CBR gets the Sailah treatment...

Discussion in 'Some Assembly Required' started by sailah, Sep 27, 2011.

  1. daywalker69

    daywalker69 Adventurer

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    Neat idea, how did this work out once you got it off the bike was it rigid enough?
  2. sailah

    sailah Lampin' it

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    It's still on the bike:lol3

    I'm asking over in the garage from some composite gurus about how I should make the part. I'm inclined to use the fleece as the base layer and build it up with some FG cloth followed by some carbon fiber top layer. I don't really want to go through the trouble of making a plug mold etc. I have made canoe paddles with a carbon top layer and they came out great.

    I may try and fair the fleece down and wax that to peel off later. It's not very stiff as it stands now. It'll hold its shape fine but def needs to be reinforced with more layers.

    I thought the idea was pretty cool too. I have to admit it was the guido show with those car customizers on Long Island. The french guy. Yep, there I said it. But he can make a mean subwoofer box!!!:deal
  3. LoJack

    LoJack Long timer

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    This is an awesome project. Have you made much progress with the body panels? I was thinking about making an aluminum subframe/tank like that but was worried about failured due to vibration since it would have to be bolted in without any insulation. Was that something you gave any thought?

    I've also been looking for an aluminum swingarm for my bike. Do you know what bike that came of and the distance between the pivot spars? Thanks, lojack
  4. sailah

    sailah Lampin' it

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    No progress, been playing with my new dirtbike.

    The swingarm is from a 2005 KTM 450EXC. Just measured it, don't quote me but looks about 8.125" as close as I can measure (weird angle)

    I'm not too worried about the tank. It will get lined. Plus the aluminum is 3003 so plenty soft. With all the plating, it's massively strong.

    I do plan on getting back after it, just slammed with work after taking Dec. off. I have the FZ1 to finish and powdercoat then can put this on the lift to make some more progress.

    What are you making?
  5. LoJack

    LoJack Long timer

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    Makes sense to use a softer alloy for that. More ductile. But I was mainly worried about the subframe portion between the tank and mainframe. I am curious to see how it lasts.

    I'm just another one of those fools with a f650dakar. Working on a swingarm with machined arms right now, but I'm still working on the design. I haven't found an extrusion with the right dimensions that doesn't have hard edges inside and out to use for the arms.
  6. sailah

    sailah Lampin' it

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    I know you aren't asking for advice but I would seriously recommend trying to find a stock unit and make your life way easier with wheels caliper mounts shock mounts etc
  7. SimpleSimon

    SimpleSimon Aspiring advrider

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    Interesting project......get anything knocked out this month? :norton
  8. sailah

    sailah Lampin' it

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    I'm slowly getting back into the CBR. Needed some inspiration for some fresh ideas. Here's the latest project, making rearsets.

    Originally I had intended to machine up some billet aluminum hangers and attach the pegs I bought off GasGas. When I was laying out the peg mount, it lined up with a flimsy bolt hole meant for hanging the exhaust. That hole was just a sheet metal cover for a 1.25" tube that spans the frame.

    Perfect, so I drilled out the sheet metal to expose the tube.

    [​IMG]

    Went scrap hunting and bought some steel rod in 1 5/8" OD. Made up some bushings that will slide into the frame about an inch and weld a bead around the edge as well as a couple plug welds. I tapped the bushing for a M12 1.75 bolt.

    [​IMG]

    The actual peg is on the right, although it's just a mockup. I necked it down to 20mm, used a 20/26mm needle bearing, and the outer ring is what I will weld the brake lever to. The lever will pivot around the peg for smooth shifting. I tried something similar with a single row ball bearing on the FZ1 and got a lot of play. This is much tighter as the needlle bearing is 16mmwide vs the 8mm of the other one I used.

    [​IMG]

    [​IMG]

    Here it is all assembled. I'll need to fine tune it, but it works really well as is.

    [​IMG]

    [​IMG]

    This is about where I envision the rear MC will be and the wrench approximates where the brake lever will be. Where my thumb is, is the lower bolt hole I will use to attach the M/C bracket, the other holes shown in the drawing are the upper frame mount and the (2) 6mm bolts that attach the M/C to the bracket

    [​IMG]

    I met a gentleman who owns a waterjet shop and he said he could cut out my brake lever and shifter out of aluminum plate to my design.

    I need to clean up the design a little but I'm keeping it simple.

    [​IMG]

    I plan on cutting out the MC holder (FYYFF) first out of some aluminum I have on hand just to check the bolt holes are correct. Once that locates the master cylinder, then I can tweak the drawing of the lever to make sure it will line up.

    I have some studded rod ends (don't get excited :wink:) that will actuate the brake MC and also the shifter linkage on the other side.
  9. TerraRoot

    TerraRoot Adventurer

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    you not worried about ripping up the frame when you fall off? hell even draggin those pegs looks scary..
  10. sailah

    sailah Lampin' it

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    Honestly? Not really. If I figure out the lean angle is going to be a problem, I can clearance an angle. I do plan on plastic inserts for the ends like sliders. In a low speed get off offroad should be fine. High speed get off, I'm worried about other things. Bikes are fixable especially one that I built from a $350 beater

    I did consider your point though in the design phase but basically decided it wasn't worth designing around and with a nylon insert should be fine

    If the pegs stick out too far I can always shorten them as they are pretty long. By tucking them in closer to the frame could potentially eliminate the dragging issue. On my fz1, the bike sits so high you don't have a prayer of dragging pegs and I like to hustle
  11. TerraRoot

    TerraRoot Adventurer

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    doh, forgot you have longer suspension, how much extra do you have btw?
  12. sailah

    sailah Lampin' it

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    I don't know what the cbr had but the ktm in dirt gear is full 300mm
  13. sailah

    sailah Lampin' it

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    Got the pegs done and mocked up the levers with the studded rod ends.

    [​IMG]

    Made the actuator

    [​IMG]

    Decided to weld the bracket out of steel

    [​IMG]

    Flipped my mock up lever around for the shifter and welded a tang. *Shortened up the connector to the stock honda shift arm and tapped the rod end for the m6 thread

    [​IMG]

    Now that I have the mock up done I can redraw the actual arms, get them water jet cut and weld them to the collars. *Both work excellent with very little play and have good feel
  14. sailah

    sailah Lampin' it

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    Got my parts from the waterjet guy he did a great job. *I had to bend them in the redneck press brake (aka clamping it in a vice and beating the crap out of it with a BFH)

    Couple tweaks but got them mounted. *I was worried my welder wouldn't weld 3/8" plate on its breaker but it did fine. *Everything works great, very pleased with how they turned out esp functionally.

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]
  15. sailah

    sailah Lampin' it

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    Made some more progress.

    Welded the flange on the tank to mount a petcock I pulled out from an old YZ450

    [​IMG]

    Mounted a new set of forks I bought from an 07 KTM 525EXC along with the dirt wheels, 320 Braking rotor, caliper and master

    [​IMG]

    Since the CBR is wider than the KTM motor, I needed to align the chain by cheating the countershaft sprocket closer to the case. Did this on the lathe by chucking up the new front sprocket and narrowing it as close as I felt comfortable.

    The chain was still slightly cocked, meaning that I needed to space the rear sprocket out by about 1/8"

    Drew up a spacer ring on some 1/8" 5052 plate and roughed it out on the bandsaw. Drilled the center out and mounted it to a mandrel and then turned the outside to about 7" diameter. Reversed the jaws and then turn the inner ring to 125mm diameter to fit a KTM hub. Sorry no pics of that happening

    Then I laid a KTM sprocket and centered the centers, clamped it, and used a transfer punch to mark the holes.

    [​IMG]

    Drilled out with a center drill

    [​IMG]

    Voila with bolts installed

    [​IMG]

    Here's the wheel mounted up

    [​IMG]

    And chain alignment. I need to move the swingarm guard outboard a little as well as the chain guide

    [​IMG]

    Glory shot.

    [​IMG]

    [​IMG]

    The next major project is building a header from scratch. I ordered a bunch of mandrel bends from Cone Engineering along with collectors and some spare tubing. I plan to hug the block as close as I reasonably can, the pairs of tubes will need to split the oil filter and collect below the pan. I'm using mild steel tubing and plan to get the header jet coated. I debated SS but Cone recommended using mild and then coating.

    [​IMG]

    The header should be a really fun project, it wasn't cheap and it won't be simple. Lot of things I need to work around. Exiting to a Ducati Arrow race can

    [​IMG]
  16. TerraRoot

    TerraRoot Adventurer

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    never minds the pipes, test ride and vids needed! :clap :D

    (you know the gearchange is reversed right?)
  17. sailah

    sailah Lampin' it

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    I think that might wake up some neighbors...test ride will be done soon, I think it should be ready in a month for the beta ride. I expect there will be future modifications needed and changes so I'll hold off on final paint work and powdercoating until I know it's right.

    I'm 99% certain that the gearchange is normal. In fact I just shifted it into neutral yesterday to get the chain around the sprocket and I don't seem to remember being confused on the pattern. You sure about that?
  18. TerraRoot

    TerraRoot Adventurer

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    [​IMG]

    heres a shot i just took of my much abused cbr, maybe you are shifting from second into neutral?
  19. sailah

    sailah Lampin' it

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    Huh, guess I was wrong thanks for pointing that out. I'll have to flip the lever on the shift rod and lengthen the connector.

    Or pretend I'm badazz and meant for it to have gp shifting...:D
  20. mfpthebronze

    mfpthebronze China Rider

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    MUST. NOT. FOLLOW. THREAD.



    :lurk Argh!

    Couldn't help myself. You're making me want to invest in a lathe and welder - but I could buy a beater bike for that money too! Choices, choices.

    Can't wait to see the finished project! Teach on Shifu!