At It Again....Thinstrom 650

Discussion in 'Land of the Rising Sun: ADV Bikes from Japan' started by glitch_oz, Jul 26, 2007.

  1. Superstar

    Superstar Been here awhile

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    I feel unworthy even reading this thread.




    But I'm still going to read it anyway!

    Great work, I am really looking forward to you posting again.
  2. freecat

    freecat Been here awhile

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  3. CodyY

    CodyY ADVenture Capitalist

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    Damn, Dude. I thought I made some pretty cool shite.
  4. D-Mac

    D-Mac Been here awhile

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    WOO HOO! Great project. I'm in awe. :clap :clap :clap

    Keep it coming!

    Cheers, D-Mac
  5. glitch_oz

    glitch_oz Long timer

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    Just a quick "HI" folks...
    No, I haven't forgotten this thread...or the project :1drink
    Nothing new has happened to the bike, we've had our Euro-Alps trip
    (ohhhh, maaaan...what a ripper!!) and afterwards things just came like a tidal-wave....work, home, family....and a ride-report, that took 2 months to write!!

    The time spent on that would've finished this bike....and the next!!
    Anyway, I'll be back to my usual shenanigans soon, there's a free week coming up after New Year, we'll see what we'll get done then...just hang in a liiiiittle longer :wink:
  6. glitch_oz

    glitch_oz Long timer

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    Rain, showers, drizzle....the weather front that drenched the north of Australia had finally moved down to Melbourne and isn't the desert in the back (called: garden) loving it?? :wink:

    Finally, after months of not even looking at it, there was some time to get stuck into this project again and it took a good hour and a coldie to pick up the pieces... :freaky

    Key focus is the rear of the bike... the tank-pods are finished and the front will be another chapter...or three. :1drink :1drink
    The rear then....single seat conversion, underseat exhaust and all that jazz...

    With a fresh start, the various remaining lugs of the rear subframe were attacked....somehow I had to get that CBR600RR tail to fit. :evil

    The subframe's got 2 cross-braces, one doubles as a support for the seat-release, the rear brace is the support for the OEM rear rack, quite a hefty item.

    Somewhere along the line I'd fiddled with a new cross-brace for the shortened seat...and wasn't happy with it....2hrs wasted. :evil

    Made another...another 2hrs wasted. :evil :evil

    Left it there and created another FU a week later, I just couldn't get the bloody angles right. :evil :evil :evil

    Yesterday morning finally produced a good one, the one with the seat-latch mounted, gardening wire holding the bent "legs" firmly in place :D

    [​IMG]

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    The view from underneath the seat...

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    ... with the OEM rear brace still in place to keep things aligned

    [​IMG]

    Marking out the seat for the chop, note the seat-latch about 150mm forward of it's old position.

    [​IMG]

    No going back NOW :huh :huh

    [​IMG]

    Made a temporary brace and bolted that into place before cutting out the OEM rear brace, frame rails de-lugged and roughly cleaned up.
    Yup, the little Ryobi Angle-grinder earned it's keep :D

    [​IMG]

    The 600RR tailpiece tapers a lot narrower, and earlier (starting further forward) around the rear, the final 110mm of the framerails had to be cut and angled to make the plastics slide forward sufficiently.

    Once more: Cut, bent and wired

    [​IMG]

    Things sorta fit, but it's very tight....don't like it, this needs more work.

    [​IMG]

    Up the clacka ....Yup, accepted!!! :lol3

    [​IMG]

    This is starting to look something, bummer it's just a mock-up.

    [​IMG]

    [​IMG]

    Then comes the hard part....cut and nibble on those plastics to make them fit around the essential structural parts...that was easy, but...
    Shorten the legs of the old rear OEM brace to provide 3 jobs...one as a brace to strengthen the sub-frame, the second to create a key support for luggage/ pannier-rack mounting points/ rack/ whatever...
    third, to be the rear-support structure for new hanger-brackets for the underseat zorst, which have to be designed/ made/ welded to the brace....

    The OEM brace fits the bill, sliding forward by about 120mm, the crown sitting about 15mm lower than before....check clearance for the exhaust can under full compression of suspension....fine. Loads of space actually...and there's a set of 20mm raising dogbones in the mail at the moment.


    Let's now repeat the whole process for the third crossbrace, which has the same 3 functions as the rear one...but sits just to the rear of the "seat-brace".
    Again, it's a mounting point for luggage and for the front section of the exhaust can.

    It's damn fiddly to match up height, length, width, cover (i.e. rain-protection of electrics), positioning, angles and lots more to make all the parts and needed items fit together, leaving provision for electrics/ tail-light..indicators and all other stuff...like a small tooltray etc etc...and where the hell am I going to mount the lock for the seat-release? Later...:oops:

    It's slowly coming together....
    2 cross braces wired into the "pillion-seat" area....the third just in front of it with the seat-lock.
    The rear brace proved to be too narrow in the crown to support the tail-plastics... a piece of sheet-alum cut and slightly angled "extends the crown to "bite" underneath the plastic lip (it'll be epoxied to the steel brace underneath after the welding...this way it can all get powdercoated in one hit)...enough to get a couple of pushpins in to secure the tail, cushioned on rubber-strips, of course.

    [​IMG]

    [​IMG]

    Next step is welding it all up, making hanger brackets for the exhaust and wiring them in...not forgetting the dampening rubbers in the hangers (don't want the vibes of the can shake the tail to bits, eh) ....some plastics-work on that Honda tailpiece for new mounting-mounting points, heat-bending the plastics in a smooth arch around the shock-adjuster knob and...and...and...

    Cop ya next time around :tease:tease
  7. SaPPeR

    SaPPeR Equal Opportunity Hater

    Joined:
    Jul 27, 2005
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    PNW
    Love watching this guy work .... good shit :thumb

    :lurk
  8. glitch_oz

    glitch_oz Long timer

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    Thanks mate...

    It's always good to let things sit a little....discovered this morning that I left the center-brace 1.5-2mm too high, as there has to be a gromit lateron to fix the plastic lugs of the tailpiece to the brace....forgot the thickness of the gromit.:huh
  9. Fiddlestix

    Fiddlestix Leapin' Lizard

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    Allen Park, Michigan
    Sweet!! Kind of looks like a bull dog...very muscular shoulders and narrow hips!! Real cool!

    Dave :clap
  10. Yellow Pig

    Yellow Pig Allergic to asphalt!

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    SoCal
    This is one sweet transformantion to watch come along!

    great work. Leep it comming.

    I must admit I was hoping for a dirt mutant rather than a street mutant. :clap
  11. glitch_oz

    glitch_oz Long timer

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    There've been quite a few "dirt-mutants" featured here already....the most impressive to me was the recent SV650 transformation....oh Gosh, wish I had those skills and means available. THAT was more than impressive !!:clap :clap

    Then again...just because this one sprouts a "sporty" tail, doesn't mean anything.
    The primary intent was to finish up stripping weight out of the original design, keep the practicality and long-range-comfort factor, keep the luggage-capabilities, but built something unique and "easier on the eye"(well, at least in my eyes) than the factory version.

    A bit more dirt-capable (lower weight), a little more motard, a little more naked-bike, a little more tourer...just a bit of an improvement of all the core-values of the original design and intent.

    Then find ways to improve on other items, like service access....the CBR-tail will be mounted with only 4 bolts (2 hidden) and 2 pushpins. Unplug the rear lights/ indicators and remove the complete part in one hit....access to everything.

    The tank-pods can stay on the tank, they're not attached to anything else.
    Access to all bolts/ fixings holding the tank (again, one hidden-under-the-seat bolt) is easy/ open....2mins to remove tank and have access to everything underneath.
    Clean access to the radiator cap without shifting/ removing anything.

    Service and repairs will involve a maximum of 3-4 mins total to strip ALL "top"-components if needed.... to leave you with with a bare core-bike
    Compared to around 30++ mins for the same job on the factory item for someone who's quick and knows what they're doing....that's a fair improvement.

    But yeah, it'll still primarily be a road-bike...with a bit more ability in each/ all of its core values.:D
  12. glitch_oz

    glitch_oz Long timer

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    Nothing got done for a while…the 2 little Posties took preference, getting them ready and kitted out for the soon-to-start Cape York Ride.

    The recent heat also didn’t make the tin-shed-garage look all that inviting….:(

    Got the crossbraces welded up, removing the temporary one.
    Then it was on to finally getting serious about all the lining up of various parts, making them match, drilling holes for panel-screws etc etc, as I didn’t really feel like spending time welding plastics in the 38C heat.

    [​IMG]

    Things are starting to gel…that knob of the shock-adjuster needed a cut-out.

    [​IMG]

    In the end there was no way around it…the welding and shaping nearly took 2full days, piece after piece, things were coming together….slowly “draping” the plastics around the seat-brace, repairing the old crash-damage (that “lateral wing” on the left side that was ground off) while at it.:chug:

    [​IMG]

    The hardest part: the lip all around the top-edge, to stop rainwater running into the electrics under the seat.

    [​IMG]

    Looking better and cleaner.
    Slowly things are turning to factory-like finish and fit.:glu

    [​IMG]

    [​IMG]

    [​IMG]

    The tail piece is held in place by the front screws in their original locations, 2 screws poking through the central crossbrace and 2 OEM Suzukli pushpins at the rear, which were slightly shaped to fit as far inboard as possible as I want to have them invisible in the end, covered by the rack-plate which will substitute for the rear seat :eek::eek:

    The ends of the 2 “boomerang-shaped” below-tank panels were trimmed to cover the forward ends of the tailpiece….no screws or such to be seen anywhere. Neat! :thumbs:

    [​IMG]

    Should be plenty of clearance for that underseat exhaust :bs

    [​IMG]

    Dremeling out some of the bracing of the seat-base, so I can heat-bent the lower lips inward, making the seat-pan narrower around the back.:so

    [​IMG]

    Some “structural” work around the back of the seat-pan ….the cover has to have something to hang onto!!
    ALWAYS minding the weight…

    [​IMG]

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    Contact-glueing and shaping the filler-material (EVA---same stuff as used for filling/ shaping the tank-sidepods)

    [​IMG]

    Marking out the seat-foam for the chop

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    After the first shave…plenty more work in that one.

    [​IMG]

    Another hour or so of shaping, grinding and rubbing it down with 40grit to smooth out the tiny ridges.... the cover can go on.

    Tried the Original, but the rear is way out of shape to make things fit so I got a piece of marine-grade, dark-charcoal, textured vinyl.... measure/cut/stitch a rear panel with the old Singer-Leatherpatcher and things are looking good. :)

    [​IMG]

    Neat, even spacings everywhere :so:so

    [​IMG]
  13. DRZ400SK4

    DRZ400SK4 Long timer

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    Very nicely done.

    It's a real pleasure viewing these photos of your craftsmanship, as you progess with the thinstrom projects.

    :thumb
  14. glitch_oz

    glitch_oz Long timer

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    :wink:
    This doesn't hold a candle to that recent SV650-based built, though
    OMG, THAT is ART!! :eek1 :eek1
    Anyhow...slowly plodding along...:1drink
  15. JAFO

    JAFO displaced Jeep guy.....

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    Link to the SV650 build?
  16. jeremyseattle

    jeremyseattle n00b wannabe adv'r lurker

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  17. glitch_oz

    glitch_oz Long timer

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    Mucking around the garage this morning while getting the last bits together to shove into the packs of the posties before they leave this place for Brisbane tomorrow, an old DL1000/'02 nose cone fell off a shelf...and things started to spin instantly.

    [​IMG]

    What, if....YEAH, that's a start for the front end!!

    5 mins later, a few quick nips with the tin-snips and things have shrunk by 120mm width...

    [​IMG]

    I need some headlights to take it from here, but it's a start...
    The nose also has some very useful plastic lugs, threads and other mounting-points for fixing instrument panel and other stuff....:thumbs::thumbs:

    To think, that the 5-min episode cut a $370 nose-cone to pieces "while walking past" gives me the shivers now...:freaky :freaky :lol3
  18. glitch_oz

    glitch_oz Long timer

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    As I promised myself to finally pull the finger out and get going again, a fresh start was made a couple of weeks ago. :wow:

    Got stuck on the metal-work, welding etc, as that’s not my strong suit…:rolleyes:
    First job was to tear the tail-plastics off again, make 2 crossbars with stand-offs (Crossbars had to be as "in-offensive" as possible....as in... bits sticking out)
    to go on top of those rear-subframe braces and get stuck into converting an old Hepco-Becker pannier rack, only keeping the frame-loops.


    After cutting off the “mounting-arms” and cleaning up the pipe work it’s into fitting, bending and otherwise preparing new hookups with the help of vice, hammer and multigrips and a long length of tubing for bending...and a bloody bucket of sweat.

    [​IMG]

    The idea is to built the frame as narrow as possible but with still enough clearance around the bodywork to not touch or rub when fully loaded and hitting some decent potholes at speed.
    And...STRONG!
    Also as low as possible to keep the centre of gravity low…but still give useful positioning for using the panniers as mini-tables when camping/ being on the road.

    As I LOVE the Quicklock-frames on our WTF1000s, this had to become a cheap copy of it, something where only the crossbars stay on the bike, the rest can be removed within a couple of minutes with a minimum of fittings or bolts and only one spanner/ shifter.

    Gardening wire holds things in place before tack-welding….

    [​IMG]

    …a piece of thick leather protects the rest of the bike while I’m trying to not blow holes into the thin walling, set my own arse on fire or burn the garage to a crisp…

    [​IMG]

    The first welds of my life…it ain’t pretty, but strong enough to hold things together before they’re off to a proper welder….getting there, it all fits well.

    While at it, I also located and tacked the 2 modified OEM exhaust hanger brackets underneath 2 of the sub-frame crossbraces…ready for that under-seat exhaust.


    [​IMG]

    Toying with ideas while the metal cools down (guard courtesy of BikeMart/ Ringwood)

    [​IMG]

    Yup…looking fine :so

    [​IMG]

    [​IMG]

    Also tried out the set of Gobi’s panniers….they also fit neatly, but are a little further up (the boxes are higher)….not enough to interfere with a topcase, which still has to come.
    [​IMG]

    Through the week, the TKC80’s showed up and 2 trips for fitting was all I could squeeze in, in between work…:doh:

    After butchering one OEM-front guard into oblivion (I won’t show you pics of that :bs:bs), let’s have a go at #2 then, first with the tin-snips

    [​IMG]

    [​IMG]

    …then I used the big grinder at work to come up with this temporary shape.
    Very short in the front, about half the original material is gone.
    The back is too long at the moment, waiting to be shortened once I get into crashbars and bashplate construction lateron…

    Whoever’s removed a Strom-front guard will know what a pain those 2 deeeeply recessed threaded-plates are, that sit behind the bolts holding the brake-line stays/ splitter on the right.
    In the pic, I cleaned and roughed the inside area, siliconed the threaded-plates in place and let them cure while a bolt holds them in place. Works well with the other 2 Stroms, I never have to shed bark trying to hold them in place while trying with the other hand to get the bolt to bite.
    Farkin stupid, Suzuki!!

    [​IMG]

    John Stamnas in Cooroy/ Queensland came up with another set of very neat braided lines, and as usual, they were here within 24hrs.:thumbs::thumbs:

    [​IMG]

    [​IMG]

    The rear subframe and complete luggage rack went to the bead-blasters for a decent cleanup , then across to another mob for powder coating, should be back middle of next week.

    Made an alum bracket and 2 high-density drilled foam blocks as brake-line guides, using the original bolt in the lower triple clamp. The primer is drying overnight on that…

    Pissfarting around before “shutting shop” for today.

    (Sorry for those pics, some of the details are hardly visible…brakelines and gaffer-tape blank out some bits)
    Just playing around with the previously chopped-down K2 nose-cone and the “beak”

    [​IMG]

    [​IMG]

    The beak will become part of the front-mask…eventually….then a couple of those 70mm new-fangled lights (one low/ one high), set as high as possible in the top of the original light-cutouts (the instrument cluster from the top will determine the final loaction)….YEAH!!!

    I LIKE IT!!!

    It’ll be a “face” like NO OTHER!:upyrs::bs

    [​IMG]
  19. SloNEZ

    SloNEZ Guano Loco

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    Grand Rapids MI
    OMG - that is looking so cool!
  20. pdxstrom

    pdxstrom The Bearcat

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    West Coast
    I love this thread!!!!!