Author Topic: Brookesy's K2 Project 2009 (Read 3256 times)

Brookesy · « **on:** April 15, 2009, 07:24:12 PM »

Thanks to Bob for sorting out my old account.
So, I'll Start this project thread again.

Here goes...

Brookesy · « **Reply #1 on:** April 15, 2009, 07:26:58 PM »

OK,
so here we go... I'm back and ready to go

This bike is in the "Inspiration Gallery" and it's definitely part of the inspiration for my K2 project
Also, some inspiration will be taken from the CR750's and the impetus to start again has been provided by a Ulysses clubmate who is building a 750 chopper, needed some parts - quite a lot of parts actually - and bought one of my parts bikes from me.

The bike below is a Post Classic Period 4 Race Bike and lives in Queensland
It's bloody quick too! The owner has spent quite a bit on it and Leo who rides it makes it look easy

Some of the details (i last saw it a couple of years ago, so things may have changed and the memory might be a bit fuzzzzzzzy)
It's pretty close to 1000cc capacity from memory. 38mm Marzochhi front end (Ducati) which has had the internals replaced with modern cartridge fork bits. This makes everything fully adjustable like a modern bike, but hidden away out of sight. The triple clamps are replica Marzochhi and have a lot less offset than CB750 clamps. Makes a fair bit of difference to handling apparently. The frame has had the seat rails lowered and just enough bracing etc.
Ohlins shocks and steering damper. The seat unit and number plate are from T-rex Racing Developments in Oz
Brembo brakes up front and those lovely, S#xy CR carbs

I'll post some stuff on my project soon

Brookesy · « **Reply #2 on:** April 15, 2009, 07:27:55 PM »

So, this one i got from the "Inspiration Gallery" but maybe a little too late since i've already done most of my frame mods. Maybe next time around... Tough stance though and that tank!

Has anyone got more info on this bike?

Brookesy · « **Reply #3 on:** April 15, 2009, 07:28:48 PM »

So,
Here's where i left off.
CAD drawings of the Stock K1 which aren't finished but i'll get back to that eventually

Brookesy · « **Reply #4 on:** April 15, 2009, 07:29:37 PM »

And here's the current concept.

The frame has been modified. Brackets etc. cut off. Anything that can be removed has been - hopefully nothing that shouldn't have been Seat rails have been lowered 38mm and top shock mounts reversed to lay the shocks forward

The tank is being stretched about 70mm. 2 beat up tanks, angle grinder in hand, lots of sweating over the result
I managed to work out how to do it with only 1 weld across the tank, which i'm not trusting to my mig welding skills
The top of the tank has been removed from the base so i will lengthen the base once the 2 halves of the top are together. A local tig welder has the tank at the moment - can't wait to get it back. If all goes well i'll post some pics of the progress.

The wheels are (i think) aftermarket F2 jobbies. Disc rear - excellent

Brookesy · « **Reply #5 on:** April 15, 2009, 08:59:52 PM »

An update...

The seat unit and number plate are in transit - should be here by Friday i hope
The tank top skin has returned from the welders - nice job they did too.
The next step is to see what the tank and seat look like together mocked up and modify the tank to take the fuel cap and work on extending the tank base.

Things to sort...
Pingel fuel taps hopefully - once i track down a supplier locally - make threaded bungs (2 taps

Also, a tank breather - i have some ideas but any input would be good

An aside...
A trailer hub weather cap (the bit wot covers the bearing) seems the right shape but not quite big enough for a breather housing (CR750 style etc.) so something from a car hub might be ok, but i want to put a non-return valve in it so it needs to be bigger - more thought reqd.

A spanner in the works...
Picked up a 1977 Z1000 Kawasaki today.

Fairly original and complete but with a dodgy head
The search begins - find a head or someone who can repair it properly

A further aside...
My list of desirable 70's bikes is coming together
CB750 K2 hybrid / racebike thing - current project, which will hopefully be for a few track days and a squirt or two on historic rego
CB750 K1 stock - will be restored "properly" when i've finished collecting parts
CB750 K2 mild custom - the details are a bit sketchy still but it will get done
Z1000 - this one will get done after the K1

Desirable 80's bikes on the wish list
CB1100 RC or RD
1100 Katana

A spanner in the shed...
Clean up continued on the weekend making room to work and organising my stock of parts
It's going well except now i have to make room for aforementioned Z1000 and also a mate's drumkit

We knocked together a bike bench in about 15 minutes which isn't as flash as a hydraulic lift bench but it cost $0

I'll try to get some pics tonight

Brookesy

Brookesy · « **Reply #6 on:** April 16, 2009, 02:46:30 PM »

With the Z1000 safely stored in the back of the shed work continues.

Some of the problems that need to be solved are the charging system and crank

I'm trying to work out how to fit a more modern alternator to get more ground clearance on the left hand side of the bike. The original alternator setup is bulky and heavy. There must be some way to fit a later system which can fit behind a modified cover to achieve less weight and more ground clearance. The M3 racing setup would be perfect but they're not making them anymore and even the cover is prohibitively expensive. Anyone who's done it or is thinking about doing it - share please... Hopefully it's possible to do it with minimal workshop equipment

While we're on the subject of alternators
Is there any alternative to buying the rotor removal tool?

CB750A crank and cam sprocket - Wanted - I'd like to fit the Auto crank to get the advantage of Hyvo camchain
So if there's anyone with a spare Auto crank and cam sprocket - please get in touch

1000 Gold Wing clutch - i need more info on how this is done - i bought a Gold Wing clutch but i expect there's some modifications needed to fit it - again, if anyone has done it - share please...

EFI - i believe there's a thread on this so i'll check it out
or
CR carbs - maybe

J.Webster Designs · « **Reply #7 on:** April 16, 2009, 03:06:40 PM »

looks like your gonna have some fun.... keep us updated. and keep the pics coming... WE LOVE PICS

Retro Rocket · « **Reply #8 on:** April 16, 2009, 04:46:42 PM »

Quote

I'm trying to work out how to fit a more modern alternator to get more ground clearance on the left hand side of the bike.

And there lies the question, work that one out and retain the electric start and you would be on to a winner. I wonder if it is possible to run an alternator where the starter motor is mounted, i know this would do away with the starter but it would make for a very compact left hand side.

Mick

MCRider · « **Reply #9 on:** April 16, 2009, 04:58:18 PM »

Quote from: retro rocket on April 16, 2009, 04:46:42 PM

Quote
I'm trying to work out how to fit a more modern alternator to get more ground clearance on the left hand side of the bike.

And there lies the question, work that one out and retain the electric start and you would be on to a winner. I wonder if it is possible to run an alternator where the starter motor is mounted, i know this would do away with the starter but it would make for a very compact left hand side.

Mick

To get there, I think the electric start is a sacrifice. Many have postulated that this or that will work or can be made to work. Like a CB350 (lordmoonpie) alt but I don't know what they used for a cover. The CB400T Hawk looks possible and sure is tidy. Again the cover. So Ken at CycleX has a get up that runs sans cover! and is an interesting idea. He claims the coolness factor of an exposed alternator is quite high, I agree but what about rain?

Sigh.

Brookesy · « **Reply #10 on:** April 16, 2009, 05:19:31 PM »

OK, so i know a bit more now

CycleX - i'll have to look for them and see if any ideas spring to mind

The cover shouldn't be a problem if the setup works without a cover?
Maybe the orig. cover can be modified?

MCRider · « **Reply #11 on:** April 16, 2009, 06:42:18 PM »

Quote from: Brookesy on April 16, 2009, 05:19:31 PM

OK, so i know a bit more now

CycleX - i'll have to look for them and see if any ideas spring to mind

The cover shouldn't be a problem if the setup works without a cover?
Maybe the orig. cover can be modified?

hERE TIS: http://www.cyclexchange.net/Honda%20Cafe%20Page.htm Scroll down about an inch/ maybe 1/10th of the way (he uses really long pages) Th NEW CycleX Charging System.

On second (or fifth) look it doesn't seem to cozy up to the crankcases like we would like.

My expereince with some aluminum fabricators here locally is that if they had an idea and something to look at they could make a cover.

I'd like to pursue it someday. I've got a dusty old CB400T in the corner... If the alt looked even close to working, I'd buy up a rat and strip it. Put the whole electrical system on the CB750

That M3/CR replica get up was over $1500, Mark told me they just weren't cost effective enough to sell enough to keep making them. The actual CR piece was much more than that.

Its been 40 years, you'd think someone would have modded up something by now.

Brookesy · « **Reply #12 on:** April 16, 2009, 10:34:21 PM »

Thanks for that - i'll take a look

So, surely the collective brains on this forum can formulate something that works Fellas?

Would a starter motor be able to be modified to work as an alternator - driven by a belt?
Maybe a small alternator piggybacked on top of the starter motor housing?
I think some late model bikes have an offset alternator
Would there be room under the carbs? (just thinking...)

Retro Rocket · « **Reply #13 on:** April 17, 2009, 02:44:14 AM »

Hi Brookesy, i have spoken with terry at length about this very subject and would love to find an answer. Who ever does is going on my christmas card list....

Mick

Brookesy · « **Reply #14 on:** April 24, 2009, 02:31:28 AM »

Mmmm...
Still no pics but nothing really worth taking pics of yet
I got the Seat unit in the mail - it's nice too. Unfortunately i don't think it looks that great with the tank i'm building - bugger!
(Retro - it does look better with an F model tank - another option)
Still waiting for the triple clamps, rearsets and clip-ons to arrive.
Then i can set it up and see what has to happen next.

The current Plan B option is to build my own seat unit using the contours of the tank as a guide - it looks good on paper but we'll see...

Waiting for stuff to arrive is a pain!

Brookesy · « **Reply #15 on:** April 30, 2009, 02:44:25 AM »

So the tank is progressing
The stretch is working out ok and the next job is to fit the filler cap. After cutting Tank “A” vertically thru the top skin only about 210mm behind the filler cap tank “B” was cut 140mm behind the filler cap. The front half of Tank “A” was kept. The rear section of tank “B” was kept. Lots of bashing and re-shaping later the halves matched pretty well. Completely removed the top skin from Tank “A” and had them Tig welded together from the inside.

Some time in the past life of Tank “A” some Gumby had drilled holes to help the 20mm or so of bog (filler) to stay attached allowing fuel to seep thru the paint. The wrinkles in the tank and holes will be fixed. The top of the tank just above the badges also had some big dents under the bog (filler) each side of the tank.

The rear edge of the tank has been rolled to get a nice finish and lower rear edge will follow the line drawn in the pic. The front tank mount “U” shaped bits have been removed from the base and moved forward about 20mm. This allows the tank to wrap around the frame at the join where the rear section is lowered. Should give more clearance to the clip-ons and also I didn’t want the tank to look too long. The fuel filler and rings to help form the filler recess are shown also.

Once the tank filler is completed (might take a while I can’t get back to it for a few weeks) some form of tank venting is required. Any ideas?

Then more bashing, welding, cursing.

Knee indents? Still not sure.

Brookesy · « **Reply #16 on:** April 30, 2009, 02:45:32 AM »

I’m not sure what these are. Any info would be helpful.
They will probably be used on the bike but I’m still not sure.

Brookesy · « **Reply #17 on:** April 30, 2009, 02:46:51 AM »

Shows the tank and seat unit together. It’s grown on me.

Brookesy · « **Reply #18 on:** April 30, 2009, 06:27:07 PM »

Ooh, Ooh!
The Pingel fuel taps & weld-in bungs just turned up in the mail - along with a Juicilicious Pingel Catalogue...

Work on the tank can continue a bit further but not this weekend.
A 3-day ride on the CB13 starting tomorrow morning

Should be good weather but a chance of low temps in the morning (we had a 1 degree c morning eirlier this week)

I drew the outline of knee indents on the tank and need to look at it a few times to get the picture of what they would look like

more later

Brookesy · « **Reply #19 on:** May 11, 2009, 03:05:17 AM »

The Triple Clamps from T-rex Racing turned up in the mail today - Thanks Rex

The process is basically...
1 Find a set of 900 Bol d' or triple clamps
2 Remove the spindle and bin the rest
3 Send spindle to Rex
4 Rex has the replica Marzocchi triple clamps cast / heat treated etc.
5 Machines them to suit - 35mm fork tubes in this case but i can go to 38mm later
6 Sends 'em back
7 Grin, caress, play with the clamps etc.
8 Fit new bearings etc. when i get time (Roll on Saturday...)
9 Wait for rearsets & Clip-ons to arrive then i can set it all up and check what has to be done to the tank

The knee indents are almost certain and some indents for clearance to the clip-ons will probably be needed too

News:

Author Topic: Brookesy's K2 Project 2009 (Read 3256 times)