Project Full Circle:Ninja 650 gets a makeover

Discussion in 'Some Assembly Required' started by sailah, Nov 9, 2012.

  1. sailah

    sailah Lampin' it

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    Thanks! I had it loaded in the truck with the tank and seat on and stopped to look at it. It does appear to be looking better, hopefully it will start to come together with the tank done and I can start to work on the rally fairing.
  2. 4play

    4play Next?

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    Yeah well maybe if I told you how much I spent and how many hours I have worked on it maybe it would lose some luster:lol3 I can honestly say it was probably not worth all this extra time. [/QUOTE]

    That feeling will fade when you ride it :deal
  3. LocuL

    LocuL Gnarly Infantry

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    Sailah, just saying i´m keeping an eye on this beauty.

    :evil
  4. sailah

    sailah Lampin' it

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    Mikael, I'll trade you...:D
  5. sailah

    sailah Lampin' it

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    Been awhile you were probably thinking I had abandoned the bike:lol3

    Truth be told I have been working teaching classes during my free time and that has hemmed into bike time. Also needed to spend some bike time getting the FZ1 rebuilt for a spring trip to Laurel Fork, WV.

    Anyways I'm back on the Ninja

    Bought a carbon Scorpion exhaust can (seems just as well made as my arrows) but I needed to adapt from the 1.75" main tubing to slip fit in the Scorpion 2.125" inlet. Bought a bunch of SS tubing and they make an expansion joint you see on my crossfeed. The I had to turn down the 2.125 tubing I bought to slightly slip fit. Then welded the two parts together as the start to my exhaust system.

    [​IMG]

    Also found a decent stock header that I bolted up

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    Ah the dong is back. Spend considerable time jacking around with this thing. I know have it precisely laid out in CAD and just working on some final details. I also had to bend the lower portion at 15 degrees so the pegs would lay flat. I will park this one up and predrill the holes on the waterjet out of thicker material. Plan is to run some struts underneath and weld them to a crossmember

    [​IMG]

    This tank was a gigantic pain in the ass. I finally got it stitched back together, will def need to line it. I also need to weld in the tank bung

    [​IMG]

    Then I went to fit it all together and the airbox needed to be modified. I machined up some brackets out of scrap billet aluminum that I will bolt to the air box then tap into to secure some aluminum cover plates. I left enough space on the lower for gasket. It should be sweet.

    [​IMG]

    Bike as she currently sits

    [​IMG]

    Lots more work to do but should be fun. I like doing things like exhaust and luggage hoops on the bender. I hate the dumb work like sheetmetal because I'm not very good it it and it takes me forever.

    The nav tower might be a winter project depending on how things go. I would like to ride it this summer and knowing how I am progressing these days that might back me way up. It shouldn't be difficult to add that on at a later date and just run a Trail Tech X2 to get on the road.
  6. PhiSig1071

    PhiSig1071 What's ******width?

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    I can't wait to see what this looks like with a Rally fairing.
  7. Roadracer_Al

    Roadracer_Al louder, louder, louder!

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    Looking good!

    So... have you learned your lesson yet... when are you going to just do your own frame from scratch? :rofl
  8. sailah

    sailah Lampin' it

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    I thought about it but the registration headaches would be problematic. I really dig the ninja motor it would be great to do a custom frame but only if it was going into production and even then it is easier to modify the frame and title it as the original bike. I wonder how the chopper guys get around that?

    I'm seriously debating leaving my job at the moment as things are unsatisfying to say the least. Problem is that it pays well and I have a ton of flexibility to do whatever I want even when I'm working. I guess you could say I love the pay, love the flexibility, hate the constant pressure, goals, quotas etc as I'm in sales.

    I don't think I'd be very well fed building these though:lol3 but I would like to venture off into something that harnesses my creative side as I feel that is wasting away in my career.

    Sorry for the off topic rambling but things came to a head today and I started thinking. Which is when I get in trouble...
  9. sanjoh

    sanjoh Purveyor of Light

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    In Florida the chopper guys get titled as Assembled from parts. ASPT on title.
  10. yokesman

    yokesman Been here awhile

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    Here in socal the AAA girl asked me if I had modified its style?
    Guess I need to complete the registration before I do,I dont think they will notice the dl tank on my gladius.
  11. 4play

    4play Next?

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    I'm not sure about kali, but the "style" category in the states I've lived in was "motorcycle" I don't think she meant cruiser, crotch rocket etc.
  12. Salsa

    Salsa Been here awhile

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    Did she give you a clue what effect it had on registration?

    Don
  13. Roadracer_Al

    Roadracer_Al louder, louder, louder!

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    In some states, you start with a titled frame, saw off everything behind the VIN-stamped headstock and "customize" from there.

    In some states, it is possible to start completely from scratch, and bring the old frame and VIN to the DMV where they will stamp a new VIN in the frame at the time of the first registration.

    Sorry to hear that you're not having a satisfying work experience. Sometimes you can re-engineer your work place a bit: suggest that instead of having daily sales meetings, try weekly meetings.

    You can also request a meeting with the people that are pressuring you and say "Hey, I know what my job is, you don't need to constantly tell me" and "all the pressure from you makes me irritable, therefore, less effective at my job.' And "think of it this way: even if my performance doesn't improve when you get the fuck off my tip, you'll be getting the same results for less effort on your part."

    Who knows... you're on the cusp of quitting, what's the worst that can happen? You might actually solve some of the problems and start enjoying your job.
  14. Salsa

    Salsa Been here awhile

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    35 years ago (in Kalifornia) I made an engine change and later a frame change and was in the process of getting it OK'd, but I quit. During the last 6 years, I have done 2 by putting a new engine in and getting them inspected. With the paper in hand, the cutting torch went to work making "Safety Changes"!!!!

    I don't know if that is the "Right" way, but I don't see bars in front of my eyes.

    Do you know the frame change can be done in Kalifornia now?

    Don
  15. Rich667

    Rich667 Been here awhile

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    I took a gs 500 frame, cut off the neck and built my own trellis frame around an ex500 motor for a streetfighter i'm working on. Its registered as a gs 500. Im not sure if its 100% legal here in PA (i have talked to 3 or 4 different inspection guys and got different answers each time) but I haven't had any issues thus far. According to pendot, I believe you technically have to register it as a reconstructed or modified vehicle and go through the same enhanced inspection bs of doing a 100% custom frame if you modify the frame in any way. 99.9% of people who look at my bike are so clueless as to what it is, I dont worry much about it.

    Nice bike by the way, This build has really sparked my interest in building a similar beast.
  16. sailah

    sailah Lampin' it

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    Had some second thoughts about the exhaust location running up the side like on normal bikes. I grabbed the can that was on the bike and twisted it around to the other side. It's a little long, but fits under there reasonably well. Might run into a kick stand issue. Having an underslung exhaust would clear up a lot of real estate though and make the rear racks much cleaner.

    I also had a look at the Scorpion exhaust I bought and the endcap is stamped with an "A" just like my Arrow exhausts. Put them next to each other and they are the exact same thing. So I might try and fit the shorty carbon arrow can I have and if it works, I'll shorten the Scorpion/Arrow I have to complete the exhaust system.

    [​IMG]

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    Pic with the backend put back together

    [​IMG]

    Played around with footpeg position, think I might raise them about an inch from where I thought I wanted them. I also mapped out the rear brake lever and master cylinder locations. Think I might have to make a custom lever the KTM one I have doesn't fit the way I want it.

    Once I get the exhaust done, I can finish the rear sets, plumb the fuel tank and then start the wiring. Bike should be ready for a test ride shorter than I expected.
  17. sailah

    sailah Lampin' it

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    Played around with the exhaust today. The more I see the can down low like that the more I realize that's where it belongs. I tried it on the chain side but obviously it interfered with the chain when the swingarm is slack and also the kickstand. I took the Arrow aluminum can apart by drilling out the rivets and then took it over to Tech Shop to use their horizontal bandsaw to slice 3.75" off the end of the can. Had to cut the screen as well and remove some packing. Put it right back together as a shorty.

    It fits really well on the brake side where it was originally. Just need to make a small bracket to weld to the frame and I can call the exhaust project done without welding any stainless.

    The other motivation was I didn't really like the look of the pipe up the side of the bike. I am designing a rack system that uses Wolfman soft bags. The idea is that it drops on the frame as a solid unit, straddling the passenger seat. When I get to camp I can remove the bolts, and the entire rack system comes off, bags and all. I like the look of the bike with no racks so I think having the exhaust underneath cleans up the whole look.

    Nice to be able to check something off the list for once.

    You can see in the pic how I plan to brace the footpeg brackets back up under to the frame. Fortunately the exhaust clears all of that.

    [​IMG]

    [​IMG]
  18. sanjoh

    sanjoh Purveyor of Light

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    The arrow can you have is stupid loud, I pity the guy behind you with the shortened version:D

    Have you had it out yet:ear
  19. sailah

    sailah Lampin' it

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    Well it can't be any worse than the FZ1 can aimed right at your face if you're behind that bike at full song. But only for a minute:deal

    Yeah I've had it out of the garage a bunch of times:D

    Spent some time on the bike today. Finished sealing off the airbox. Done.

    Went to mount the subtank and the main tank hits the vent line bung. :bluduh I haven't been happy with that tank since I made it so I decided to make it again. Drew it out on CAD this time and printed out all the sides. Cut them out with a straightedge and taped the box together out of cardboard. It fits much better. So I'll waterjet the parts this week and reweld the tank.

    I got sick of dicking around with that Braking master cylinder so I bought a quad master cylinder from a Yamaha

    Need to figure out the catch tank as the stock one has a hole and I don't like the location anyways.

    Going to rob the battery from the CBR and use it for the Ninja. Need to build a box.

    Lots of little projects but I'm committed to sticking with it until I'm done. Hopefully on the road in a couple months.
  20. PhiSig1071

    PhiSig1071 What's ******width?

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    Please stick with it til it's done, this is going to be one of the coolest bikes I've seen yet, especially if you get the rally fairing on it.