The original thread had a bunch of broken image links so i decided to make a new thread.

After seeing the pictures many of you are going to remember this bike. I just moved again, 1/2 way around the world (again) & this time it was to the southern hemisphere. The engine started up with no issues! I'm taking the steering stem in to a machine shop to have a safety pin taped so the steering stem doesn't fall apart.

things to do:
1) finish exhaust (95% done)
2) build new wiring harness (doing this today i hope) - DONE!
3) removing forks and steering stem off bike and going to machine shop today - DONE!
4) figure out where I'm going to put all the electronics. - DONE!
5) buy a brake light & indicators
6) install 900RR clutch cable
7) make linkage for rear brake
that's about it...














The muffler was just temp and those turbo stickers are coming off...

 

this is more or less what im doing with the stem

 

that are you planning here?

 

That tail looks great. Where did you move to?

 

It was a press fit and it would most likely work as is but I wanted a safety net. i would have welded it, but the stem is 4120 and the rest is Al.

 

moved to AU.

 

your stem bolt is a press fit?

not sure I see what's happening there.

edit... I see it's the bottom

 

and please let me know if you see something wrong in any of these. I'm off for the next 3 days (today included). Turns out, rather than taping an M24 in the stem, they want to tig weld a nut in the bottom of the stem and use something smaller like a m12. I pic it up in 2 days.

 

This is getting difficult! The guy that was going to weld my exhaust for me just broke his welder. If I take it to a local shop, they want over $500. I'm really not sure what I did was a good idea but I ended up buying a tig welder. My mig welding is ok at best. My beads look better than most of the stuff I see on the FAB thread. TIG is another story. I've heard nothing but bad things when it comes to the learning portion of TIG welding. Oh well... what's the worst that could happen? Get this, the welding store I was at (BOC) had a $2000 welding helmet.

stainless mandrels, welding helmet lol, filler rod & argon on order - should be here in about a week.

 

nice... let's see your work.

 

I was watching tig welding videos for hours last night. doesn't look all that hard
I can't wait to get the parts in! Speaking of, I just picked up the stem and it's perfect. They tig welded a nut in the bottom of the stem and machined a retainer. Bolt size is M12.

 

I need some help here. I bolted up the headset and its not staying tight. Looking at the picture, #6 and #8 are locked together using #9. Once they are locked together they can both still turn. Do i just tighten them against each other really tight then lock them with#9?




:::EDIT:::
ive installed and removed the steam over and over and over. if It's too lose, it starts to have play at the top. if it's too tight (i cant turn) and there doesn't seem to be a middle ground. im using the steam and everything else on the top half from the original bike. I'm not sure what else to do. I may end up getting new #4,6,8,9 & 10.

 

Never mind... Lets just say I'm an idiot and call it a day. The steering is perfect!

I found an area where I think I can all the electronics. My plan is to weld up a small tray that would sit under the rider's right butt cheek. I have a black HKS BOV that I was going to hide up near the air box. should i leave it open or reroute it to the intake to suppress the sound? PSHHH!!!

:::EDIT::: check out my relevant signature.

 

more delays...
I got the Tig welder last week, wrong cables were in the box so i took it back to the store. Yesterday I picked it up, everything was good until i plugged it in and found that it didn't work. !@#$

If everything goes well, It's prob going to be at least another week before I can get another welder.

:::UPDATE:::

I just ordered a Lincoln Invertec V155-S TIG.

 

Glad to see you still working on the bike.

 

sorry for the most boring thread, waiting for the tig welder feels like the longest wait ever. I'm told it will be a few more days. Meanwhile, I did just get the new front sprocket and chain installed. That was a nightmare! the sprocket was rusted to ****. I'm pretty sure I almost broke my gear puller taking the sprocket off but all is good now.

The exhaust will be routed where the original overflow res was located so i'm replacing it with one of these. Hopefully it fill all fit.

 

I got the TIG and been practicing for the last 2 days. so far things are coming along nicely. I finally welded a tube that looks good! The problem I'm having is cutting the tubing for the exhaust. The best price i could find on a band saw where I live is ~$1500 so im using a chop saw. The cuts aren't the greatest so it's going to require a lot of work on the bench grinder before the welding. I should have at least part of it done tonight.

:::EDIT:::

I decided to start off with the toughest part first and work my way forward.

 

with all the noise I'm making, I always feel like I'm pissing off my neighbors. this is what i imagine.
http://www.youtube.com/embed/ZbcCt-nJxvU

 

I had some trouble welding the flange up. I needed more heat on the flange than the tubing. the flange initially required 60amps and the tubing only about 20. I could have been a little prettier but it's not bad... what do you guys think?


I cleared the kickstand but the spring touches a little. no big deal...





hard to tell from the picture but there is more than enough clearance for the chain.


:::EDIT:::



bead pic:

 

I got a lot of work done today. The ECU/fuse box is done. The wiring is is all tied up. The res is mounted though I'm not sure I really like where it is. I may end up moving it later. I really wanted to do all this in stainless but I couldn't find the supplies so i'll need to paint it before too long. and the bike still starts!













yes that is bird **** on the tank... >

 

will she live?

head tube angle on a 919 is 67º?

 

that has been one of my concerns. Someone else I was talking to about a year ago said they had no problem even without a damper so i figured it would be ok. that being said, I'm planning on using a damper with this one.

:::EDIT:::
what is the max angle that is reasonable before i really need a damper?

so far my specs are,

1000RR fork length 683mm
(919+1000RR) wheelbase 1448mm

I also found a cool calculator for this sort of thing. http://www.rbracing-rsr.com/advchoppercalc.html

 

I used an overlay (in red) of a 07' 1000RR on top. yeah its a very rough estimate but it gives a general idea. My guess is that the swing arm is up a little more than stock. Wen i made the brackets they could have been very slightly off.

 

that's really hard to say because more than angle is important... rake/trail, wheel base and weight distribution, specifically where and how high that weight is distributed, are really critical. I have to say with a lot of HP and gearing for any bike north of say 130'ish, should have some form of damping.

I have even seen tire combos that can mess up a bikes ability to punch thru the oscillation zone. better safe than sorry.

 

I agree 100% on the steering damper. I was just using the picture as a rough comparison for the head angle. Since I'm using 1000RR front end, the Triple Clamp Offset, Triple Tree Rake, Front Tire Diameter and fork length are all the same. The 1000RR wheelbase is 1405 where as mine is 1448. I did another overlay with a 600RR to again have a very rough estimate. the fork angle and swing arm angle "look" to be the same so i should at least be in the ballpark. I do expect the swing arm to drop a mm or 2 once I take the bike out for a ride. I'm expecting the brackets to stretch a little after some hard riding.

I think it's time to get the linkage software back out.

:::EDIT:::
so far i have,

Fork Angle 23.6 deg (i did my best to measure this using a picture and a protractor. let me know if there is a better way)
Trail in inches 4.07" (103.3mm)
Rear axle centerline to centerline top of steering neck, inches 51.39" (1305mm)
Wheelbase: Rear axle centerline to front axle centerline, inches 57" (1448)
Top of steering neck centerline to ground, inches 36.05" (915mm)