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Project Racer

Work in Progress

Moderators: chrisu, paul doran, Taffus, KeithZ1R

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Zomerset Zed
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Posts: 239
Joined: 30th May 2014
Location: Somerset

Updates

#16 PostAuthor: Zomerset Zed » Wed Mar 21, 2018 7:07 pm

So booking in for Bikers Classic in July has given me the hurry up. Better get (even) busier :shock:

After trying to locate an endurance style belly pan that will actually fit the wide P&M frame and hold an engine full of oil and look the part i gave up and took the cutting disc to the "XR69" fairing that came with the bike:

IMG_20180217_153732.jpg


However, i don't think the wood is going to work, so i made up some brackets to mount 2 x Dzus fasteners each side. I used some 20 x 2 ally flat bar from the offcut bin and mounted that to the lower cradle frame rails using rubber lined 32mm ID P-clips i ordered in:

DSC03132.JPG


Spacers were required on the rear mounts to get near the curve of the belly-pan. This is because the frame rail curves in behind the crank area.

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Also in these pics you can see:

I have started fabricating the clutch actuator arm mount.
I have bought a chain (and many sprockets)
I have polished the exhausts up with scotchbrite pads
Lots of other things that i now can't remember :gom

Found a crack in the collector once it was cleaned up. Will have to get that welded.

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I designed some inlet pieces for the CR carbs which cam without any fitted as P1 only had Suzuki rubbers left in their cupboard. Got them CNC'd and a variety of o-rings to see if i can fit and seal. I had to cut a releif in the threaded ends so the thread would bottom out once in the carb.

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In the end i didn't fit any o-rings and used some RTV sealant to seal from any leakage.

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Bought some stainless clamps off ebay and cut off the excess track. Cabrs fitted:

DSC03139.JPG


Also managed to fit the throttle cables and the throttle with only minor dramas.

Time to strip all the gubbins off the tank and see what we are
dealing with:

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Well, its 17.7 litres then

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Spent a good hour or so pushing the dent out of the front top of the tank under the breather fitting. End result, dent partially pushed out, found out it was already bogged as well as witnessed by the cracked filler next to the breather. Now need to leak test it somehow?

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Zomerset Zed
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Posts: 239
Joined: 30th May 2014
Location: Somerset

A bit more progress

#17 PostAuthor: Zomerset Zed » Fri Apr 06, 2018 6:02 pm

So got a load of parts from the CNC guys today:

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First up is trying the new LH wheel spacer which now sits on the ledge properly allowing the wheel to sit in exactly the right place for the axle to slide straight in unsupported. Its a push fit into the bearing so stays on the wheel when its removed. Similar arrangement is on the brake caliper side:

DSC03145.JPG


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New 520 sprocket and chain (split link temporary)

Also lock-wired the sprocket bolts on.

Opted for an endurance style P&M seat unit from ragged edge racing:

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And a KR1000 endurance fairing:

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Rear brake bled and working a treat:

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Oil cooler mounted. Mount made from ally extruded angle:

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Yet to be finished.

Made up an ally plate that mounts to the crank case to take the clutch cable threaded adjuster. Fitted the CNC machined clutch actuator with some oilite bearings, fitted a silver steel 8mm rod cut to the right length for the push rod. All seems to work fine:

DSC03158.JPG

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Zomerset Zed
100Club
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Posts: 239
Joined: 30th May 2014
Location: Somerset

Re: Project Racer

#18 PostAuthor: Zomerset Zed » Mon Feb 04, 2019 6:52 pm

So here is the finished bike. I completely ran out of time to do any more on the project report as things got very frantic trying to prepare 2 x classics for Spa and Chimay races last July and continue doing a 50 hour working week and moving house and business in the mix too!

Having discovered i am taking on way to much at my age i have decided to move the P and M on and i will be putting it up for sale soon so someone can race it properly in 2019. If any interest is shown i will get on to de-wintering it soon......

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