Still making some great progress on a bunch of bits. First is finishing up the crankshaft end cover. Its finally welded and ready for action. All that is left is to make a sleeve to press over the OD of the crank to block the side oil hole and find a lighter M12-1.0 bolt for the end.
In order to get enough space for the caliper to clear the spokes, I had to come up with a spacer for the rotor, which is an FZR600 item. The spacer can likely be lightened more, but here is the initial shot.
Spacing for the forks to keep the wheel centered is 8 inches, which is a bit wide but shouldn't hurt anything.
The axle is a hollow CBR item, which I am using front and rear, since the front was converted to 20mm bearings. Here is a shot of the modified axle and spacers.
The axle spacers still need some finish work as does the rotor spacer, with an eye to lightening everything but keeping it safe.
Now that I have spacing established for the forks, I drew up a few versions in different offsets for the triple clamps. I still need to work out geometry with different offsets before I settle but wanted to play around some. The top will be 3/4" while the bottom will be 1.5-2.0 with lots of relieving for weight savings, but I do want something very stout for the front end.
Here is an overall frame shot with tank and seat I plan to use.
Last are the frame gussets I designed. They are 18 gauge steel. I made the dimple die from aluminum since it was only getting used a couple times and it worked flawlessly. I will be looking into some x-bracing near the swing arm and some more near the neck. I am still debating moving the upper frame rails like livefast_dieold did or doing a frame kit. The problem with a frame kit is weight. More to come there.
I am kind of bouncing all over on this and my mind has gone to the carbs. I need to use round tops and need to do more investigation on what I can do to them internally. Does anyone have experience boring these out? I'm wondering if this is something I can just jig up and use a boring head on my mill to take a mm or two out of the throat. Are there mods to the slides that will help? Any thoughts here are much appreciated, since I think this will be the most restrictive part of the engine by far.