PDA

View Full Version : Project bike.... From road to trackday bike..



morepower
04-16-2010, 10:39 AM
OK new here.. but bought this a few weeks ago. The bike is in great condition and all the bodywork is brand new.. But as it was an evilBay buy I just assumed it looked OK and was like any other older RS250. So I was shocked when I went to collect it.....
http://img707.imageshack.us/img707/8453/bn9vnbwkkgrhqiokketkeuv.jpg
It was bought with the one goal of having a small 2 stroke 250 trackday bike.
Some race bodywork, suspension and a diet..
So have sorted out a Kawasaki ZX6r B1 front end forks, yokes, calipers and wheel with discs. These will be fitted in about a week or so along with a Bitubo fully adjustable rear shock (High and Low speed compression, rebound, preload and length.)
http://img2.imageshack.us/img2/3577/img2083copy.th.jpg (http://img2.imageshack.us/i/img2083copy.jpg/)
Possibly getting a pair of ISR 6 piston calipers and 275mm discs to suit too.. Depends on the set I am waiting for off a customers bike...
http://img251.imageshack.us/img251/2927/img2085copy.th.jpg (http://img251.imageshack.us/i/img2085copy.jpg/)

Have a set of Tyga side by side pipes now too...
http://img686.imageshack.us/img686/1228/img2086n.th.jpg (http://img686.imageshack.us/i/img2086n.jpg/)
http://img101.imageshack.us/img101/997/img2092p.th.jpg (http://img101.imageshack.us/i/img2092p.jpg/)

Just need to sort out the fairing and seat unit. Looking at fitting a Honda RSW 250 fairing and seat unit to the bike to make it look more like the last GP Honda's and KTM's.

If I need more power I will look at that after the rest of the bike is sorted. Hoping to have the bike ready to ride and paint in 2 to 3 weeks.

Seems a shame to remove so much from a really nice clean bike but it was always going to be a project bike and most of the parts have paid for the bits I have already bought or plan to buy helping keep some of the cost down too....

zx250r
04-16-2010, 01:44 PM
i hate you english...rs250's come in candy machines while that bike over here would fetch $10,000 easy!

I'm jealous, beautiful bike

beek
04-16-2010, 03:11 PM
sent you pm regarding fairing

soofle616
04-16-2010, 05:19 PM
OK new here.. but bought this a few weeks ago. The bike is in great condition and all the bodywork is brand new.. But as it was an evilBay buy I just assumed it looked OK and was like any other older RS250. So I was shocked when I went to collect it.....
http://img707.imageshack.us/img707/8453/bn9vnbwkkgrhqiokketkeuv.jpg
It was bought with the one goal of having a small 2 stroke 250 trackday bike.
Some race bodywork, suspension and a diet..
So have sorted out a Kawasaki ZX6r B1 front end forks, yokes, calipers and wheel with discs. These will be fitted in about a week or so along with a Bitubo fully adjustable rear shock (High and Low speed compression, rebound, preload and length.)
http://img2.imageshack.us/img2/3577/img2083copy.th.jpg (http://img2.imageshack.us/i/img2083copy.jpg/)
Possibly getting a pair of ISR 6 piston calipers and 275mm discs to suit too.. Depends on the set I am waiting for off a customers bike...
http://img251.imageshack.us/img251/2927/img2085copy.th.jpg (http://img251.imageshack.us/i/img2085copy.jpg/)

Have a set of Tyga side by side pipes now too...
http://img686.imageshack.us/img686/1228/img2086n.th.jpg (http://img686.imageshack.us/i/img2086n.jpg/)
http://img101.imageshack.us/img101/997/img2092p.th.jpg (http://img101.imageshack.us/i/img2092p.jpg/)

Just need to sort out the fairing and seat unit. Looking at fitting a Honda RSW 250 fairing and seat unit to the bike to make it look more like the last GP Honda's and KTM's.

If I need more power I will look at that after the rest of the bike is sorted. Hoping to have the bike ready to ride and paint in 2 to 3 weeks.

Seems a shame to remove so much from a really nice clean bike but it was always going to be a project bike and most of the parts have paid for the bits I have already bought or plan to buy helping keep some of the cost down too....

Sell it stateside for a monster profit then buy one that's a little more rashed up for your track bike. As was stated above, the street RS250's grab 9-10k easy over here.

eddie v twin
04-17-2010, 05:02 AM
Your'll need too Renew the DYLITHIUM crystals Cap'n to gain warp speed

Eddie

morepower
04-18-2010, 01:08 PM
Nice one Eddie... The bike is a bit extreme and not too many seem to like it... But it is what the customer feels is nice and hopes to sell 52 of them at 107,000 each... Will see what happens... would be nice to build some but he has to sell one first...

morepower
04-20-2010, 07:00 PM
Just borrowed a RSW fairing to offer up to the bike..... Needs some work but once the front is lowered and pulled back it will look a lot better but needs some cutting and as this one is not mine I have to now order one but do have a good idea of what is now needed to make it all work,....

http://img219.imageshack.us/img219/585/imag0074.th.jpg (http://img219.imageshack.us/i/imag0074.jpg/)
http://img442.imageshack.us/img442/8232/imag0075f.th.jpg (http://img442.imageshack.us/i/imag0075f.jpg/)

Need to order a seat unit now and will get all the body work ordered tomorrow... Hope to have it all done for the end of the month..

morepower
05-18-2010, 01:42 PM
Next instalment... OK not done much but been busy and now it has to be done at a quicker pace as I have booked a trackday for next week!!!!
Got the new rear shock and it has now been fitted and tested before the bike was stripped so I can get on with the bike.... The Bitubo shock arrived and looks stunning it has the usual Preload, compression and rebound damping but has the added benefit of High AND Low speed Compression damping as well as length. Once fitted we took the bike out for a quick ride. The shock was used out of the box and due to my extra weight we added about 3mm of preload and as I like a quick turning bike added 4mm of shock length. It is now so much better than before. Turns quickly but is not unstable and the rear soaks up harsh bumps better than the stock shock but is still firmer overall than the stock set up. Hitting bumps on the road is not a problem and now the front is the weakest link... So for the next step... The Kawasaki B1 ZX6 front end...

Picfest.....
http://img339.imageshack.us/img339/2642/img2107w.jpg
http://img571.imageshack.us/img571/4030/img2119.jpg
http://img693.imageshack.us/img693/7454/img2109us.jpg
http://img34.imageshack.us/img34/9092/img2113g.jpg
http://img163.imageshack.us/img163/8403/img2116b.jpg
http://img34.imageshack.us/img34/8821/img2127t.jpg
http://img443.imageshack.us/img443/1269/img2128r.jpg
http://img52.imageshack.us/img52/1025/img2124u.jpg
http://img204.imageshack.us/img204/7968/img2129s.jpg
http://img412.imageshack.us/img412/710/img2130g.jpg

Will post up more as soon as the new stem is made... But hopefully the new bodywork will be on early next week.... Then the bike will be on track next friday!!!

lt1bird
05-18-2010, 02:42 PM
nice..... should be a fun project...

2T Institute
05-18-2010, 04:40 PM
Nice one Eddie... The bike is a bit extreme and not too many seem to like it... But it is what the customer feels is nice and hopes to sell 52 of them at 107,000 each... Will see what happens... would be nice to build some but he has to sell one first...

I wouldn't like to count on that. It might be me but I'm having trouble seeing where $400k AUD has been sunk into (what appaers to be) an old air cooled gixxer?

Patrick.sheil
05-19-2010, 08:49 AM
how much that shock set you back?

morepower
05-19-2010, 11:36 AM
The rear shock was done as part of a deal being in the bike trade.. But retail in the UK it is 697.00 inc VAT.

morepower
05-26-2010, 06:48 PM
OK update.. Spent about 2 1/2 days now to get this far.... so here are the latest photos..
So today got the Kawasaki ZX6 front end fitted into the bike and cut down the stock subframe and started fitting and cutting the fairing. Hope to have the bike ready to ride for Friday and its first trackday!


http://img714.imageshack.us/img714/226/img2145x.jpg
http://img193.imageshack.us/img193/2944/img2146l.jpg
http://img30.imageshack.us/img30/7287/img2147c.jpg
http://img89.imageshack.us/img89/2839/img2148o.jpg
http://img291.imageshack.us/img291/580/img2150r.jpg
http://img268.imageshack.us/img268/779/img2151yy.jpg
http://img541.imageshack.us/img541/9261/img2152.jpg
http://img411.imageshack.us/img411/9112/img2154q.jpg
http://img30.imageshack.us/img30/1766/img2155hg.jpg
http://img411.imageshack.us/img411/1128/img2156x.jpg
http://img59.imageshack.us/img59/8026/img2157t.jpg
http://img263.imageshack.us/img263/727/img2158a.jpg

julian78
06-17-2010, 09:17 PM
thats apretty cool bike. Check out wat smoky will did with his rs 250.

morepower
07-20-2010, 09:15 AM
For any facebook users there is now a page on the bike which will keep anyone who is interested in the project updated and will also give an insight into why I have done the project and show how I have done each part of it too....

http://www.facebook.com/pages/P3-Unlimited-Aprilia-RS250-Project/130497340324983?v=wall

Cebae
07-21-2010, 05:52 PM
Nice bike, Love the Bitubo ;))))

morepower
07-23-2010, 07:36 PM
Nice bike, Love the Bitubo ;))))

Thank you... The rear shock is great. It was taken out on the road when we fitted it and out of the box it was almost spot on.... A few tweaks for how I ride and it soaks up bumps and the bike doesn't even change line when hard over mid corner.. Bumps I used to miss are not a problem to hit now....

There is some more work to do but once the bike is finished I will be able to duplicate every part to build more bikes if needed...

http://img713.imageshack.us/img713/7489/img2189x.jpg
http://img713.imageshack.us/img713/6532/img2193h.jpg

I am hoping to get it all finished for a total budget of equivelent to about $3500 US or 2250.00. I am on budget at the moment as the sale of some of the original parts have paid for some of the new ones... Plus when it is finished it will still be road legal...

almano
08-15-2010, 03:01 PM
How the Kawi front end fit? It's a plug'n'play thing or modifications reuired? What is the offset of the ZX6 triples. I belive the Aprilia is 35mm.
I want to do a front end conversion also, i was looking at the GSX-R front ends but all those only 32mm offset the best.

morepower
10-29-2010, 06:53 AM
How the Kawi front end fit? It's a plug'n'play thing or modifications reuired? What is the offset of the ZX6 triples. I belive the Aprilia is 35mm.
I want to do a front end conversion also, i was looking at the GSX-R front ends but all those only 32mm offset the best.

Sorry for the delay.. I have been working on another customer project fitting a Honda NS400 engine into a Honda RVF400 rolling chassis... LOL...

The front end was easy, Just have the stem pressed out and make a new one to the same length and bearing diameters as the Aprilia. The top thread is almost the same size as the bearing diameter so you can just use the same top nut as the Kawasaki. IF you get a front end let me know and I can get the machine shop to make a stem to fit. I had a solid one made to try it all out but I can get a hollow one made if needed.. The only down side is the ignition as the Aprilia ingition barrel and key do not fit into the Kawasaki top yoke. I may have some triples made to use the ignition barrel but as mine is a track bike I am OK with out it...

nokturnal
10-29-2010, 07:45 AM
where did you get the seat unit?

morepower
10-29-2010, 03:21 PM
where did you get the seat unit?

I have them made for me... Almost sorted with a lightweight alloy subframe to go with them too with an integral oil tank to keep the auto lube system.. Will be made to road or track spec with Led rear lights and indicators.

nokturnal
11-03-2010, 11:27 AM
I have them made for me... Almost sorted with a lightweight alloy subframe to go with them too with an integral oil tank to keep the auto lube system.. Will be made to road or track spec with Led rear lights and indicators.

I would love an SBK seat/tail for my track bike... forget this stock seat, give me a 1/2 inch of foam. :banana:

forrestgimp
11-03-2010, 09:03 PM
looks great . what's that fairing off? i'm just wodering if i may have a bit of fittment diificulty with the 500 pipes.

ghezzi
11-03-2010, 09:22 PM
looks great . what's that fairing off? i'm just wodering if i may have a bit of fittment diificulty with the 500 pipes.

Chris, remember the shock linkage has been narrowed for the 500 so the belly of the pipes would not effect ground clearance. The only problem I could possibly see is the depth, as in vertical height as the stock RS fairing doesn't have a full belly pan.

Width wise the stock fairing contains the girth of the 500's pipes.

morepower
11-04-2010, 04:26 AM
Chris, remember the shock linkage has been narrowed for the 500 so the belly of the pipes would not effect ground clearance. The only problem I could possibly see is the depth, as in vertical height as the stock RS fairing doesn't have a full belly pan.

Width wise the stock fairing contains the girth of the 500's pipes.

OK with this information I will have a look at how much room there is. I can get a couple of photos today I hope to show you how much room there is. The motor is out of the bike at the moment but the pipes are still on so I can get some photos and hope they clearly show what space you may have.

morepower
02-10-2011, 06:14 PM
Done some more work on the bike....
This will be a monocoque carbon seat unit when it is finished. I have sorted out making the mould and will be making a very limited number in autoclaved pre preg carbon to see what the difference compared to vac bagged carbon is like... I still have some work to do but will be making the mould in about 10 days and hope to have some finished seats in about 2 weeks.
http://img18.imageshack.us/img18/5253/img0181nx.jpg
http://img534.imageshack.us/img534/527/img0188vb.jpg

I am also doing the fairing too after it has a few modifications where one of the silencers runs too close to the fairing at the moment. Again this will be offered in carbon with a few prepreg carbon ones being made initially as I have some autoclave time booked with the seat unit.

See more here.... http://www.facebook.com/pages/P3-Unlimited-Aprilia-RS250-Project/130497340324983?ref=ts

almano
02-11-2011, 03:19 AM
I WANT IT!!!!
I am looking for this type of monocoque seat unit for a year now.
Let me know the price.:plus:


Done some more work on the bike....
This will be a monocoque carbon seat unit when it is finished. I have sorted out making the mould and will be making a very limited number in autoclaved pre preg carbon to see what the difference compared to vac bagged carbon is like... I still have some work to do but will be making the mould in about 10 days and hope to have some finished seats in about 2 weeks.



I am also doing the fairing too after it has a few modifications where one of the silencers runs too close to the fairing at the moment. Again this will be offered in carbon with a few prepreg carbon ones being made initially as I have some autoclave time booked with the seat unit.

See more here.... http://www.facebook.com/pages/P3-Unlimited-Aprilia-RS250-Project/130497340324983?ref=ts

morepower
02-11-2011, 07:36 PM
Not too far from finished... just a bit more filling and then getting the surface perfect for making a mould...

http://img838.imageshack.us/img838/986/img0205n.jpg
http://img193.imageshack.us/img193/364/img0206wv.jpg
http://img708.imageshack.us/img708/3719/img0208sa.jpg
http://img151.imageshack.us/img151/8499/img0209tq.jpg
http://img18.imageshack.us/img18/6083/img0210hq.jpg

There is loads of space for the electrics and oil tank in the seat hump..The subframe you can see will not be used in the finished seat unit. Hope to get the weight down to less than 2Kg for the whole thing and have a battery lined up that is less than 1KG too...

Spoken to Dymag who are now making wheels again and may have some for the bike if I can talk to them very nicely....

DanRS500
02-11-2011, 08:29 PM
Richard, do you remember me talking about a KTM motard 5" rear, I passed the info on to a fellow forum member and he has fitted one easily if Dymag don't come through for you... Here is his post. http://www.rgv250.co.uk/forums/index.php?/topic/21650-80-hp-rgv/

morepower
02-11-2011, 08:41 PM
Richard, do you remember me talking about a KTM motard 5" rear, I passed the info on to a fellow forum member and he has fitted one easily if Dymag don't come through for you... Here is his post. http://www.rgv250.co.uk/forums/index.php?/topic/21650-80-hp-rgv/

Yes I remember.. I was contacting Dymag about some wheels for another customer. Carbon RC45 wheels. But as I have done a couple of projects that have had a lot of publicity round the world they may see this as a good one to get involved in too.. The Sheene Icon bike has not been as well recieved as the owners had hoped but it has been seen all over the world and Dymag have been mentioned in every reveiw. They had the option to be used on the GSXR 600 I built but the then owners of Dymag didnt come up with the goods. The new guy in the UK I think knew this and may be willing to help with this little project..

But the KTM wheel is another option... I have just been too busy with a Honda NsS400 RVF400 Hybrid for a customer.. So the Aprilia has been put back a bit.......

morepower
02-12-2011, 05:57 AM
I am hoping that when the project is done the shape will be close to the shape of the KTM 250 GP bike.
http://img822.imageshack.us/img822/3669/hiroshiaoyamagp2502007j.jpg

DanRS500
02-12-2011, 07:14 AM
I love the shape of that whole bike...

morepower
02-13-2011, 06:21 PM
I love the shape of that whole bike...

So do I.. If I can get to 90% as nice I would be happy. I still have some work to do if I want to have a road legal kit with headlights. I have some RVF400 lights to try as I think they do seem to have more of a race bike (ok endurance racing) look than most of the other lights available and they are available at a reasonable price. I will look into that hopefully this week.

DanRS500
02-14-2011, 02:53 AM
Just lokked at the pics on the RGV forum mate, if you took the kink/dog leg ouy of the bottom of the tail and it was one nice smooth curve that tail would look orsm, and very close to the KTM GP... I would love one...

morepower
02-14-2011, 05:13 AM
Just lokked at the pics on the RGV forum mate, if you took the kink/dog leg ouy of the bottom of the tail and it was one nice smooth curve that tail would look orsm, and very close to the KTM GP... I would love one...

I would love to remove the kink/dog leg but as it has the stock subframe inside this one I am using this to also give me the correct location for the electrics and battery. These fit right under the seat pad area and I dont think would allow me to smooth this out. I will look again today as I may be able to do something while I have all the fibreglass out but I do think space in that spot is limited. I dont want to have to cut the loom to extend it as I would hope to sell a few of these seat units when I have done all the work I can and made a mould. I am hoping to have 5 to 10 sets done in autoclaved carbon in a couple of weeks time as I will be up at a friends unit who has an autoclave. After that I think the rest will be vac-bagged for ease as I can make them here to order after that.

I will be also making some other parts too possibly carbon swingarm covers and frame protection which again will be a batch of autoclaved ones.

I dont think I have done too badly for my first attempt. I like the shape I am just a bit limited with this one due to the need for the stock subframe I have had to use for support. The next time I can use cheap glass versions of the monocoque unit and cut that about and have more freedom to shape it how I like.

morepower
03-09-2011, 07:47 PM
Ok quick up date... No photos today but will be some tomorrow I hope...
The engine is in the bike now....got a new motor to put in it.... Pistons have no carbon on them and neither do the heads, so looks like they have done less than 50 miles since a rebuild. Nice...

The chassis has been cleaned off and the engine is like new externally too. So I hope by tomorrow afternoon to have the bike ready to run with the new light weight battery too.. The body work will be fitted up once the bike is fired up and I will get some photos of the bike in its still unfinished state and then see if I can mock up some paintwork designs for it too..

Next week I am off to the get the moulds made up and the first sets of bodywork done too. Hope to have road and race bodywork done. I have up to a week making the moulds and parts up at the supplier as I am going to be doing most of the work up there too.. I just hope the headlights arrive before the weekend so the road version can be done before I leave at the end of next week.

So my plan I hope time willing, is have carbon self supporting seat unit, fairing, under tray with full battery box moulded into it,Fuel tank, front mud guard and then some carbon swing arm covers and full length frame protection too. I will post up pics while I am there or progess and hope to have the bike ready to take to the track by the end of the following week.

If I get this all done and people like it.. Then once I have made sure fitting is sorted and the seat unit is good and strong enough.. I will offer all the parts for sale. I have had some requests and plan to have 10 sets made straight after I know it all works out OK. 7 are already accounted for if they fit as expected and I am happy with the strength. Prices are going to be about 1200 to 1300 for the seat unit, undertray, fairing with alloy clock/fairing mount and my lightweight 300g Battery. The tank is estimated at 800 but this will wait until I am sure there are no issues with fuel attacking the resins and the sealing compound does its job fully. The road legal version will be 150/200 more I hope.

morepower
03-12-2011, 11:44 AM
Still got loads to do but after a quick weight check last night the bike weighed in at 121Kg with the really heavy seat unit which is full of car body filler and steel sub frame bonded in to it... A rough estimate for that is 8 to 10KG !! I have estimated if I went the whole 9 yards and had light weight wheels as well as full carbon I can get the bike down to 102Kg in track day/ race trim.

Here are a few pictures of the bike just before it is sent to have the bodywork moulded up..

http://img34.imageshack.us/img34/7677/img2714w.jpg
http://img848.imageshack.us/img848/5465/img2712.jpg
http://img585.imageshack.us/img585/8024/img2708i.jpg
http://img851.imageshack.us/img851/1730/img2705.jpg
http://img856.imageshack.us/img856/4865/img2702.jpg

Hope you like the shape.....

adamball
03-12-2011, 12:09 PM
i carnt wait to see this bike finished it is gunna look the nuts keep the pics comeing mate i wish i was half as talented as alot of you boys on here, i have sent you a pm for abit of advise thanks adam

morepower
03-12-2011, 12:17 PM
i carnt wait to see this bike finished it is gunna look the nuts keep the pics comeing mate i wish i was half as talented as alot of you boys on here, i have sent you a pm for abit of advise thanks adam

Got the PM... will answer later.. Have to go out... But thanks for the support.... will be nice to finally have it done....

adamball
03-12-2011, 12:24 PM
Got the PM... will answer later.. Have to go out... But thanks for the support.... will be nice to finally have it done....

thanks mate look forwd to your reply

Sandman1979
03-13-2011, 03:10 AM
She looks nice :)

Tash
03-13-2011, 12:22 PM
Looking good Richard, are you calling in on your way past? I have got your NSR500 fairing in now, I will give you a call tomorrow to see what your plans are.

Mark

stealth
03-13-2011, 01:13 PM
Can't wait to see the finished project mate, thanks for stopping at ours on the way up and will look forward to seeing some pics when it is done

morepower
03-13-2011, 02:08 PM
Looking good Richard, are you calling in on your way past? I have got your NSR500 fairing in now, I will give you a call tomorrow to see what your plans are.

Mark

Speak to you tomorrow.....

morepower
03-18-2011, 05:49 AM
OK.. Got the final specs and prices for the kits... Due to the cost of pre-preg carbon I know these will not be cheap. But I have 10 kits being made and there will be 5 in plain black carbon with some detailed parts shown in glossy show carbon and 5 in full show carbon. I know some will want to paint their bikes and not show all the carbon off so the black carbon ones will be ready for paint. The show carbon will be a high gloss finish over all the kit.

The kits come with an Alloy SES fairing mount to my spec.
Light weight 350gr battery with quick release connectors worth 140.00.
Monocoque self supporting seat unit.
Full carbon fairing supplied with Probolt lightweight stainless D ring Dzus Fasteners.
Seat pads.
The prices will be 1300 for black carbon and 1600 for the show carbon.
There is an optional LED Tail light and turn signal unit if you want the bike for the road. This is 110.00.

There will be a headlight option soon and the Carbon Fuel tanks will be ready to be produced in about 4 weeks time these will be tested before I offer them for sale and again will be offered in a cheaper ready to paint carbon and a full show carbon too. IF anyone who has ordered a full body kit wants a fuel tank then existing customers will get a 20% discount on the fuel tank.

The supplier is looking at doing carbon wheels to in 4.5 through to 6.00 inch rim sizes if there is a demand. These will again be Pre-preg carbon and not wet lay and vac bagged carbon. He is currently working on a GP project with a company and wheels is part of the project so to do the other sizes needed is not going to be too hard to do but will require some extra tooling so these will be late in the year if there is enough demand.


So anyone interested in the body kits please PM me I do have a few requests so please be quick to let me know if you are interested and then we can sort out the details.

Again PM me responses about the wheels and I will pass the information on to the supplier to try and push him into making the wheels if you want.

morepower
03-22-2011, 11:53 AM
Just a quick and rough mock up to show it in a single colour...

http://img694.imageshack.us/img694/5074/img2707l.jpg (http://img694.imageshack.us/i/img2707l.jpg/)

morepower
03-26-2011, 11:33 AM
Just tested a battery pack for the bike and just for a laugh I tried it on my Yamaha R1 to see if the tiny battery would start it up...It did!!

I am now going to get them made up and fully diode protected too. These will come in an insulated Carbon case and be sold in 2.5Ah, 5Ah, 7.5Ah and 10Ah sizes soon. I have a local company who do power supplies for industry and motorsport who have offered to assemble them for me and after talking to them and looking at others being sold which use the same cells it seems mine will be one of only 2 companies they have seen who actually diode protect the cells and ensure they are balanced charged for maximum power and reliability. Prices will be available soon and I will be looking for a US and Australian distributor as soon as the first ones are produced in a couple of weeks..

vG7ohWsDr2g

morepower
03-29-2011, 01:26 PM
Just started work on carbon swing arm protection...
http://img850.imageshack.us/img850/402/img0282q.jpg

adamball
03-29-2011, 02:51 PM
Just started work on carbon swing arm protection...
http://img850.imageshack.us/img850/402/img0282q.jpg

they are gunna look the dogs bits when you get them ready for selling i want them keep up the pics love this project

morepower
03-29-2011, 03:53 PM
they are gunna look the dogs bits when you get them ready for selling i want them keep up the pics love this project

Thanks. I am trying to push what I do to be more than just someone who works on bikes. By building stuff like the Honda NS/RVF Hybrid I am doing some pure special building. The P3 Suzuki GSXR600 was to show how well we can build a bike and make it work well enough to break even the highest expectations of the guy who we asked to test the bike at the Nurburgring. The Sheene Icon bike showed the attention to detail possible too. This Aprilia project was to show what could be done on a budget but as the Honda came along and I needed to practice some new techniques (to me) and make some parts from scratch I have used my own personal bike to be my test bed.

Luckily almost everything I do will be made and available for sale too. I have teamed up with a structural carbon manufacturer who has helped me and we have a few things planned for the future. carbon wheels in 4.5 and 5 inch widths is just one of them and we have been looking at making them more like the forged alloy wheels and made with solid spokes which are then machined so they will look different to the Dymag or BST alternatives.

morepower
03-30-2011, 02:12 PM
OK been playing again... Now have some Mk1 carbon tank protectors.

http://img819.imageshack.us/img819/7642/img0177fo.jpg (http://img819.imageshack.us/i/img0177fo.jpg/)

What do you think?

adamball
03-30-2011, 02:30 PM
OK been playing again... Now have some Mk1 carbon tank protectors.

http://img819.imageshack.us/img819/7642/img0177fo.jpg (http://img819.imageshack.us/i/img0177fo.jpg/)

What do you think?

i dont want to sound like bum kisser but some people have got a rare talent some like myself can do basic things but thats it and others like yourself can turn there hand at anything this project just makes me want to do and try more things with mine keep up the good work mate really good project AND I WANT SOME CARBON SWINGARM PROTECTORS ASAP LOL

morepower
03-30-2011, 03:11 PM
Cheers Adam... I am getting the moulds made for the swing arm and then frame too.. I will sort them out for you and let you know as soon as they are done..

I just try to do stuff and if it doesnt work.. I either try again or do more research until I can do it.... So rare talent or just stubborn? I think it is just stubborness...

http://img850.imageshack.us/img850/7396/img0176xc.jpg

DanRS500
03-30-2011, 04:29 PM
Nice work, someone wanna give Richard a mk2 tank to play with for us?

morepower
03-30-2011, 04:36 PM
Well get me a Mk2 tank for a few days and I will make them...... If you get me a tank you get some free tank pads.... Deal???

jaxxon
03-30-2011, 05:36 PM
I am hoping that when the project is done the shape will be close to the shape of the KTM 250 GP bike.
http://img822.imageshack.us/img822/3669/hiroshiaoyamagp2502007j.jpg

No only if you could get the tail section to flow like the GP bike... I always felt the tail section was too fat on my RS250-- it looks old school vs. the GP bike looks modern

morepower
03-30-2011, 05:43 PM
No only if you could get the tail section to flow like the GP bike... I always felt the tail section was too fat on my RS250-- it looks old school vs. the GP bike looks modern

I dont think I am too far off.... I just need a thicker cross section under the seat for the Aprilia electrics... But the tail is not too far off and will hopefully have a cut out section close to the frame to make it look lighter too.. Going to test the strength of one with it cut out to see how strong it is... If not then it can stay solid.
http://img34.imageshack.us/img34/7677/img2714w.jpg

DanRS500
03-31-2011, 01:38 AM
Well get me a Mk2 tank for a few days and I will make them...... If you get me a tank you get some free tank pads.... Deal???

I have a spare but I'm too far away... Otherwise I would take you up on the offer...

morepower
03-31-2011, 03:26 AM
Will see if anyone from the RGV forum or the PB Magazine forum can get me a tank. I dont think it will be too hard to give away a free tank pad just for borrowing their tank for a day or two...

DanRS500
03-31-2011, 06:03 AM
If you get one could you make me more of a carbon infill than pad please, I want to fill the whole knee cut outs in the tank with carbon, so like a tank pad that wraps all the way round and fills in cut outs...

morepower
03-31-2011, 08:00 AM
If you get one could you make me more of a carbon infill than pad please, I want to fill the whole knee cut outs in the tank with carbon, so like a tank pad that wraps all the way round and fills in cut outs...

OK will try it.... See how it works out..

morepower
03-31-2011, 11:31 AM
OK first half of the swingarm mould done. just needs a bit of polishing and I will try to make up a part tomorrow. Will just be in glass first to prove it works. Have never used wax to create the parts finished shape before so this was an experiment for me...
http://img20.imageshack.us/img20/1152/img0285nl.jpg

adamball
03-31-2011, 12:20 PM
Will see if anyone from the RGV forum or the PB Magazine forum can get me a tank. I dont think it will be too hard to give away a free tank pad just for borrowing their tank for a day or two...


i have got a mk2 tank you can borrow for a bit if you need it let me know and i will sort something out for you regards adam

Pro Backmarker
04-01-2011, 09:59 AM
I am hoping that when the project is done the shape will be close to the shape of the KTM 250 GP bike.
http://img822.imageshack.us/img822/3669/hiroshiaoyamagp2502007j.jpg
I know where you can buy the frame and bodywork from Kallios FRR250 if you want a real project ;)

morepower
04-01-2011, 05:06 PM
I know where you can buy the frame and bodywork from Kallios FRR250 if you want a real project ;)

Tell us more...... Hmmm......

Pro Backmarker
04-02-2011, 04:39 PM
2000€ for the tank and bodywork (2007), 7,500€ for the frame (2007), swingarm and airbox, and 6000€ for the TTX forks (2008).

Bloke bought 2 of them (no motors) and stripped them to make a supermono.. sad huh!

morepower
05-12-2011, 04:27 PM
Sorry for lack of updates..Fairing and tank up with the carbon supplier and the rest of the bike is just gathering dust until the bodywork arrives.. BUT I have been making frame and swing arm protection. I wanted to use Pre-Preg for them but the material I want to use for abrasion resistance is not made in pre-preg form at the moment.. (will be soon I hope) So been busy making moulds and testing my layup as I am still very new at all this chemisty and material stuff.. But here are my first attempts at the protectors. I have just made 3 parts to test. One was to check for surface finish with some odd carbon twill scraps then I made 2 parts. One carbon with several layers of abrasion resistant material and a final layer of carbon then one with a carbon outer and 2 layers of the other material.
I will have the rest of the moulds ready and producing some parts at the end of next week..... Finally after making a few mistakes... LOL
So here are a few pics of my first attempts at Vac bagging..
http://img718.imageshack.us/img718/962/img0449ub.jpg
http://img195.imageshack.us/img195/6148/img0451og.jpg
http://img84.imageshack.us/img84/791/img0453za.jpg
http://img577.imageshack.us/img577/4267/img0455sq.jpg
The one with only 3 layers (one carbon and two abrasion resistant material) is 100gr...
http://img685.imageshack.us/img685/191/img0461kb.jpg

Just a quick update on seals... Went to sort out the master cylinder ones as they had a question... So got some blurry video footage of some being made for another customer...
http://imageshack.us/clip/my-videos/801/54272257.mp4/

tygapaul
05-13-2011, 02:57 AM
Not wishing to steal anyone's thunder here but I just stumbled on this thread and we have just introduced swing arm covers. One thing to note, the Mk1 and Mk2 use different pressings so we will have two specific models.http://www.tyga-performance.com/site/images/bpcc-9012-0dcd9ddd.jpg

http://tyga-performance.com/site/product_info.php?products_id=2197

robby-hk
05-16-2011, 06:31 AM
Nice work Tyga. May I ask what the differences are between Mk1 and Mk2 swingarms are exactly ? I ask as I have a Mk2 with a dented swingarm, and have bought a Mk1 swingarm to replace it....hope it fits my bike ?

Cheers

Robert

morepower
05-16-2011, 09:22 AM
The difference is very slight and just in the pressings so it is not critical to fitment.

forrestgimp
05-17-2011, 05:03 AM
Let's see what they both look like on the bike please..


can we have prices please in AUD


hey paul While your in the carbon frame of mind why don't you make a cabon seat unit?

Also Seeing youre insisting on Jumping Morepowers train can you make a self suporing rear seat like he has?

DanRS500
05-17-2011, 05:27 AM
can we have prices please in AUD




This works...

http://www.xe.com/ucc/

forrestgimp
05-17-2011, 07:02 AM
This works...

http://www.xe.com/ucc/

That's nice, now for some prices in foriegn currency to convert eh?

morepower
05-17-2011, 08:19 AM
Well while we are on prices... the frame AND swing arm protectors will be AUS$195 plus shipping for the first 10 orders... got 7 left. Pauls swing arm covers are AUS$148.87 plus shipping. They do look nice though Paul... Nice one..

tygapaul
05-17-2011, 12:07 PM
Morepower, your protctors look good too. I really had no idea you were working on them, it just seemed like a good idea at the time.

I don't know all the differences between the swing arms but we made our covers off the MK1 expecting them to fit both models. However, the MK2 has slightly different pressings so that the result would be that if you put them on you'd probably complain to us if you expected them to fall on but on the other hand be pleased with yourself if you had a go expecting them not to fit at all. They kind of want to spring off as it is. As for the critical domensions, I am not sure of the differences but I doubt anything major.

The self supporting seat is a nice concept...

morepower
05-17-2011, 04:56 PM
I have asked Dan to try some swing arm protectors and will be sending a set he can cut up and let me see the differences as I may find a MK2 would fit both easily or I can hybid a MK1 protector to work with both.. But I know the frame protectors will work on both MK1 and MK2 bikes.

I am hoping to have an oven sorted in the next few weeks to so I can swap over fully to Pre-preg soon and I have been talking to a material supplier about creating the abrasion resistant material into a pre-preg form which should allow me to add one more layer with no weight or thickness penalty. I want to minimise the use of carbon to the outer layer and build up the inner core protection more. It is more about protection for me than a cosmetic cover to be honest..

If this material will be suitable for Pre-Preg I will be using it in the Fairings and in parts of the seat unit to stop the carbon from exploding on impact if there is a crash.. The structural parts will always be carbon though.. I have a guy here who along with me will be testing the fairings and I will be the crash test dummy for the changes to the seat unit...

mcludd
05-18-2011, 01:42 AM
Here ya are print this and stick some on your hat and elbows etc

morepower
05-18-2011, 03:14 AM
Here ya are print this and stick some on your hat and elbows etc

Thanks... Will do.. I dont usually crash but when I do it looks impressive...

DanRS500
05-18-2011, 06:28 AM
My dad always told me there is no point doing something if your not going to do it properly Rich...

morepower
05-18-2011, 08:20 AM
My dad always told me there is no point doing something if your not going to do it properly Rich...

True.... My best was a slow speed highside infront of about 80 people the day before a big photoshoot at the Nurburgring, of the GSXR600 I had built.. It was not too bad but had to have photos taken from one side... I also separated my collarbone from my shoulder and less than 48 hours later had to ride home with no pain relief with the bone moving about the whole ride back...

To be honest that bike was the one that has made me look at carbon parts in a different way. It was 50Kg less than stock and still road legal. But it had 3 crashes and the way the carbon shattered (I had cuts and splinters in my body to show for using it too) has made me think about using other materials to improve the crashability of the parts and not just use carbon as the ultimate material. It is good but can be much better in a composite with other materials that add to the benefits and not just all carbon or other materials as a filler to save cost. So that is another reason I am working with a few different people in the composites industry to find new ways to improve the products.

Manicmatelot
05-18-2011, 03:30 PM
Have you made or though about making a generator cover or clutch cover Rich..? Not sure what strength of material would be needed though..?

morepower
05-18-2011, 06:09 PM
Have you made or though about making a generator cover or clutch cover Rich..? Not sure what strength of material would be needed though..?

I have looked at covers as most race bikes now have to have covers over the cases... I know it is not needed on the 250's but I wanted to look at how it would be done for other bikes.. I have thought about doing some covers for a classic trials bike as I have an engineering shop owner who is into his trials bikes.. He has one case in Magnesium that is almost rotted through.. So he has tried to buy one but they are so expensive that he has asked me to look into making a composit one for the engine. So I may play with that then the cases on my spare motor if the simple trials bike one works ok.

Manicmatelot
05-19-2011, 10:29 AM
Well if you do make some Rich i would definately be interested as no one seems to be making any for our bike..

morepower
05-26-2011, 04:17 AM
Well if you do make some Rich i would definately be interested as no one seems to be making any for our bike..

Looking into it... but may be covers to go over the cases as this is easier and more like the stuff used on race bikes to act as protection. Making full cases is a bit more involved as the ignition side needs to hold the triggers and the generator coils so would need to be made so it could be machined up to get these in the correct places. But covers would be easier....

morepower
06-08-2011, 07:51 PM
Made a quick mould for the radiator bracket. I have used an Aprilia rad on a Honda NS/RVF hybrid project so have made a carbon bracket for that and have used a new RS250 bracket to make the mould. So if anyone wants a radiator bracket which will fit all years let me know..

This is the first one and not the best. The second one is better as this one was made up from scraps of carbon material. But it gives you an idea.

http://img339.imageshack.us/img339/3796/img0550yt.jpg

Also the frame and swing arm protectors are almost all done. I have 8 sets left at 125.00 plus shipping.
Here is a picture of the right hand side set and I will have the left hand ones done in the next day or two. Here I have shown from mould through trimming of the swing arm protector. Just to show how it starts out...
http://img577.imageshack.us/img577/7941/img0556zq.jpg

Manicmatelot
06-09-2011, 11:42 AM
Rich,
Are you selling the frame protectors seperate from the swingarm covers..? If so how much and also i would be interested in the radiator bracket. Did you ever previously say you made a fairing bracket out of carbon for the mk1..?

morepower
06-09-2011, 05:47 PM
I can do the parts seperately which do you want?..... and the radiator bracket is 35.00 posted. Not made a carbon fairing mount... the stock one is tubular and I hacked the one I have to make the fairing fit so I am using an SES race products one..

Chrisb41
06-09-2011, 07:33 PM
If your making one like either of these for the fairings, I am VERY interested......

http://www.oppracing.com/image_display.php?image=58&id=588
or
http://www.oppracing.com/image_display.php?image=24628&id=6047

Manicmatelot
06-10-2011, 08:44 AM
The frame spar protectors Rich and like chrisb41 i second that! I emailed SES and they told me that their fairing bracket is only for the Mk2 :( GpTech make one for the Mk1 but it's 158 over here!

morepower
06-10-2011, 10:09 AM
OK... well if I can get a MK1 bracket which is rough but not hacked about it may be possible to make up a carbon one if we can cover it with some cured glass sheet to look like the the ones posted then make a mould from that... IF you want to have a go I can send you some glass fibre sheets with a blue gel coat finish to cut like card and make up the shape.. I can then make a mould from that.... I dont mind.. I just dont have a bracket here to use.. Mine is the one SES have and mine is a MK1 version so they may soon make a MK1 bracket anyway... I had forgotten about the different clocks to be honest... Luckily all of the ones I have sold for my body kit are Mk2 versions mine is the only Mk1...

OK frame spar protection are 90.00 for you posted.

Manicmatelot
06-10-2011, 11:24 AM
pm me your details Rich reference payment etc. Cheers Jules

oldgit
06-10-2011, 01:14 PM
Hi Morepower

Fantastic work - wish I had a fraction of youre skill

Where r u in the uk

morepower
06-10-2011, 01:48 PM
Hi Morepower

Fantastic work - wish I had a fraction of youre skill

Where r u in the uk

Leicestershire... I am about 4 miles from Mallory Park.... Horrible place to be on a Wednesday.... I can hear the bikes practicing all afternoon.. I have itchy feet and want to drag a bike out and just go and ride.....

cyclox
06-10-2011, 03:08 PM
Leicestershire... I am about 4 miles from Mallory Park.... Horrible place to be on a Wednesday.... I can hear the bikes practicing all afternoon.. I have itchy feet and want to drag a bike out and just go and ride.....

how terrible... I feel your pain ;)

oldgit
06-11-2011, 01:01 AM
Aaaah Mallory

Loved racing there in my younger days

Let us know if you go to Brands anytime would love to pop down and say hello

morepower
06-17-2011, 03:33 PM
Will add a few pics.. OK they may also be on another thread but as they are part of my project I thought it is best to keep them in this thread too..

http://img577.imageshack.us/img577/7941/img0556zq.jpg
http://img593.imageshack.us/img593/5088/img0563wa.jpg
http://img535.imageshack.us/img535/1782/img0582mz.jpg
http://img820.imageshack.us/img820/5386/img0597jd.jpg

morepower
06-21-2011, 04:05 PM
OK very scabby looking but I have had to alter the finished shape to make several areas a bit stronger is it is quite narrow in two places. This change will make it easier to mould and allow me to remove more material than I have added from else where..

This is the plug I made which I will do the finishing off tomorrow. I have to smoothen it out and do a bit of filling the holes will be drilled tomorrow too so please tune in tomorrow for another update. I am hoping to have finished carbon for Friday. ...

http://img18.imageshack.us/img18/6571/img0601sw.jpg (http://imageshack.us/photo/my-images/18/img0601sw.jpg/)

DanRS500
06-22-2011, 04:51 AM
What is you plan for the alinement marks mate?

morepower
06-22-2011, 06:51 AM
What is you plan for the alinement marks mate?

Going to look at getting a clear sticker made that uses the holes to reference it up and it should work out from that then have the marks printed in silver.

Good idea?

Stuboy911
06-22-2011, 08:25 AM
could you not use the existing indents from the mould and paint them before the laquer?
no way to lose or mess up the marks with a sticker..

morepower
06-22-2011, 12:08 PM
could you not use the existing indents from the mould and paint them before the laquer?
no way to lose or mess up the marks with a sticker..

Hmmmm... Iwill have to get a new bracket from Aprilia and mould the opposite side then and see how it works out...

OK... Will order up a brand new bracket tomorrow...

DanRS500
06-22-2011, 04:17 PM
Or you could put a layer of lacquer over the sticker...

morepower
06-22-2011, 05:01 PM
Or you could put a layer of lacquer over the sticker...

I will get a new bracket first and see if I can mould from the opposite side and get the marks to show. It is easier from a fresh part and I will try and make the needed changes to that part. It will not be too hard I think as I think I can build up where needed on the actual part..

imdying
06-22-2011, 06:59 PM
It'll be awesome either way.

Wouldn't think the alignment marks are too much of a problem, that's what a finger up the exhaust port is for :)

You could just dot punch/drill the marks on the part before you take a mould, they'll show up no trouble at all.

morepower
06-23-2011, 03:03 AM
It'll be awesome either way.

Wouldn't think the alignment marks are too much of a problem, that's what a finger up the exhaust port is for :)
You could just dot punch/drill the marks on the part before you take a mould, they'll show up no trouble at all.

That is how I had to do it as the bracket was so covered in crap...

The little hole idea is good too...

morepower
08-05-2011, 04:49 AM
Been a while since my last update.... The bodywork has been up in Scotland for a while... The parts I saw from the first mould were not great. OK but not great. So I have had the guy send all the pattern parts to a guy we know who only makes moulds. He is closer to me so any remedial work needed can be done here.. So have had the seat unit back here for over a week and re-fitted it up to the bike to sort the issues out. But while it was back here I have had a slight change of plan. As I now have 2 seat units that both need some work the original one has been blended in to the tank to create a monocoque seat/tank combination. After a week of remedial work and re-aligning the seat unit after it has been knocked out of place the pattern is now done. So the first 5 people who have had the prototype set ordered will now be getting the new seat/tank combination at the price they were quoted for just the tank. Plus unlike the prototype oven cured Pre-preg they were getting the new parts will be autoclaved pre-preg. The new mould maker has been making moulds and carbon parts for about 30 years so I really have found the best person for the job. So now James up in Scotland only has to actually make the parts up and put them in his new autoclave. The moulds will be done in the next 2 weeks. I know this will NOT change as Vic has always worked to his promised deadline. James will be getting pushed hard by me and the customers to finish the parts now.. So I hope to have pictures of the finshed parts really soon.

Here is an early picture of the seat and tank together before it was fully smoothed off and sprayed with a resin based product to give the surface finish we need. The initial estimates of weight for the combined unit is 2kg plus filler cap and fuel tap.

http://img143.imageshack.us/img143/9945/img1161k.jpg (http://imageshack.us/photo/my-images/143/img1161k.jpg/)

Now this has been done.. I hope I can now finish off the few frame and swing arm protectors for customers next week and have some more radiator brackets to send out too.. It has been a hellish few weeks and this has had to be done now as Vic has sheduled work coming up in 2 weeks for another customer so he has to get mine done now or I have to wait 2 months before he can start it.. So I have had to work round others and my wifes holiday demands the past month or so.. But now I hope I can finally clear the work load and as soon as the parts are made.. I can finish off the bike and possibly get one track day in before the season comes to an end....

chris675
08-05-2011, 07:14 AM
want one, need to get back to battering the overtime

morepower
08-17-2011, 02:19 PM
The monocoque seat/tank combination will be moulded and ready in 3 weeks. Hopefully OCRSVfactory will be the first forum member with a full kit and it will be made while it is up at the mould makers so no waiting for it to be sent anywhere.. Just make the mould and then the first parts will be in the mould the day after. Want these done and I want my bike running so I can get at least ONE trackday before the season ends.. It has been way too long and used someone who has been way way way too slow.. The new mould maker is not a biker and it is just a composites specialist so no messing about with him involved.

Well one for Forestgimp AND DanRS500 with his frame protector in the bag now too..
Here is the last swing arm protector in the bag for his Mk2 swing arm... Luckily unlike Tyga I do have them for the MK2.... HAHAHAHA......

http://img36.imageshack.us/img36/1887/img1246i.jpg
http://img716.imageshack.us/img716/6567/img1250lv.jpg

Radiator bracket made too..
http://img153.imageshack.us/img153/968/img1248k.jpg

OCRSVfactory
05-06-2012, 12:13 PM
Hey Rich,

Where are we with the body work.? Been a year and would like to get the bike going....

halliwell_23
05-06-2012, 04:19 PM
I think he is gone after the great brake seal debacle of 2011.
You can catch him on his FB page.
he still seems to be trying compounds and bonding agents trying to get the best result.