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Old 03-30-2013, 07:40 AM   #1
muttley92 OP
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what do you get if you combine and RS 125 and a 640 LC4???

This a a build thread for a supermono road bike, it's been done before but I've never seen a proper build thread. Several people have asked me for this so here it is.
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Old 03-30-2013, 07:48 AM   #2
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First things first

I should start by saying that I am 20, I live in the UK, I'm studying a masters degree in Mechanical Engineering at Loughborough university and this is something I'm doing for fun in my spare time.
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Old 03-30-2013, 07:52 AM   #3
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This is what I started with






The engine came from ebay 2004 640 LC4 from a duke II, the bike is a 2009 Apilia RS 125 that was a cat B write off and it arrived in bits.
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Old 03-30-2013, 08:12 AM   #4
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getting the engine in there







This engine looks like it was made to fit in the Aprilia frame! The mounts needed filing down by about 2mm to fit in the swing arm, and I had to take a little off the front of the swinger for clearance. The earlier engine is easier to get in the frame (you don't need to do anything to the swing arm) just the bushes. It's tight, but it fits
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Old 03-30-2013, 08:12 AM   #5
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From the LC4 thread and I'm in.
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Old 03-30-2013, 08:18 AM   #6
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Engine mounts

I cut down the standard RS engine mounting plates and modified them slightly








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Old 03-30-2013, 08:20 AM   #7
pennswoodsed
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what do you get 640+rs125

Quote:
Originally Posted by muttley92 View Post
This a a build thread for a supermono road bike, it's been done before but I've never seen a proper build thread. Several people have asked me for this so here it is.
A frame twisting mind bending wet dream ,and that's before it starts ! Subbed on the title value alone..
Go for it ,Ed !
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Old 03-30-2013, 08:24 AM   #8
muttley92 OP
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Then I made an exhaust













It's not the best but I made it, it's mine and it will work
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Old 03-30-2013, 08:38 AM   #9
pennswoodsed
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Remembering your field

Hi,
Your 2nd post ,engineering student so maybe this is dumb ,the front mounts are single shear on a butt weld ,I would want to spread moment above and below weld. Maybe.
regards,Ed
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Old 03-30-2013, 09:32 AM   #10
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Quote:
Originally Posted by pennswoodsed View Post
Hi,
Your 2nd post ,engineering student so maybe this is dumb ,the front mounts are single shear on a butt weld ,I would want to spread moment above and below weld. Maybe.
regards,Ed

Or overkill !!!!!!!!!!!!

Don
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Old 03-30-2013, 09:55 AM   #11
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Quote:
Originally Posted by pennswoodsed View Post
Hi,
Your 2nd post ,engineering student so maybe this is dumb ,the front mounts are single shear on a butt weld ,I would want to spread moment above and below weld. Maybe.
regards,Ed

I'm no engineer, but have been around these thumpers for quite some time and the front mount looks like a crack waiting to happen.
Did you make the mounts just for a temporary hanger? Redo them later?

Good luck with this...........it looks like it will be a nice combination once completed!

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Droptarotter screwed with this post 03-30-2013 at 10:54 AM Reason: spelling
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Old 03-30-2013, 09:59 AM   #12
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That was considered. It's 3mm stainless 304 on both sides, since the engine deadweight is only around 40kg max and majority of the weight is on the rear mount I think it will be just fine. But I'll keep an eye on it and if it should crack I'll find a solution.

muttley92 screwed with this post 03-30-2013 at 10:41 AM
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Old 03-30-2013, 10:02 AM   #13
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Got hold of an FCR





And many thanks to the Loughborough University Formula Student team for letting me use the lab and the weld set!
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Old 03-30-2013, 10:12 AM   #14
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just to make things easier

Once finished the exhaust was difficult to fit so i modified it simular to the stock pipe


and i knocked up some rad mounts from the remnants of the standard mounts.


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Old 03-30-2013, 10:15 AM   #15
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first look

All the standard fairings fit fine over the new engine, would make a hell of a street sleeper if the left hand side fairings were still in one piece!

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