The Frankenbusa Saga. Holy crap I'm still here!

[dtechnologies]

Time is something I don't have much of so tomorrow I'm going to rebuild the forks as-is...I'm sure it won't be too bad. I can't afford to replace fork tubes anyhow.

While I didn't get much done today, I did manage to get a few things done...

I mounted up the carbon fiber chain guard I picked up on eBay. I strongly recommend a person steer clear of eBay when it comes to carbon fiber. This chain guard was warped slightly. I resolved this by using a zip tie to secure the guard to the brace of the swing arm. The added benefit of this is that it makes the guard more rigid.

I've also started mocking up aluminum to fabricate my solo subframe with carbon fiber race seat. It's going to be short, stubby, ugly, and should be super light and have just enough room inside for the engine computer and a few other electronics goodies. The carbon fiber seat (from the same guy as the chain guard) is also warped but it won't show once it's bolted down and my fat ass is on it.



Three days to go before I have to go back to work...

[dtechnologies]

The last two days have not been nearly as productive as I'd planned. Despite having the week off for vacation, I'm still not getting much done. The good news is that so far today I've made some good progress

First, I picked up a BT020 120/60-17 for dirt cheap at a local dealership. Seems people don't like this tire but I love it. I had great luck running it on my FZ1. It was on sale so including mounting and balancing I only paid $160 CDN. You can see it's size compared to the old 70 series tire...should give me about 1/2" lowering and another 1/2" clearance to the rad.


Being very eager to get to the forks, I dove in. Finally I have all the tools, oil, instructions, and everything else I need. I decided to do them one at a time so I could compare them assembled.

I started by taking one apart:

Then set to work taking the insides apart. Without proper Suzuki tools, this is quite the task. The instructions from Schnitz were OK but could have been better. I admit I got pretty nervous when I had to use a pipe wrench to seperate a piece from the inner cartridge. Because everything is being done backwards due to a lack of tools, I had to make my own spring compression tool:

The reason the cartridge has to be taken appart is so that a small spacer can be put in to compliment the shortened main spacer...pretty smart:

The Completed cartridge:

The time had finally come, I could stand them next to each other and compare. I was pretty happy at this point.

Even though I have to pull the turbo and header off, I had to see what the bike was going to sit and look like back together.

Here's a shot showing ground clearance. Quite a bit by my estimation thanks to that lowered oil pan (no peanut gallery commentary required).

[dtechnologies]

Well I managed to get a bit of work done before heading in for the night.

First I wanted to see how far the bike would lean with the newly lowered front end...and it's not good news. With the forks shortened and the 60 series tire on the front, the bike can't lean very far.

I guess I'll have try and get a bit more clearance when I do the final mounting of the up-pipe pieces...or make sure all hard turns are to the right 

I also mounted the front brake calipers and was pleasantly surprised to see that the shortened forks have provided a perfect amount of slack to make up the difference. I won't be ordering new brake hoses now...not unless there is a clearance issue with the radiator and the cross over hose.


I spent a lot of time today trying to decide on how to build the subframe. I mocked up different things with aluminum and so far haven't found anything I like. One of my plans was to put the ECU and other electronics into the subframe but the smaller I make it, the more I like it. Tomorrow I'm going to try switching to steel and making it very small. This will force me to get creative to locate the ECU and such but I'm much better at being creative with wiring than with raw steel.

[dtechnologies]

It's definitely too little too late to get this project done before I have to go back to work tomorrow but I'm a hell of a lot closer.

I played with some subframe stuff last night and ended up with some aluminum framing but I guess I needed a good nights rest to get it done. I brazed the pieces together this morning and what I ended up with not only holds my weight but took several blows from a 2 lb. deadblow...that's good enough for me.


At this point mounting the rear brake master cylinder was a snap:


With all that angle aluminum I was inspired to mount the headlights...something I'd been struggling with:


On a whim I decided to install the 24-1 stator wheel I picked up. I still have no rock solid way to measure how many degrees before TDC the gap passes the sensor...I guess I'll end up spending a few hours with a degree wheel one of these nights.


One of the things I've been thinking about a lot but have been putting off is mounting the battery in the swing arm. I mocked up a few things and this is what I came up with:

The shelf is 6061 Aluminum and will be attached to the swing arm using 1/4" threaded rivet inserts. I still need to trim it so that it slots around the chain guide and the rear brake support rod ear. The black bottle is a 20oz. paint ball bottle with an MPS valve and regulator and the aluminum bottle is a camping fuel bottle which will be used for tank, rad, and crank case overflow to meet racing requirements. I might switch to two smaller bottles and dedicate one to coolant so I can recirculate the coolant, eliminating the requirement for yet another container/bottle.

[dtechnologies]

If you haven't noticed by now I'm uploading all my pictures to Flickr. It's a fantastic service.

If you go to http://flickr.com/photos/tags/frankenbusa/ you'll see all the photo's tagged 'Frankenbusa' which should obviously be all the project photo's of my bike both new and old...if you care.

[nemsis]

nice

what are you using for headlights?

for that chain guard is their anyway you can screw it into the swingarm bracing from the back side and get rid of that wire tie

[dtechnologies]

nice

what are you using for headlights?

for that chain guard is their anyway you can screw it into the swingarm bracing from the back side and get rid of that wire tie

The lights are Hella Optilux foglamps. I'm going to put some Eutrolite Xenon bulbs in to give them that HID feel. If I remember I'll do them one at a time and try to take a picture of the difference in their look.

I do intend to do away with the zip tie but it's not a high priority. Because of the curve in the brace, it doesn't sit flush on the inside. What I'll likely do is drill a hole in the brace and thread it ( or put in a blind threaded insert) and an angle cut spacer to bridge the gap.

[dtechnologies]

Somebody asked me today what I had left to do on my bike. After listing just some of the things I need to do yet, their comment went something like, "Holy crap. It's like you're building the thing from scratch!" I hadn't realized it but in a lot of ways that's what I've been doing. I don't feel so bad for taking so long now.

[dtechnologies]

Finally got to a computer to fill in yesterdays pictures.

Here a couple of shots of the battery shelf once I finished installing it.


Getting under the bike was a bitch. If it weren't for the hoist, I don't think I'd have been able to do it


I went back to work today and was asked 'Is it done yet?', 'Did you get it running?', etc, no less than 5 times...I've definately been doing this too long.

I shipped my throttle cables to Motion Pro today. That bad news is 5 days there, 8 business days to make them, and 5 days back again. The good news is that the quote was only $30 a cable plus return shipping.

Today I'm taking the day off. There's wrestling to watch and sleep to catch up on.

[dtechnologies]

I have good news and bad news and unfortunately both are preventing progress.

I've had a touch of stomach flu for the last couple of days and been spending some quality time in the bathroom. Since I don't work on my bike at home and it's highly contageous, I've decided to quarantine myself for a couple of days.

The good news is that I've just learned that starting this weekend I'll be getting ready to become an instructor at one of Alberta's largest motorcycle rider training schools. I'm super excited. I might buy another bike (a beater) this week just so I have something to ride while I'm finishing the Frankenbusa as it's going to take more time once I start teaching.

[dtechnologies]

My APE studs and nuts came today...at least I picked the right day to be sick.

Since I ordered them I can't decide if I want to go to all the work to put them in now. I might just retorque the head and clamp them down tighter than the manual recommends.

[dtechnologies]

My hours have been changed at work so that I'm now working the night shift and have Mondays and Tuesdays off. Because I drive 40 minutes to work on my bike, this means I need to move my bike a LOT closer if I'm going to get this damn thing done this year.

So far I have no solutions beyond quitting my job...which isn't an option.

[reaper0995]

My hours have been changed at work so that I'm now working the night shift and have Mondays and Tuesdays off. Because I drive 40 minutes to work on my bike, this means I need to move my bike a LOT closer if I'm going to get this damn thing done this year.

So far I have no solutions beyond quitting my job...which isn't an option.

living room buildup! 

[dtechnologies]

My hours have been changed at work so that I'm now working the night shift and have Mondays and Tuesdays off. Because I drive 40 minutes to work on my bike, this means I need to move my bike a LOT closer if I'm going to get this damn thing done this year.

So far I have no solutions beyond quitting my job...which isn't an option.

living room buildup! 

I've considered that...it may happen yet.

[reaper0995]

how much do you have left on it? it looks like a little on the turbo setup, radiator for intercooler, tail section, handlebars, swingarm stuff...tuning....anything else other than the normal small put together peices?? 

[dtechnologies]

Here's my current 'to do' list:

- Mount the seat to the subframe
- Find the holes in the header and dump and plug them.
- Paint all the exhaust and up-pipe sections with VHT 1500 degree paint
- Re install all those pieces plus the wastegate and BOV.
- Install the MPS low rise crank breather cover
- Re-plump the fuel system to better utilize the increased under tank space
- Scratch build a clutch slave support
- Buy and install a steel braid hose for clutch
- Find rad(s) and plump the intercooler
- Mount the water pump, the ECU, the MPS electronics air shifter valve, the reg/rect, and battery
- Install air shift cylinder and air hoses
- Install throttle cables (when they get back from Motion Pro)
- Mount signal and brake lights
- Mount some switches somewhere for lights
- Install ignition switch somewhere
- Mount my Veypor VR2 speedo and harness
- Handwire EVERYTHING
- Retorque head to ~45lbs.
- Get to tuning!
...
- Anything else I forgot...

It's still a fair bit of work but each step individually shouldn't take long. It's getting out there to do it. I'll have this coming up Monday-Tuesday and maybe the next before I start teaching again. If I can narrow the work down to electrical and some basic assembly by then(aka: get the dirty stuff done while I still have a garage), I'm pretty sure a living room finish is in the picture.

[reaper0995]

WOW!  ...thats a lot on the plate still. 

[dtechnologies]

Compared to what I've gone through so far this is nothing. The road has been long and twisty but there's light at the end of that tunnel.

During this journey I've learned a lot. Most of which is thanks to the kind folks on this forum...without their support, I wouldn't have been able to take this to the level that I have.

When I started, this project was a 'I should put a dry shot of nitrous on' and becamse 'put a turbo on my 'busa' project and now it's a complete transformation into a creature that is part turbo hayabusa, part street fighter, part junk yard leavin's, but all me.

I'm sure most will look at my bike when it's done and call it the biggest piece of shit they've ever seen but I've never been satisfied to have something that is even remotely close to something somebody else has.

[reaper0995]

well, then what about that gas tank...it looks like mine 

i think its pretty cool.  lots of work makes for some cool stuff.  i really like the way the swingarm and tail section so far looks.  it really compliments well and the distance between looks cool 'cause you don't ever see it like that.

[gsxturbo]

Compared to what I've gone through so far this is nothing. The road has been long and twisty but there's light at the end of that tunnel.

During this journey I've learned a lot. Most of which is thanks to the kind folks on this forum...without their support, I wouldn't have been able to take this to the level that I have.

When I started, this project was a 'I should put a dry shot of nitrous on' and becamse 'put a turbo on my 'busa' project and now it's a complete transformation into a creature that is part turbo hayabusa, part street fighter, part junk yard leavin's, but all me.

I'm sure most will look at my bike when it's done and call it the biggest piece of shit they've ever seen but I've never been satisfied to have something that is even remotely close to something somebody else has.

man its all about what makes you happy lifes to short to worry about what everybody else thinks i think you you have done a fine job with what you have had to work with considering how hard it is getting parts and making everything yourself keep up the good work

[dtechnologies]

Well my cables are in limbo. It's been 2 weeks and they still haven't arrived at Motion-Pro...5 days my ass. I put on the package that the cables are going to 'be serviced' so that no duty would be charged...no doubt they're sitting on them trying to decide if I'm pulling a fast one or not...fucking customs.

Additionally, I found a part that I absolutely must have for my bike! Unfortunately it's from Germany and not cheap. By the time it gets here, it would cost me over $300 CDN but I can't find another piece like it for less. Plus it has a small area at the front where lights or small gauges can be mounted. Seems like too much money for this (unpainted no less):



It pains me to no end that I don't have the ability to make something decent to bridge the gap between the tank and the frame. It's just too irregular an area and I don't have the tools or the skills.

Does anybody have any suggestions?

[dtechnologies]

Thanks to my wonderful employer and a few other tricks that life has thrown into the mix, this is very very likely to be the last day I'll have a garage to work on this project in. I'm trying to get everything done today that I absolutely need a garage for...I'm realizing that it's too little too late. Tomorrow I have a meeting with my boss and his bosses...I might have more time (and a lot less money) depending on how that goes...

I modified the last elbow between the up pipe and plenum to accept my BOV this morning. It's a cheapy but I took it apart and the construction seems solid...and it was free. I modified it a bit so that it would fit better. I'm getting fairly good at welding with my cheap borrowed MIG. I'm sure there are still a few holes that I'll need to plug after it's painted...epoxy is my friend.


Speaking of epoxy, I've also mounted a bung for the intake air temperature sensor. I had to mount it off center between carb 3 and 4. I wanted to put it right in the middle but there just isn't room. Plus I don't think I've ever seen a sensor located anywhere but on the side. I had to use a flanged steel nut with recut threads. I'll run a tap through again once the epoxy is set to be sure and then hit it with a quick shot of paint just to be sure it doesn't rust. I could have bought a stainless nut I'm sure but at this point I just don't have the time to fuck around.


After lunch I'm going to try to clamp the throttle bodies to the head using standard hose clamps as somebody mentioned earlier that it can be done and dis-assemble the headers. I need to be sure the dump and gate all fit properly (some of the bolts are at odd angles) as tonight I'm going to see if I can't acid bath all my steel parts and paint them with VHT 1500 degree paint. I may use regular engine enamel for the up pipe sections but only if I don't have enough VHT to go around. Any holes at that point will be plugged with high temperature exhaust cement.

[dtechnologies]

Well my after lunch plans have changed already.

It would seem that my work related stress is taking it's toll on my ability to concentrate on just about anything. I was emailed an article about abuse in the workplace and the similarities to what's been happening to me at work lately are sobering. I have to leave. I'm going for a ride to clear my head.

I also had a great idea on the way to pick up my bike. Something that I've been struggling with is how to determine how many degrees before top dead center the missing tooth on the stator wheel passes the sensor. I think I've figured out a way. I remembered that I have an extra stator cover that I got from a laid down 'busa. I'm going to cut a big ass hole in the side of it right where the VR sensor is and one where the crank shaft is. I'll spin the motor to TDC and then turn the motor until the missing tooth is at the sensor. I'll use a degree wheel on the crank to measure. Home made tools rule.

[dtechnologies]

I did some welding on my headers this afternoon to patch visibles holes...but I ended up burning more holes than I patched...either I'm not as practiced as I thought or I got a little crazy when I was grinding.

I managed to put together my stator cover idea and I think it will work quite well. Because everything is one piece I can't mount the VR sensor without the stator but with the mounting holes for the sensor visible it's an easy matter to just measure for the center line between them. I didn't get a chance to actually measure anything today. I'm sort of scared to turn the crank. The engine hasn't run for so long and has had no oil for almost as long.


I'm definately not going to meet the deadline I set for myself of May 1st. 

[reaper0995]

afriad of no oil?  i have an idea....i saw this in a hot rod magazine.  it was a product that essentially was an air canister that would turn to the on position when the key was in accessory mode.  then you leave it there for a few seconds, then start your motor.  was supposed to remove the wear/tear on the engine startup to 'protect your investment' or something.  now my idea is to take off the oil pressure sensor that most people T off for the turbo feed line, then make a tiny adaptor and connect one of those air blowers from a compressor.  then just add a little bit of pressure, see what it does (like nothing is going on bad...), then maybe add a little more.  might push a little oil through your system, or something like this.

now, it might be a good idea to wait and see what other people have to say about this one before doing it, for i have never done this.  just sounds like it could work, or at least not be any more harmful than it would be to turn a non oiled crank.     <---hopefully not the