problems? No idea.Ill throw myself off that bridge when I come to it.
Onwards and upwards.

kaw-a-holic wrote: Davido,
I was doing some research for a Clutch Master Cylinder and notice the year of ZX9 you are using for parts has a MC reservoir attached to the lever. The angle that the MC reservoir was designed to sit on clubmans not on upright handle bars. This may cause air bubbles in the line. Just something to verify won't be an issue.

Correction, they were designed for clip-on not clubman. The drag bars may be alright as they would be close to the same angle.

davido wrote: Hmmm! Ok,well something else to think about. I did buy straight bars (actually,I think i they were the first thing I bought on this project ,To kill the cruiser!!) but Ive also been having these strange perverted thoughts about clip ons!!! So Im not sure which way Im going to go. I have the straight bars,so Ill work with them for now.
So many details come up that you cant forsee everything. My attitude now is just to plow on . I noticed the gearchange rearset that I mounted is mighty close to the side stand. Is that Goin g to cause problems? No idea.Ill throw myself off that bridge when I come to it.
Onwards and upwards.

Yes, I have had the same conversation with myself. I decided I needed to get it up and running then doing some of the tweaks that aren't required. And then I saw your post on the hydraulic conversion and Had to do it too.

Im sure other people have posted about it here but Im done trawling through the archive .Too many hours have been eaten up doing that already.If someone can point me to a specific build that would be great,otherwise Im just having a go at it. This is the build that inspired me;
www.badseeds.fr/construcbstwo.html
near the bottom of page 4.
Are you posting about yours? If you did,I could follow yours while you follow mine then neither of us could go wrong?!!?!
(Shops were closed today so I didnt get a hole drill.Ill get it tomorrow.)

So,apparently 42mm is an odd size for a hole drill and nobody has it,so I went with a 41mm.

The hole was spot on centered

I sanded it out a bit and got a nice snug fit

How it meets up with the push rod

and itll sit something like this

so i will recut the profile on the front of the MDF before I transfer it to the alu plate

Thats it so far.
Something I forgot to mention,the main reason for using the MDF is to end up with a template.The plan being to cut the alu slightly oversize then run around it with the router to get a finished shape. So all the mistakes can be done on the first piece of MDF,then I make a second MDF plate, the good one, with all the holes drilled in the right place,the right profile to mate nicley with the block and nice clean ,sanded edges to run the router around. Then go for the final piece on the 10mm alu.
I havent tackled such thick aluminium before but the guy at the aluminium center reckons its no problem to use wood working bits.So long as I keep the piece cooled . A jigsaw for the rough cut then a copy bit on the router and lots of WD40.
We will see!