Well it's been a busy week shopping for parts but I think I'm almost done.

Got a super set of OZ wheels shod with Racetec rubber


A mint condition gsxr K9 front end, I sent the yokes to streetfighterbling.net for them to make a billet set


One set of billet rear sets, not sure what bike they are for. (the heal plate will have to go)


Got a new shock


RSVR swing arm


And the engine, electrics etc from this blade, 1999 with 24K on it, I bought a complete bike as a donor just for peace of mind as I know the engine is sweet (the other side of the bike is trashed, lol)


I have ordered the alloy to make the frame and the turbo is sorted, time to get building

So made a start fitting the OZ Aprilia wheel in to the gsxr forks, the spindle (axle) is the same size so no need to change bearings and inner spacer, disc's on the gsxr wheel are 137mm apart, the disc's on the OZ wheel are 133mm, if I was using the gsxr yokes I would have made 2mm spacers to go between the wheel and disc's, but as I'm having billet yokes made I have told the CNC guy to make the yokes 4mm narrower, job done.

Next problem is the gsxr disc's are 310mm and the OZ disc's are 320mm, this means I can't bolt the calipers down


To solve this I pulled the standard locating tubes out and made longer ones with 5mm collars


Problem solved, caliper locked down and disc's clear of caliper


Just need to make a spindle spacer to centre the wheel in the forks but I'll have to wait till the yokes are made.

yo mister cabbie!!
just give us everiting!!!

Time to get going on this, the new headstock is coming and the new yokes will be here in 2 weeks.

As I'll be making loads of trips to the welders as this bike grows I've made a trolley to wheel it back and forth (needs a 4x2 screwed underneath still to make it solid) this will be the bikes home as parts get added, got the swing arm in place and checking for chain alignment.


The frame rails arrived, don't expect any fancy shit with this frame, all I've got is a hack saw


I must show you guys this product



I was going to fully strip the motor and have it aqua blasted as it was covered in corrosion, dirt and grime, you couldn't even see any alloy for crud!

I saw this product on eBay and thought might give it a try, fuck me! I used a tooth brush and scouring pad and look how it came up, this took 30 mins!



The front still needs going over again with a pad and product but a few hours and the motor will look like new, awesome.


Here's the headstock for the frame.

Ok time to build, I've been over the design 1000 times and I'm happy with it.

Got the front end together, I had streetfighterbling.net (little plug for them) make the yokes 4mm narrower than the original gsxr yokes as the disc's on the OZ wheel are 4mm closer together than the gsxr wheel's disc's, this just means the calipers are in line with the disc's, some new spacer will be needed but I'll do those later.


calipers and disc's all line up nice


You guys have any idea how hard it is to do this on your own? lol lol


Everything in line and ready for the frame build


Motor lined up


And straight


Made up a template for the frame rail cuts and angles


And the first bit of chrome, the clutch cable holder, lol

Didn't get much time to play today, got the frame rails masked and marked, will try get these cut and bent tomorrow.

Frame rails cut


And bent, I need to go to the welder tomorrow and have them tacked in position to check for fit.


So off to welders tomorrow to get frame rails tacked, I've made up a pattern to clamp the rails to so the rails should be within a 1 or 2mm, thats close enough for this.


Also turned down some cap head screws for the yokes

Busy afternoon, got the rails tacked


First fitting! fuck me spot on with no adjustments needed, nice




For those who ask how I cut the angles
I make paper templates of the angle required


Then draw it on to the rail, if both cuts are the same length then the join will meet up perfect


Last cut done


Frame fitted.


I might call this project "THE BOXER" get it? made from box section and boxer as in fighter!

So I've been back and forth to the welder for the last few days un-tacking and re-tacking to get the frame perfectly straight, the next step is cutting the outer 50mm hole and inner 40mm hole for the swing arm bosses, I've been dreading this as 1mm out and it's "start again time" something I didn't want to do!
So, as I only have a small drill press I measured the hole centres like 100 times, lol
I took my time and the holes turned out perfect, nice, now I can relax as the frame is now spot on with the swing arm boss holes done (I can't fuck it up now)



streetfighterbling guys made me a stainless swing arm pivot spindle


I had a little go to see how the frame would look mirror polished, nice me thinks!


The bosses should be here mid week so it might be a rolling chassis in a few days.

Good progress today.

The bosses turned up from streetfighterbling.net (little plug, lol)


I designed them with a lip on the outside that would be welded in place


But after seeing them I didn't like it so I turned them down and will get them welded then blend the boss and frame to look as one piece


I had the inner sections made 10mm longer than I needed so I could turn them down to an exact fit


Ok, here we have the inner bosses turned down to the correct width and all clamped up with the swing arm spindle ready for the bosses to be welded in place tomorrow


With the back of the frame clamped up I checked the frame at the front for alignment, I'll settle for this as all I had was an angle grinder to work with!


Here's the frame fitted, looks god to me.


Started marking out the cuts to the frame.


Getting exciting isn't it, lol lol

I spent the afternoon working on the frame lower sections

Bosses welded in place and rubbed down


Still had to make a few tiny adjustments to the frame welds but it's perfect now, it even holds the headstock in place the fit is that good


I cut and folded the back and side of the lower frame rails


Then ground both smooth, bottom rail ready to be welded


It'll look good me thinks!


And plated up


Headstock welded (there is more frame work here to come)


All welds rubbed down and frame fitted, forks are dead straight and all seems in line, so far so good




The bar above the swing arm is just for support till I know where it's actual position will be, next job is make and fit the rear shock.

[quote=Gingerilla;980289]pics of afore mentioned shock mount??[/quote]

Heres the bottom linkage mount welded on


Now I was going to just weld a piece of 2x1 box section across the frame with a bracket for the top mount BUT where is the bling in that! so I've designed a fully adjustable top mount for ride height, I've ordered the materials and will be making it this week, it's a bit complex so might take a few days.

So the materials finally arrived, here's the parts I had made (streetfighterbling.net)


I turned some bushes out of 60mm dia Acetal bar


Here the unit together, I didn't have any cap head's so used stud and nuts to check for fit, the outer parts will fit though the frame and be welded then blended so all you'll see is a recess and allen screw head


And with shock and adjuster, I'm pleased with how it looks.


Got the frame drilled and ends welded in


Ground down flush


And mocked everything up for fit before welding the arms in etc



Made a start on the engine mounts (these are NOT finished, they will be boxed from the bolt to the frame) and no the mounts are going to be made of MDF these are just the patterns to send away.



Also made a start with the frame boxing, these are just the start and many more sections will be added as the build continues.

Got the inner rear sections welded in, blended in the top section


Both sides blended, wet'n'dried then a little polish




Got the rear lower engine mounts


I'm going to have them welded with a 5mm gap from the engine both sides, after I slide the bolt though I'll line the sprockets up exactly then make spacers to suit the gaps.


10mm angle for the rear set hangers


Right hand hanger made


And just to prove I get the workshop dirty


Got the rear lower mounts welded on, made two spacers, 2mm on right and 21mm on left, motor is now bolted tight in the frame so I can get the other mounts fitted, I'm using studding for the engine bolts for set up and will get stainless ones made later


Got both rear set hangers welded on



Chain alignment is spot on


So here's where we are now.

Got the carbs stripped, cleaned and rebuilt


And made new plates plus cleaned up the linkage




I made up all the spacers required to fit the mounts for welding.


I didn't plan on fitting the ride height adjuster to the engine bolt but it looks ok and will save a load of work making up a mounting stud.


Finished getting the engine mounts welded on


I had to drill all the holes out to 11mm as some where a bit tight but no big deal, engine in frame and bolted up, phew!


So, got the height adjuster thingy welded up


And cleaned up


And fitted


And we now have a rolling chassis! nice, I checked it over and wheels etc all true.

Started the frame inner sections


Coils fitted


Front subframe mounts made



Got all the seems welded up and both cross bars too


I was going to make the seat but remembering what a bitch the last one was I caved in and bought a YZ 125 seat, made a start on the subframe.



I'm having a real good time building this bike it's like it's just coming together with no effort!



Subframe sections made


And fitted, need to make the seat holders now.



I'm away at the NEC this weekend with the Kwaka so here's a few outside pix till I get back

Didn't get much time with bike this weekend but started the seat mounts.

Cross bar in (needs welding)


Started machining a piece of acetal for the support


Support finished


Made some temp plates to get fit right, I'll have some nice CNC plates done later


So got the front seat holder and latch thing finished, I did have to alter the subframe at the front as the seat was a little high.




And as I hate all things black the fork bottoms are getting painted


My mate Vince had to be the first to put his arse on it, fat cunt, lol


Couple of outside shots with seat on.