Laverda Makeover, More Range

Discussion in 'Some Assembly Required' started by G 981, Apr 5, 2018.

  1. G 981

    G 981 Been here awhile

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    In preparation for some island hopping and general touring in the north of Scotland this summer I thought it would be a good idea to have a bigger tank with more range as fuel stations can be few and far between.

    So, I bought a beat up fuel tank that I could use as the basis. I chose a beat up one so I wouldn't be removing a good one from the gene pool.
    Here she is:

    [​IMG]2017-12-05 13.00.24 by Grant Duguid, on Flickr

    My plan was to cut the sides and pull them more vertical and increase the top line a bit, as much as I could before running into clearance issues on full lock.

    [​IMG]2017-12-08 13.23.12 by Grant Duguid, on Flickr

    [​IMG]2017-12-08 13.22.49 by Grant Duguid, on Flickr

    So I talked it over with my painter friend, who I met when I lived in Spain. I had seen him do something similar with a Yamaha XJR1300 tank and the finished result was impressive.

    He started by beating out the dent as best he could.

    [​IMG]IMG-20180207-WA0002 by Grant Duguid, on Flickr

    Then he cut the sides off and blasted inside and out.

    [​IMG]IMG-20180214-WA0000 by Grant Duguid, on Flickr

    Oh, and I also wanted a vented flush filler cap so he frenched in one from an R6.

    [​IMG]IMG-20180215-WA0002 by Grant Duguid, on Flickr

    [​IMG]IMG-20180215-WA0005 by Grant Duguid, on Flickr

    He then welded the sides back on added some strips of metal and raised the roofline a bit.

    [​IMG]IMG-20180305-WA0000 by Grant Duguid, on Flickr

    [​IMG]IMG-20180306-WA0002 by Grant Duguid, on Flickr

    Here it is compared to a carbon version of what I started with. The aim is to increase capacity by around 5 litres, or just over a gallon.

    [​IMG]IMG-20180307-WA0000 by Grant Duguid, on Flickr

    [​IMG]IMG-20180307-WA0004 by Grant Duguid, on Flickr

    The tank was then internally coated and the exterior was smoothed over with aluminium filler (less sag).

    [​IMG]IMG-20180314-WA0000 by Grant Duguid, on Flickr

    It was then primed along with a pair of sidepanels I supplied.

    [​IMG]IMG-20180316-WA0000 by Grant Duguid, on Flickr

    I'll leave it there for now before the big reveal.
    #1
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  2. G 981

    G 981 Been here awhile

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    #2
  3. G 981

    G 981 Been here awhile

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  4. G 981

    G 981 Been here awhile

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    #4
  5. c1skout

    c1skout Been here awhile

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    Impressive! That's a pretty color too!
    #5
  6. polarbearrider

    polarbearrider Adventurer

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    #6
  7. G 981

    G 981 Been here awhile

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    It's based on an original Laverda colour.
    By coincidence rather than design it has turned out to be very similar to the original prototypes from 1969.

    [​IMG]IMG_0529 by Grant Duguid, on Flickr
    #7
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  8. G 981

    G 981 Been here awhile

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    #8
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  9. G 981

    G 981 Been here awhile

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  10. G 981

    G 981 Been here awhile

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    Managed to find time today to fill the tank. Measured 4 litres out of the old tank then rode it to the gas station and brimmed it.
    In total it took 23 litres.
    Came back and measured litre by litre some water into the old tank. 18 litres.
    That makes 5 litres extra over stock. Result!
    I had estimated 4 to 5 litres extra.
    Realistically this will give me an easy extra 40 odd miles before reserve.
    Could make all the difference.

    [​IMG]2018-04-08 19.17.11 by Grant Duguid, on Flickr

    This is just phase 1 of the makeover I am going to give it.
    More changes planned but will only get round to it as time and funds allow.
    Might have a single seat and less shiny chrome and alloy.
    #10
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  11. G 981

    G 981 Been here awhile

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    Starting to scope out phase 2 now.
    Early in this project I was heading towards a street tracker sort of look.

    [​IMG]IMG_2039 by Grant Duguid, on Flickr

    But then I did a U-turn and went the dual seat route.
    But I think it's time to refresh the look and the second phase is the rear end of the bike.

    I sourced an SFC 750 style seat base and today I removed the rear mudguard assembly and made a new inner mudguard and bolted the r/r to it. I made it out of a plastic inner mudguard from another bike and just used a Dremel to shape it. Had to cut around the lower monoshock mount. Also used some old tank rubbers to sit the seat base on for now. I'll have to figure out something more permanent at some point.

    [​IMG]2018-04-17 11.24.53 by Grant Duguid, on Flickr

    [​IMG]2018-04-17 11.25.03 by Grant Duguid, on Flickr

    So I offered up the SFC seat, seems to fit ok although I will have to finesse it a bit here and there.

    [​IMG]2018-04-17 10.37.52 by Grant Duguid, on Flickr

    [​IMG]2018-04-17 11.34.52 by Grant Duguid, on Flickr

    Might have a rethink on the sidepanels but I'll wait until the covered seat pad arrives. I'm having it shaped to my requirements (not SFC style) and covered in black suede.

    But then I found an old seat base from another project and offered it up. Looks like it has potential but it would require a ton of finessing and resculpting to do the job.
    Does look ok though.

    [​IMG]2018-04-17 11.30.11 by Grant Duguid, on Flickr

    [​IMG]2018-04-17 11.29.51 by Grant Duguid, on Flickr

    I'll keep updating as I go if anyone is interested.
    #11
  12. YamRZ350

    YamRZ350 Been here awhile

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    Yes please. Don't see very many of these over here. The tank work is really nice!
    #12
  13. G 981

    G 981 Been here awhile

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    Sussed out the front seat fixings today. I cut slots in the base so the seat lugs for the original seat hold it in place. The base now rests evenly on the rubber mounts.
    I'll drill hole in the rear/side of the unit to catch a couple of frame lugs, rubber mounted, and then job's a good 'un.
    Sort of replicates how the seat fits to an SFC.

    The seat cover is away to be suede covered so I'll wait until I can test fit it before drilling holes in the base.
    Also waiting on a fibreglass front mudguard and new sidepanels and then they will all be sent off for paint.
    Suppose I can make the sub-loom up for tail light and indicators while I'm waiting.

    [​IMG]2018-04-18 12.56.42 by Grant Duguid, on Flickr

    [​IMG]2018-04-18 13.04.03 by Grant Duguid, on Flickr
    #13
  14. G 981

    G 981 Been here awhile

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    Small update.
    I should get the sidepanels and mudguard late next week or so.
    I'll need to rework the sidepanels to fit as I moved the sidepanel lugs rearwards about an inch previously, as the long 1000 sidepanels clashed with the K & N pod filters. Now planning to use the shorter 1200 sidepanels to fit the revised look better.

    [​IMG]IMG-20180424-WA0000 by Grant Duguid, on Flickr
    #14
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  15. G 981

    G 981 Been here awhile

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    #15
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  16. Wildebeest90210

    Wildebeest90210 Long timer

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    Chanced on this because of your post in Café Racers. You should mod the title, I never opened it thinking it was just a thread about a tank. Will be watching with interest now :lurk
    #16
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  17. G 981

    G 981 Been here awhile

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    Done, thanks.
    #17
  18. G 981

    G 981 Been here awhile

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    This is going to take a while to complete so here's the back story on the project.
    Started in 2004. Looking for a new project I bought a wreck from a breaker. Cracked frame, seized engine, no papers and very little else.

    [​IMG]rsz_img001[1] by Grant Duguid, on Flickr

    I had a pretty good idea of what I wanted. Basically, having owned Laverdas since 1979 I wanted to improve and eliminate issues I had found with standard Laverdas. I started with the frame. It got monoshocked (Wilbers), swing arm pivot double-skinned, steering head extended 6cm and braced back to the frame. Then I went with early GSXR wheels and discs, 4 pot Brembos, and floating underslung caliper at the rear. The battery wa lowered as far as possible, just above the swing arm.

    Initially the look I was going for was a sort of street tracker.

    [​IMG]IMG_2039 by Grant Duguid, on Flickr

    But things change and I decided to make it look more standard (although it was anything but).

    [​IMG]IMG_6113 by Grant Duguid, on Flickr

    The engine got a rebuilt crank, new liners with high comp pistons, a Corsa-spec head (big valves, 36mm ports), 4C cams and offset smaller spark plugs.

    [​IMG]2015-08-08 15.52.25 by Grant Duguid, on Flickr

    I fitted a Kawasaki alternator (250W instead of 125W), Sachse electronic ignition and an m-Unit electronic fusebox/relay.

    [​IMG]2016-10-10 11.22.25 by Grant Duguid, on Flickr

    It also got Mikuni RS36 carbs, K&N pod filters and a large bore straight through exhaust system.

    [​IMG]30123852_369052186905570_6967727011963863040_n by Grant Duguid, on Flickr

    The GSXR wheels allowed wider tyres, tubeless radials and stickier compound, but I had to fit an offset 520 chain and sprockets to clear the 150/70 x 18 rear tyre (120/90 standard). I had a cartridge conversion done on the front forks by Maxton to sort out the front end.
    It also got modern switchgear and span adjustable levers and a remote reservoir front brake m/c. Also fitted a vented flush filler cap as the original fuel cap used to leak when you braked hard.

    [​IMG]2015-12-11 15.27.27 by Grant Duguid, on Flickr

    These are some of the details I can remember.
    Due to life (lost job/divorce etc etc) getting in the way I didn't finish it and get it registered until around 2014. I had been living in Spain all this time, and then returned to the UK just over a year ago, and registered it here. I set it up for touring and even fitted hard luggage.

    [​IMG]2016-05-12 13.33.51 by Grant Duguid, on Flickr

    But it was time for a change, so now I'm changing it back to a style similar to the street tracker I posted earlier. Next changes will be fibreglass front mudguard, less chrome/polished stainless and some more colour changes. That's it about up to date now.
    #18
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  19. G 981

    G 981 Been here awhile

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    A little bit more done today. Fitted the rear indicators and started sussing where to mount the front ones.
    Not much else I can do for now but at least the front mudguard, seat base and sidepanels are in the post to me now.
    Hopefully get into it next week.

    [​IMG]2018-05-06 11.34.00 by Grant Duguid, on Flickr

    [​IMG]2018-05-06 11.33.49 by Grant Duguid, on Flickr
    #19
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  20. G 981

    G 981 Been here awhile

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    Fibreglass sidepanels and mudguard arrived today. Drilled holes and test-fitted the mudguard. The sidepanels needed finessing to fit the relocated mounting lugs on the frame.
    Next job is to fix the mounts to the sidepanels. Still waiting on the seat pad base to arrive and then the tailpiece mounting holes can be drilled and all the new parts sent for painting.
    Poco a poco.

    [​IMG]2018-05-08 12.55.45 by Grant Duguid, on Flickr

    [​IMG]2018-05-08 14.04.50 by Grant Duguid, on Flickr

    [​IMG]2018-05-08 12.44.27 by Grant Duguid, on Flickr
    #20
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