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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    Oh I will I can smell the finish line. This project has really come together from all the thinking, scheming and planning. I tried not ot fall victim to "that's good enough" as I am used to doing. Really tried hard to focus on doing good work.

    A lot of the work has been the result of improving my skills vis a vis welding, lathe work etc. Some is due to having access to better fabricating tools. Most of it has come from not repeating dumb mistakes I made on previous builds and the ability to see around the corner. Most of the time:D

    The rally fairing will probably be a fall/winter project as it involves substantial design work, welding, fabricating and down time. I might get a wind in my sails this summer but it's hard to argue with using a trail tech to get on the road in five minutes or weeks designing the fairing and nav tower.

    It will happen but really focused on that first time of letting out the clutch and the bike moving on its own power. That's a feeling I'll never get tired of.

    Thanks for the kind words too. Appreciated.
  2. PhiSig1071

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

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    Have you had any consideration of manufacturing and selling some of the parts you made for the conversion? I know you used a lot of factory stuff, but some of it you hand made. If someone could source the factory stuff you used (swingarm, shock, forks, etc) and then buy the custom parts and put them together, they'd have a bad ass ride. It would be kind of a "testing the waters" of selling custom stuff without going whole hog and selling complete bikes.
  3. sailah

    sailah Lampin' it

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    I had originally intended to do that with this bike but things got so one off I scrapped the idea. Depending on how the bike turns out I may build another one using different components that don't require a tank rebuild seat pan etc. that I would prototype for others to build using a stock ninja as a base and off the shelf components from ebay.

    I wish I had gone that way from the start with this bike but no regrets. Helps me be a better fabricator. Two years ago I had never welded or used a lathe so I've come a long way from those first days of using a sawzall and grinder
  4. sailah

    sailah Lampin' it

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    Lots of work done but no pics because phone was dead.

    Rebuilt the subtank using a shear instead of a bandsaw. Much nicer. Also bent a lot more of the joints instead of welding. Fits better with more clearance of the shock and also sits flat in the frame with room to rubber mount it.

    Built a battery box out of aluminum that mounts directly above the exhaust and below the swingarm. It's close quarters back there but I have clearance for everything even at full droop

    Got the exhaust mounted and the final mount will be welded to the footpeg brackets. I went to cut those today on the waterjet but I guess the ruby in the nozzle was cashed so they are waiting on the new one.

    Also built a surge tank for the radiator that will mount just to the right of the shock and below it. Hopefully I'll get a quart out of it, haven't measured it.

    The new master cylinder arrived so I will get that bolted on and bled.


    Still got lots of small projects to do but making progress.
  5. sailah

    sailah Lampin' it

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    Lots of good progress today. Built the coolant reservoir tank. Bastard took me all day. It's a tight fit in behind the shock...

    Made it out of 5052 aluminum. I bent most of the long sides on the brake. Having a hydraulic shear for stuff like this makes things SOOOOOO much easier and faster.

    [​IMG]

    Built this bracket and welded it to the frame. It doesn't look like there is enough clearance at the bottom but there is to the swingarm at full droop

    [​IMG]

    And installed. I have a strap that will secure it in with some foam weatherstripping as insulation/padding.

    [​IMG]
  6. Te Hopo

    Te Hopo AKA Deanohit

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    Awesome build Sailah, I found this thread last night and read all 21 pages of it.:deal
    Great to get up this morning and find a new update. :D

    This is easily the coolest dirt Ninja build I've read, the custom work, stance and practicality are awesome.
  7. sailah

    sailah Lampin' it

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    Thanks for the kind words. I'm over the hump on this build, they all have 'em, and can see the finish line. Very happy with how things have gone so far.
  8. sailah

    sailah Lampin' it

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    Couple more pics showing the new subtank and the coolant tank in place. The new subtank is slightly narrower so I can weld angle to it and bolt to the subframe. The first version I made was a little hooptie, this one fits nicer and has a little more volume due to the angle on the left side. plus the welding was nicer.

    [​IMG]

    A PDS shock sandwich. It doesn't actually touch the reservoir hard to hold in the pic. The black line is where I'm trimming the fiberglass section. It will be black suede seat of course.

    [​IMG]

    Coolant cap I stole from the CBR and then bought another on ebay.

    [​IMG]
  9. yokesman

    yokesman Been here awhile

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    That al welding is looking good.
  10. sailah

    sailah Lampin' it

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    Thanks you can see the brown burn marks to the right of the tank where I decided I would try to MIG weld. I can't MIG weld for shit.
  11. kajj

    kajj Been here awhile

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    Awsome build!

    :beer
  12. sailah

    sailah Lampin' it

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    Thanks!

    In the interest in trying to do daily updates, I measured, removed and remeasured all the cables (throttle x2, clutch) and sent them along with the KTM 950 throttle tube to Motion Pro for some new custom cables.

    I also designed out the new radiator guard in Inventor and hopefully the waterjet is not being used at Tech Shop and I can go cut out the frame. I think it looks really good, I'll post some pics later.

    I also ordered a new MSR clutch perch as I did not like the stock Ninja version. Having that shipped to Motion Pro as well so they can get the end links correct.
  13. nuggets

    nuggets It's all my fault...

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    Hey Sailah,

    I've really been enjoying this build. Thanks for sharing. This really makes me want another project bike.
  14. sailah

    sailah Lampin' it

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    Cut my first piece out on the waterjet unsupervised

    [​IMG]

    It's the radiator guard. I had more trouble importing the dxf file into the waterjet machine program than anything.

    I need to redo it from this pic but I bent the tabs and fit it up and corrected all the issues in the file. I also put a nice radius on all the corners in the new drawing. I'm out of aluminum so I'll need to hit the scrap bin Monday

    [​IMG]

    Here's the first run. I corrected the angle on the left so the cutout matched the angle on the filler neck. I also redrew the bent parts to make tabs instead of those long bends which are taxing the brake.

    [​IMG]

    [​IMG]

    I do have the steel plate so I might attempt those tonight or tomorrow
  15. sailah

    sailah Lampin' it

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    I spent another 15 minutes on the waterjet ($30) and came up with my test rearset. The outside shape is good. and the mounting holes and footpeg holder holes are in the correct location. However the brake master cylinder needs to be moved quite a bit and the banjo bolt clearance holes does as well. I played around with the stock KTM brake lever and I think it will work out perfectly. I need to modify a couple things but fairly simple stuff. I also chewed off the end of the bracket using the plasma cutter so that the brake lever would clear. I'm going to mark the test piece up after I put the bend in the bottom and redraw, recut and retest.

    [​IMG]
  16. sanjoh

    sanjoh Purveyor of Light

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    The end is near:clap Are you riding it to the RDV or ?:ear
  17. sailah

    sailah Lampin' it

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    Whats the rdv? And probably not, I'm thinking my maiden voyage will be a trip with buddies around west virginia
  18. sanjoh

    sanjoh Purveyor of Light

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  19. sailah

    sailah Lampin' it

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    Can't make that. Although it would be awesome because that's where I debuted the FZ1 three years ago. Spent 2 hellish weeks up until 3-4am EVERY night just a crazy man. 48 hours before the departure time to make that rally I had never heard the bike run. And actually couldn't get it running. The morning of the departure I still had not built the seat or the left saddlebag.:deal

    I dropped tools at 1pm and ripped out of there and rode the whole way down there with no problems. I actually haven't changed anything since I last rode it down there other than a couple things because I wanted to. It was fun seeing people ride it down at the rally and just saying "What the fuck is that?":lol3

    That was the last time I saw Rick too:cry
  20. sailah

    sailah Lampin' it

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    Another good day of progress. Got the brake lever side rearset all done. I used the waterjet again and recut the part after a couple revisions. I got rid of the bolt holes for the master cylinder so I could fit it while the lever was mounted.

    Lots of stuff going on here. I bent the 3/16" plate on the ironworker so that the footpeg was level. Aligned the actual footpeg bracket (silver) and then tacked it in place. I machined up a spacer for the KTM brake lever, and you can see the bolt coming through. Welded that to the back of the plate. Then I had to machine up a spacer on the lathe to connect the lever to the master cylinder. Very fun day seeing it all come together.

    One thing I would have changed given an option is to have the brake lever plunger at a right angle to the master cylinder. It's not that big of a deal though.

    [​IMG]

    [​IMG]

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    [​IMG]

    Fortunately I got the cutout for the brake line in the right place. I'm going to wait to weld it in place until I have the other one made. Hopefully that one will be much easier not having to account for the braking system, but I will need to redesign the shifter. Which should make for some more fun machining. The plan is to weld them down the frame, and then make braces to weld up underneath to the frame crossmembers. I stood up on the one peg and it def flexes but that's with only 2 M8 bolts holding it.

    Great day where nothing went wrong. For once:D