96supercharged

Thanks for the good words guys

I'm still alive.

After a two month hiatus I'm back working on the bike.

But first, went to a local car show this last weekend with my other bike. Wasn't able to be in the show because it's cars only, but here are a few of my favorites.



Nice oval window bug



Neat chopped truck



Crazy chopped car



Really nice Chevelle



This Nova was crazy, bass boat style metal flake on this car. Way too overpowering during the day, but it looked amazing at night, tons of power as well.



This Nova was really clean. After this bike a Nova this style is going to be my next project.



And in my opinion here's the craziest car there

1967 Camaro, LS7 Kenne Bell supercharged. has a TKO 6-speed in it, dyno tested, puts out 817HP and 922LB torque, absolutely ridiculous. And the engine bay is clean enough to eat from, easily. Also the rear rims have about 8" of dish. I can't even think about all the money in this car. Super nice guy owned it.




OK on to the bike stuff.

Here's a few shots of the stuff I got from my brother after his bike accident





I've decided to scratch the swingarm I had, it just wasn't working out, I was going to have to put hours and hours into modifying it, and it still wouldn't be right, so I did the right thing and bailed on it. Now I'm building one from scratch. Here's the start of it, the axle adjustment plates. You'd be surprised how much work went into these things. I started off with square tubing that was too large, so I had to cut it down and weld it back together, then shape it. I've still got a bunch more work to go on them.




Here's the start of the swingarm pivot point



I started building my subframe/tail section. Please reserve judgement on this until it's done, remember that the actual tail section will resemble the KTM RC8 tail.





and a quick pic of the RC8 tail to refresh your memory



You can see from these pictures that I also relocated the shock mounting point. The new swinarm will allow the shock to be mounted low like that which will give me the clearance I need for the turbo and exhaust. Should be a much better solution, albiet not as nice looking.

Also, working in my Dad's garage is very cramped, fortunately he was already going to build an addition to it, and I just am helping him along. This is going to be our new fab area once it's all together. Concrete floor with be poured probably Friday, and the walls will go up next week sometime, can't wait to get it done!



thanks
Sky

pheurton-skeurto

awesome...my favorite part of this build is your vision (which is the same as your last bike project). you stack all the parts together as if the bike were complete and even hop on for a ride or two before its finished!

PTPbracket

very nice, you build bikes the same way that I do. I might use a little more cardboard for mock up tho lol

96supercharged

Got the tail section fully mocked up. It needs to be finish welded and smoothed, Then I'll skin it with sheetmetal, should look pretty cool.

As you can see I pulled inspiration from not only the RC8 but also from Rossi's current tail section. It's a little hard to see all the framing in the pics, but the tail doesn't come to a direct point, more like a duckbill that's about 3" wide.

Let me know whatcha think....






I feel this is the best shot to show the end result



thanks for looking
Sky

RC000E

yeah...aside from the MEGA hideous exhaust.... There had to have been a better solution than that.

96supercharged

Actually that's been a staple VW exhaust for a long time. Doesn't mean I think it's the best, but it's been on several feature vehicles in magazines so people think it's the way to go.

I actually am pretty sure this bug was a feature vehicle as well.

redzcstandardhatch

mint!

hope to follow this one! love it so far!

eg crunkmonster

that thing looks crazyyyyyy

bigluelok

this thing is really crazy

96supercharged

Whew! About time for an update wouldn't you say?

I worked more on the tail section. It wasn't quite straight before, so I had to cut some of it apart to straighten it. I'm much happier now. I also made some tabs to mount the tail-light and the seat. The seat is going to take some more work to finalize the mounting, but at least it stays in place now.

Then, to get an idea of what the tail is going to look like skinned up, I covered it with painters' tape



Definitely achieved my goal of replicating the KTM RC8 tail!









I also worked some more on the turbo manifold. Because of the way it mounts, there's no way to make the manifold in one piece, so I made a sleeve. This sleeve will have tabs welded at the ends where it joins on the top and bottom with a spring between the tabs, just for extra insurance.

I also made the flanges where the tubes insert into the head:

Here you can see both the sleeve and the flanges:



Pretty happy with my stainless welding right now



Now that these items are done, all I have to do is get the turbo in its final mounting position, then I can tack the remainder of the manifold together, hooray!

Also, I finally got some of my pieces cut at a friends who has a CNC plasma cutter.

I designed these parts in autocad and he cut them out. The plasma cutter is only precise to a point, these have definitely been cleaned up after cutting, but however it still can make some really cool parts. It's quite the cool feeling to design something on a computer then watch it being cut out. It's fabrication in another capacity.



The part on the bottom right is the baseplate for the sprocket adapter I'm building, this will be welded to the studs that screw into the factory holes. Obviously this will make the adapter non-removable. This is not optimal, but necessary for space reasons.

The part on the bottom left is the outer adapter ring that will be welded to the base ring. It will have studs welded in place for the actual sprocket.

All this work is necessary to run the extremely small 30t sprocket on the factory CBR F3 cush drive.

Also, because the sprocket adapter will take up space, the cush drive needed to be milled down, here's a shot of it after I milled it down:





The final part on the top is the turbine exhaust outlet flange.



Again, as soon as the turbo is mounted I'll be able to finish out the exhaust.

Stay tuned, lots of good stuff to come.
thanks
Sky

civhatch90

Awesome! you have skills

motorhead0293

what an amazing fab job! geezzz i wish i could build my own bike! awesome job!

mikeymcm

sick build!!

redzcstandardhatch

awesome

EFbomb

nonsense

yeah that's pretty much what you can do if you have an equal length merged header. The header ends right by the rear apron so the muffler has to come out a bit and curve back. I used to run a hide-away muffler on my '65 until I went with a remote oil filter then I ended up running dual exhausts. At least he's not running a stinger



^^ ok, it's acceptable for drag racing

Back on topic, the bike is looking good! You have skillz

ShaunRR

I love XS projects, even though I will probably sell my mint XS soon. Might pick up a basketcase to wrench on though, if the price is right.
.

96supercharged

Thanks for all the great comments guys!

got to finish tacking together the turbo manifold today! Here's some pics:



On this side you can see the sleeve I made so the manifold can be removed in two pieces:



And I got the turbo mounting tabs in place, so the weight of the turbo is not hanging on the manifold. The manifold will have a couple extra mounting points as well.

With the turbo mounted I was able to work on the exhaust as well, 2.5" baby With a turbo, the less exhuast the better, and that's the mantra I'm following:







The end will be slash cut a couple inches after it exits the subrame, just haven't cut it off yet.

I didn't like the swingarm pivot I made, so I decided to use a stock XS650 swingarm pivot, here's the piece:



It'll be all chopped up here shortly and I can start building the new swinger.

Here's a few shots of the bike mocked up again:







I think it looks cool with all the tubing running everywhere and there'll be even more after I mount the intercooler and make the piping for that.

Also, I got a new tool the other day, check it out:



Little 3/8" drive impact. Supposed to be able to go all the way up to 85ft/lbs which is way more than I ever use. I bolt and unbolt a lot of stuff on this bike, and doing it with wrenches is soooo slow, decided to speed things up a bit! working awesome so far.

Thanks again for checking out my build, hope to have a new update soon.
Sky

nonsense

I hate to do this, but any updates?

-RedneckDave-

I was wondering the same. Surely there are some updates since winter is over now.

I do wonder why you did not just join the primaries together on the left side of the bike. I think it would have been much more pleasing to the eye. But hey it is your bike and it is an ambitious build for sure.

96supercharged

Thanks for the interest guys. Unfortunately not much has been done. I'm a little further along on the swingarm right now, but that's it. Combination of several factors, changing jobs, relocating, ect.... But enough excuses, I just haven't been getting it done.

I've been getting psyched to get back to work on it lately though, but I'm away from my home until after the first of the month. But after that I should make a lot of progress, It's time to kick this thing into high gear.

As far as the manifold goes, it definitely would have been easier to join them earlier, but I wanted to keep the exhaust pulses separate as long as possible. With this engine firing 360* out they should be fairly separate until they enter the turbo.

Thanks again for the interest. Knowing people care how this turns out always helps to motivate me.

96supercharged

No, I'm not dead

Go ahead and skip this paragraph if all you want to see is the bike stuff:
Man, what a series of events! I got a job back in Central Oregon, moved my family over there, and it fell apart almost immediately. I was completely floored and definitely depressed about it all. I stayed in Bend for another month trying to find some suitable work over there but it just wasn't happening.
So now I'm back over here on the coast again. Probably for awhile now. Anyway the good news is that the bike project was here all along, and now I'm able to work on it again. Yay!

Bike Content.....

So now that I'm back on the bike figured I'd update you guys on what I'm working on now. Still haven't finished the swingarm, although I am further along on it. I'm hoping to be done with that by the end of this weekend.

Also, i'm going to get started on skinning up the subframe with sheetmetal, and to that end I got a couple new tools:

Shears:


and a bead roller:


These are both harbor freight items, but the bead roller has been shown to be very productive if you beef up the frame a bit. The shears should work fine for the thin sheetmetal work I plan on doing.

Also, April 1st was my five year anniversary, here is my present!


What could it be you ask? Why only the coolest thing in the world! Megasquirt engine management. Full stand alone, This is going to be amazing!

and what's this with it?


Why that's electronic boost control! :banana

If you can't tell, I'm beyond thrilled to get this. It was definitely one of the more expensive things I needed for this bike, so that's nice to get it out of the way. Also, custom engine management is my thing, I'm geeky like that. I'll be playing with this thing for probably over a year after I get it running trying to tune it just perfectly.

Now for some actual work:

I was doing some research on wide band sensors, and found out that my original placement of the sensor in the turbo manifold would be a very bad idea. Apparently wideband sensors are not like narrowband sensors in that they do not like excessive heat. The documentation on the wideband that I want says that the sensor should be located at least 12" back of the turbine outlet. Obviously with my old exhaust setup there was only about 8" of exhaust after the turbine total. So it had to be redone.
I'm kind of glad that it turned out that way anyway though because I love making exhaust and intercooler piping stuff. I think it looks much cooler this way.

The reducers I made by taking the 2.5" pipe and v-cutting a section out to neck one side down to 1.75" The main body of the "muffler" was done that way as well. Overall I'm really pleased with the look and can't wait to hear how this thing is going to sound! :banana

On with the pictures:













As you can see I've got a lot of welding left to do here nfloor
The swingarm clears the exhaust perfectly throughout its stroke, and I made a nice little exhaust brace that unbolts from the subrame.

Take a look, let me know whatcha think?

Also, I don't have it yet, but this is the headlight unit that's going on this thing:


Mine will be black not blue, but I might modify it a bit yet, we'll see.

I know a bunch of people won't like this headlight. Mainly because I don't like any of the other headlight options out there. I've literally tried about 100 different setups in my head, and none of them looked right. Maybe if I could get my hands on a brand new Ducati Streetfighter headlight it'd be different. But I can't.

Anyway, thanks again for sticking with me, and hopefully things will move forward at a better pace now.

Sky

philafelman

the bike is looking great man.....awesome fab work.

ShaunRR

Sorry to hear about your bad luck with the job.
.

96supercharged

Did some more work the last few days. Got a couple of things done that I've been putting off for a really long time.

First up, remember these?


Finally finished putting it all together, looks like it's going to work out great!





Also, finally fabbed up the mounting point on the swingarm for the shock:



The hole for the shock is sleeved as well.

Also, finally I got the steering stem and lower tree drilled, so now my front end is attached properly, now I need to get the front axle sorted and this thing will be on its own two wheels!

I got an upper triple awhile back that had the ignition loop welded back onto it. I got it cheap because of this, but I didn't want to use it anyway, so off it came. Some more shaving needed to blend it fully, but it looks about a million times better now.





I also built a stand for my bench grinder and my new bead roller. It's a touch wobbly right now, so I'm going to put some supports for the main pole. I'm really happy with it though.



Finally, not a shot you haven't seen before, but I just like this shot:



Thanks for looking.
Sky