What I did on my Christmas vacation

[Kai Ju]

I inherited the bike with the engine bolted into the frame at the lower rear and front motor mounts, the rest I did myself, except for the welding since I wouldn't trust my life to my welding skills.
I do have a garage with a motorcycle lift, aircompressor and full toolbox since I used to wrench for a living.
Tool wise I have a drill press with a milling table, a bandsaw, a combo belt/disc sander and my hacksaw and files.

This isn't my first project, back in 89 in shoehorned a 600 rotax fourstroke into a Ninja 250 and more recently converted a Super Hawk ( Firestorm ) into a naked bike with the radiator placed under the seat.

I'll give you all the help I can from 6000 miles away.

Kai Ju

[91cb-1]

How much do you think it'd cost to ship you're workshop over to me? sounds like a fantastic set up! thanks man

[Kai Ju]

Remember you don't have to buy all new stuff.
My bandsaw came from a garage sale for $50.00, the drill press was free because it needed a motor.
I splurged and bought the disc/belt sander new but that was only $70.
The aircompressor came from a local store, it was a display model with parts missing. Got it for half price. $100.00
The lift I traded for labor.
You don't have to have a lift but it's nice to have.
A good alternative is to build a sturdy box out of 3/4" plywood about 6 feet long, 2 feet wide and a foot tall.
Attach a 4x4 across the front of it with eyebolts and you have a place to butt the front or rear wheel up against and tie the bike down.
There is nothing I can do that you can't.

Kai Ju

[Daveontheedge]

Kai Ju, I never noticed before, but have you machined out your engine side covers and installed a screen? If so did you tack weld it into place? I think it looks really sharp.

[xstreamcanadian]

taillight is '08 CBR1000RR, BTW I will have a stock taillight that has been converted to LED for sale before too long. (I installed the guts from a CBR1000RR tail light in the stock housing) I'll post pics when I do

can you post any pictures of the cbr 1000 taillight? I am interested to see how you squeezed her in there. I would like to swap mine out as well.

cheers

daveontheedge

if you find a place or guy to do the machining let me know, we could go in at the same time and possibly save some $

[Kai Ju]

Yes they are 'machined ' out.
Machined is actually not the right term.
Drill closely spaced holes along the portion you want to remove, called chain drilling, then cut out with a hacksaw blade and finish with file and sandpaper.
When I looked at installing the screen I used the cheapest way out I could find, double stick tape.
I used one piece of screen for the whole cover and worked it into the double stick tape with a wooden dowel. It's been installed that way for over two years and I painted it in place when I repainted the bike over Christmas.

I'll post some pics of the tail light after I get the chance to take the tail section apart.

Kai

[Daveontheedge]

taillight is '08 CBR1000RR, BTW I will have a stock taillight that has been converted to LED for sale before too long. (I installed the guts from a CBR1000RR tail light in the stock housing) I'll post pics when I do

can you post any pictures of the cbr 1000 taillight? I am interested to see how you squeezed her in there. I would like to swap mine out as well.

cheers

daveontheedge

if you find a place or guy to do the machining let me know, we could go in at the same time and possibly save some $

If you want them cut out, I am pretty sure I can do it at work for you.

[xstreamcanadian]

oh yeah? cool, did you do yours already?

[Daveontheedge]

Not yet, I just noticed Kai Ju's the other day and thought it looked cool. I have just finished painting and polishing my new(er) front rim, so now I have time to investigate further improvements!

If you want yours cut out, let me know.

[TrailCub]

I think the cut-out covers look great too!

At one point I was running my -1 without them, but it didn't seem to be "breathing" right. Any issues with yours, Kia Ju?

Dave, what would you use to cut out the sections? Do you work at a machinists?

Cheers,

Dan

[Kai Ju]

I think the cut-out covers look great too!

At one point I was running my -1 without them, but it didn't seem to be "breathing" right. Any issues with yours, Kia Ju? "


I am actually wondering about that because I have this vexing surging issue that's kicking my butt.
But, the other day a friend of mine rode the bike, who's about 6'4" and he noticed that under certain conditions the bike would not rev past 6000 rpm unless he spread his legs. ( sounds so wrong, doesn't it? )
Anyway, by me scooting all the way forward on the seat I was able to duplicate the symptoms so this weekend I'll be looking at my vacuum chamber and floatbowl venting hoses.
I may just remove my tailsection to take pics of the CBR1000RR tail light at the same time.

Kai Ju

[TrailCub]

BTW - I'm in awe of your CB-1.5 - very, very classy and clever upgrade! Looking forward to additional pix.

I'm also hoping someone will eventually chime in with more info regarding the possible bolt-in Hurricane engine...

Regards,

Dan

[Daveontheedge]

Hey Dan, I am an aircraft mechanic so when/if I do cut them out, I was just planning on drilling out the corners and using a mini die grinder with a rotary file to cut the rest out. Possibly might try a router bit.