CSR1000 Project Build

Well,its getting there. I brought the mudguard home today and plonked it on the bike..It still needs sanded but Im happy with it.






Now I have to figure out how to mount it. I thought that a plastic part would need some sort of rubber washer/spacer thing to prevent over tightening the bolt and cracking the plastic but looking at my Bandit and the neighbours Diversion they both seem to have the mudguards bolted directly on.
Any ideas out there?
On the same subject, the tailpiece needs something similar. So I got creative today.

An allen bolt,a threaded masonary plug,a steel washer and a rubber washer. I drilled the plug out to accept the allen bolt and cut it to length. I drilled out the rubber washer to go over the plug. Put the steel washer on top of that so I have a sort of rubber insulated top hat spacer which I can tighten down enough to hold the tailpiece firmly but not crack the fiberglass .




One last thing. If youre working with fiberglass and you have any cuts or scratches o your hands ,I recommend that you leave them open and work without gloves.It makes your fingers swell up and throb with pain. Great fun!!

That fender looks great. Better than the shrouds others have. Just looks out of place. I would have embedded the washers in the fiber glass. A old trick when we installed insulation. Take a tacky bar of soap and rub your arms from the elbow towards the hands. The shards come out of the skin because the go in the other way. Gloves? What are they? :lol:
Steve

Really nice work Davido. The fastener solution is ideal. Great work as usual.

davido wrote: Well there are a whole range of them with different density from soft and fluffy up to builders foam hard. They had examples of each one in the shop and this one was somewhere in the middle. Hard enough to not totally colapse uder weight but soft enough to cushion my delicate culo.

interesting. i didn't know they came in different densities. Im curious to see how it works out for you.

Thanks for the compliments boys.Quick update. Nothing happennig until my hands get back to normal. I am back at work but my fingers are wrapped up like mummys! Its a bugger really as the fiberglassing is so close to finished, just trimming and sanding left to do.

My hands are nearly back to normal.So I had a good look at the bike the other day and my eyes were dragged to an old problem

I posted about this a while ago and did nothing else about it.Strangely enough,it hasnt fixed itself so I took it off to the frame builders to get it sorted.A major operation getting the bike out of the basement. 3 people,some rope and a scaffold plank.

Another problem thats come to light through another thread from Lacher
www.kzrider.com/forum/11-projects/600462...rt=20#s5_scrolltotop
is the ground clearance. I finally got around to measuring it with my 100kilo neighbour on board,I get this

7,5 cm!!!! Twixt the ground and the lowest point on my Harris. This isnt going to work. Its plain dangerous. Ive been going over possibilities
to get it raised .
Flovianus put me onto this idea kzrider.com/forum/5-chassis/562261-zx9r-forks , which I like very much (cheap and cheerful) but its only going to get me and extra 2cm+- at the fork,which translates to less at the exhaust.
Another idea is a stepped top yoke which is also a good idea.So good, itll cost me 300-400euros!
So if any of you have any other ideas,please lets hear them as Im a bit stuck with this.

P.S. I asked the frame builder to take some photos of the bike on the jig. If he sends them,Ill post them.

Frame back from the builders and Im very happy with it. You can see in one of the earlier photos that the rear engine mount was squiffy.Good news is that the frame itself was good and straight. He sorted the dodgy mount and got everything else lined up. He welded an extra brace in behind the mount. The back wheel was a little bit off center ( I just had it spaced with a bunch of washers),so he turned up a new spacer for that.
So the bike is straight and the wheels are centered!
On top of that,he had a front sprocket with the right offset (from back in the day,I assume) and he threw that in ,so the chain run is sorted. He also managed to drill out the broken case bolt,weld up the hole and rethread it. Fantastico! Im well chuffed. I can get the clutch conversion sorted now.

That's one hell of a swing arm. Can't wait for launch time.
Steve

sounds like he took good care of you!

glad it all worked out.

leon

Looks great Davido. Glad the cases got sorted out as well. Are your sprockets going to line up?

Sprockets and chain run are sorted. Next thing is to measure up the suspension and get the front end lifted a bit.Also a bit more welding,finalize the fiberglass,get the seat foam poured,touch up the paint,cut new adapter plates for the rearsets,get the hydraulics sorted for the clutch,etc,etc,etc,etc,etc!

The swing arm looks like the one I just got. What did you do to make it fit the frame?
Steve