MOTOBRICK.COM
TECHNICAL MOTOBRICK WRENCHING In Remembrance of Inge K. => Project Custom Motobricks => Topic started by: beachcomber on July 15, 2014, 06:09:22 AM
-
Over the past 10 years I've built several Kay based projects - most got sold on to people who wanted to buy before I'd even put the finishing touches! :dunno2:
This one's getting finished though ..... Based on a very low mileage K100 it's morphed through a Factory race rep [ until I found BMW had copied MY style idea with their S1000RR !! ], and then into a 60's style Cafe Racer complete with wire spoked wheels - and on now to a Streetfighter 'ish style.
Here's the mock up early last year [ health issues slowed progress down ], and since then I've developed a K1100 fork swap to take K1200S 5 spoke wheels. That's about where I'm at now - the final mock up and fettling of the GRP panels ready for a teardown, detailing and paint. The wheel / fork conversion has been completed and they'll be swappped in after the paint is completed.
(http://i1213.photobucket.com/albums/cc472/manfredvonheyda/SONAVON003-3.jpg) (http://s1213.photobucket.com/user/manfredvonheyda/media/SONAVON003-3.jpg.html)
(http://i1213.photobucket.com/albums/cc472/manfredvonheyda/SONAVON005-1_zps129fc6ee.jpg) (http://s1213.photobucket.com/user/manfredvonheyda/media/SONAVON005-1_zps129fc6ee.jpg.html)
(http://i1213.photobucket.com/albums/cc472/manfredvonheyda/kaywheels007_zpsf0bcb858.jpg) (http://s1213.photobucket.com/user/manfredvonheyda/media/kaywheels007_zpsf0bcb858.jpg.html)
(http://i1213.photobucket.com/albums/cc472/manfredvonheyda/kaywheels002_zpsdfb23b79.jpg) (http://s1213.photobucket.com/user/manfredvonheyda/media/kaywheels002_zpsdfb23b79.jpg.html)
(http://i1213.photobucket.com/albums/cc472/manfredvonheyda/SONAVON012.jpg) (http://s1213.photobucket.com/user/manfredvonheyda/media/SONAVON012.jpg.html)
-
This was the partially mocked up factory Race Rep version ...... however, this was built TWO YEARS before the S1000RR was released " Great minds and everything - here's the very same fairing [ R6 ] that BMW used on their pre-production mules !
And the pile of parts that got mocked up into the Sixties style Cafe Racer.
(http://i1213.photobucket.com/albums/cc472/manfredvonheyda/SONAVON165.jpg) (http://s1213.photobucket.com/user/manfredvonheyda/media/SONAVON165.jpg.html)
(http://i1213.photobucket.com/albums/cc472/manfredvonheyda/SONAVON063_zpseb3e0c8a.jpg) (http://s1213.photobucket.com/user/manfredvonheyda/media/SONAVON063_zpseb3e0c8a.jpg.html)
-
Interesting, thanks for sharing.
Looks like a K&N filter on the end of the snorkel.... did you delete the filter inside the airbox? Any other performance mods?
-
Yes, K&N style pod filter and the internal filter removed.
No other mods other than a freeflow exhaust / silencer on this engine, although I do have an 1100 bottom end in the garage which will be getting an 8V head and at some stage - an Eaton Supercharger. That will coincide with the fitting of a sidecar as and when my knee eventually gives out for solo riding [ old football injury - damn' nose tackles ! ]
Here's another alternative to deleting the filter - and complete airbox !
(http://i1213.photobucket.com/albums/cc472/manfredvonheyda/bensbikeraceretro_zps1f3aa2f1.jpg) (http://s1213.photobucket.com/user/manfredvonheyda/media/bensbikeraceretro_zps1f3aa2f1.jpg.html)
-
Here's a few of the interim build pix to date .............. these are the finished wheels / tyre combo and the new spindle / spacer [ axle ].
OEM spindle bottom - new stainless steel spindle and spacer top. Additionally 2 x shim spacers required to centre discs.
(http://i1213.photobucket.com/albums/cc472/manfredvonheyda/SOBbikes007_zpsaeea535e.jpg) (http://s1213.photobucket.com/user/manfredvonheyda/media/SOBbikes007_zpsaeea535e.jpg.html)
(http://i1213.photobucket.com/albums/cc472/manfredvonheyda/Picture360.jpg) (http://s1213.photobucket.com/user/manfredvonheyda/media/Picture360.jpg.html)
-
Finally got my K100 yop yoke [ 41.4mm ] back from the machine shop :clap:- now reads 41.7mm to take the K1100 stanchions - basically the last piece I'm waiting for before the teardown for painting and detailing begins.
-
Here's another alternative to deleting the filter - and complete airbox !
Really cool. :2thumbup:
-
Here's another alternative to deleting the filter - and complete airbox !
Really cool. :2thumbup:
Why thank you kindly Tim .... it's taken me long enough for what was going to be a "quick build" :dunno
I'm debating with myself whether to fit clip ons and rearsets . I'm a child of the 50's/60's, brought up wth clip ons down by the front wheel spindle !!! However - the back is now that of a guy who just reached his 3 score and 10 - looks over practicality !!
That said, I'm also building a Sixties Cafe Racer styled Yam TR1 - so maybe I'll stick with the Renthals fo the Kay.
-
Is this Kharma ?????? I bought this Eaton Blower for my Hot Rod [ Phase 2 Vanguard Estate ] project to be fitted with a Volvo 3ltr V6 ......however it looks too small enough [ cosmetically ] - big enough for the Mk2 Kay Fighter engine though !!! :yow
(http://i1213.photobucket.com/albums/cc472/manfredvonheyda/xcvhuk_zps5fb05efb.jpg) (http://s1213.photobucket.com/user/manfredvonheyda/media/xcvhuk_zps5fb05efb.jpg.html)
-
And here it is stripped - Merc related parts to be sold off ...............
Size 9 [UK ] garden clog [ !! ] for size ref.
(http://i1213.photobucket.com/albums/cc472/manfredvonheyda/siovhane-bay076_zpse593b4dc.jpg) (http://s1213.photobucket.com/user/manfredvonheyda/media/siovhane-bay076_zpse593b4dc.jpg.html)
(http://i1213.photobucket.com/albums/cc472/manfredvonheyda/siovhane-bay072_zps4631c4e9.jpg) (http://s1213.photobucket.com/user/manfredvonheyda/media/siovhane-bay072_zps4631c4e9.jpg.html)
-
Oddly, I have been idly toying with the same idea....
Where are you planning on taking the drive from?
-
Oddly, I have been idly toying with the same idea....
Where are you planning on taking the drive from?
Drive from the front of the crank pulley - it's the strongest point. However, using an Eaton blower [ clockwise drive ] there will have to be a jackshaft running parallel with the blower and the blower sits "backwards" to get the drive from anti-clockwise to clockwise.
I would then sit the blower on it's side with the outlet facing the right [ viewed from the front ] and then use the blower intake opening [ blank the bye-pass off ] with a 1 3/4" or 2" SU. There are other considerations of course - like blanking off the injector holes [ Nitrous Oxide foggers ] and using a suitable timing device [ MSD or similar ].
All doable .... my problem is lack of workshop / machining facilities - so I have to rely on / pay others ......... that always slows a project down !
-
I get your plan.
My thought was to stick with the fuel injection though (don't get me wrong, I like carbs and SUs in particular - I'm putting one in the land rover as soon as I find one...).
As it turns out, I think I'm shelving my plan for blowing, but I'll be interested in how yours turns out.
-
I get your plan.
My thought was to stick with the fuel injection though (don't get me wrong, I like carbs and SUs in particular - I'm putting one in the land rover as soon as I find one...).
As it turns out, I think I'm shelving my plan for blowing, but I'll be interested in how yours turns out.
Yes keep checking in - it's a longer term project due to the aforementioned having to wait for pals / pay for the parts for conversion.
Unfortunately fuel injection [ modern ] is not in my comfort zone - I'm a child of the 50's / 60's, so I'm far better off working with parts I can figure out what they are doing - and fix them !
-
wouldn't it be easier to make a spacer pulley at the alternator, notch the housing to pass the belt through, and then run a short drive belt between that and the pully on the supercharger? This would require less parts aand would spin the super the right way. Nudge the rad forward a touch and get a slimline fan and you could have your air intake there.
Yes I've been thinking of putting an m45 on my bike already (over a year).... And I've measured out up a dozen time too.
-
wouldn't it be easier to make a spacer pulley at the alternator, notch the housing to pass the belt through, and then run a short drive belt between that and the pully on the supercharger? This would require less parts aand would spin the super the right way. Nudge the rad forward a touch and get a slimline fan and you could have your air intake there.
Yes I've been thinking of putting an m45 on my bike already (over a year).... And I've measured out up a dozen time too.
Yes, this has been buzzing around in my head for 5 years now - ever since I got a real low mileage sweet K1100 less head. Ilooked at that option when I realised the Eatons run the wrong way for the Kay application. However, I'm not convinced the bearing / shaft would be strong enough - that blower takes a lot of driving !. The crank snout is the strongest place with the best bearing surface. Running a jackshaft has a side benefit of giving me two places to play with overdrive % and makes alignment a breeze. I'll be running Gilmer type belts and there's a lot of scope with OEM pulleys at sensible money.
Placing the blower on it's side also allows me to make a decent plenum for the intake to go off to the four intake runners - as you know the Eaton is merely an air pump - not a compressor. ANY compression of the charge takes place as the intake charge backs up in the manifold / plenum. With a properly designed plenum, I'm looking to introduce additional pressure for the charge. With this particular Eaton [ M217 ] the intake for the carb also conveniently sits over the cylinder head [ at right angles ] meaning I can leave the radiator where it is.
I'll add an oil cooler while I'm at it, and if I can find my old box of Nitrous parts ...........................
-
I managed to mock up the Blower on a spare bottom end at the weekend, and a jackshaft would be a very straightforward installation. There's even some decent conveniently placed mountings on the blower casing, and a 2" SU carb is mde for the job. Also plenty of substantial places on the Kay block to take brackets.
However, that is a long term project - I'll concentrate on getting the bike up and running as is first.
Back to fettling the GRP panels for a good fit, then it's final strip down, detail and paint.
-
For the comparative strength available at the front of the crank vs. the alternator drive, I'd agree that a countershaft is the way to go. Once the airbox is out of the way on top of the engine there's no shortage of space either.
-
Yes, when you look at the two options side by side - the crank snout wins out every time.
I'm a mechanical design engineer by training - and a life long tinkerer [ both as a hobby and as a business ]. And as such, I always had to err on the side of conservatism in safety / strength concerns when designing and manufacturing something others would place their trust in. And of course for my own peace of mind.
With that in mind - and maybe a little OTT, I'm considering mounting an outrigger bearing on the outside of the Hall trigger housing to further support the blower drive. The other benefit of this option is that the two drive belts will be relatively short and easy to tension / align.
-
There's no such thing as overengineering...
-
Some folk have enquired about replacing / losing the OEM instruements- hardly a thing of beauty.
As I don't get on with things electric, I took the simple way out and lowered the existing unit to lose as much of the bulk of the pod.
This is easilly achieved [ once you've done it ! ] by simply using the two mounts on the lower yoke [ K100 ]. I finished mine off with a small Bikini fairing - loads of options and you don't have to reinvent the wiring sysytem !
(http://i1213.photobucket.com/albums/cc472/manfredvonheyda/SONAVON178_zps6e61ea2e.jpg) (http://s1213.photobucket.com/user/manfredvonheyda/media/SONAVON178_zps6e61ea2e.jpg.html)
(http://i1213.photobucket.com/albums/cc472/manfredvonheyda/SONAVON171_zps4985592f.jpg) (http://s1213.photobucket.com/user/manfredvonheyda/media/SONAVON171_zps4985592f.jpg.html)
-
Hey beachcomber,
Noticed those are Renthal, ProTaper or similar handlebars. Are you planning to use the OEM grips and controls? If so, are you anticipating any issues with the 22mm vs. 7/8" fitment?
-
You're talking about the proverbial gnat's cock clearance issue.
DON'T do what I did first time around and "force" it on [ l/h side ass'y ] :nono - it just cracks the housing !!! One of those things you only do once. Strangely, the throttle side requires much less fettling ??
BTW - same probs with ALL the BMW range - see the Airhead in the background.
Simply ease the bore out with a round file - 10 minute job - hey presto.
-
When i put 7/8" bars on mine the best option for me was to sand down the bars - throttle tube was binding and the switchgear wouldn't even start to go on... That 0.225mm really gets in the way.
Long strip of emery cloth, over the bars and rub away (around the bar, not along). Took a while, but that did include tea and smoke time too.
Personally, if fitting something non-standard between OEM parts, I would always choose to modify the non-standard part if required and if possible - that way, if I ever wish to return it to original spec it's a bolt in job rather than having to replace more parts.
-
+1 what PDG posted. It plays an important role if you later want to sell the parts because the market value has risen. For our K parts, they are currently cheap and plentiful but that would be the case forever.
-
Yes - easing the bars is another option but with my nice new Renthals and their knurled ends - I decided on the second option ............. how long do you think we'd have to keep or Kays for before the value of a standard bike was worth more than a customised version - or even the disolution of it's parts ? There's still an aweful lot of ratty bikes out there and spares are still plentiful SHOULD I ever need to replace the modified parts.
When I broke the first housing [ clutch side ] a complete s/h replacement cost me £12.
I can STILL buy Kays for £400 - £600 - I got £3,750 for my last Fighter project and that was based on a £200 donor and I got £500+ for the parts I didn't want ! [ fairing, seat, etc ].
Naturally, if the donor was a pristine example worth saving for future generations - I'd pass it up.
Either option works for me.
-
Back from my Saxony chill break now and raring to get on with my projects. At least the break gave me time to make some sort of schedule for the 3 projects [ bikes ] and one Hot Rod !
Parts going off to the powder coaters and passivaters next week will include odds for the Kay.
4 Pot Brembos [ K1200S ] soaking ready for a refurb.
-
Just came accross the brand new Tomasseli Clip ons I bought for another Kay project. Hmmm, undecided now - strap-ons or Renthals ?
I might try both when I change the forks / front wheel over.
-
Just doing a trial fit of my newly reamered K100 top yoke on the K1100 forks prior to swapping them over. If all goes to plan I'll decide on which bars and get the forks swapped over in the next few weeks.
First I have to clear my bike ramp - currently has the Kawasaki KZ750 frame and engine on it !
-
Hi Beachcomber...snap some pix of your project
-
Hi Beachcomber...snap some pix of your project
Don't want to overload the system - but here's a few random pix along the way.
When I get the bike back from my pal's storage in 2 weeks, it'll be straight on the ramp and we're in the final stretch.
I need to fettle the grp panels for good fit and then prep all the parts for paint. First I have to find all the odd parts that are scattered all over my garage !
This was the bike ONE WEEK after I started .................. regrettably hasn't progressed that much !!
(http://i1213.photobucket.com/albums/cc472/manfredvonheyda/cars192_zpsc7b16654.jpg) (http://s1213.photobucket.com/user/manfredvonheyda/media/cars192_zpsc7b16654.jpg.html)
SLIGHT DETOUR !
(http://i1213.photobucket.com/albums/cc472/manfredvonheyda/SONAVON165.jpg) (http://s1213.photobucket.com/user/manfredvonheyda/media/SONAVON165.jpg.html)
(http://i1213.photobucket.com/albums/cc472/manfredvonheyda/Picture331.jpg) (http://s1213.photobucket.com/user/manfredvonheyda/media/Picture331.jpg.html)
(http://i1213.photobucket.com/albums/cc472/manfredvonheyda/SONAVON180.jpg) (http://s1213.photobucket.com/user/manfredvonheyda/media/SONAVON180.jpg.html)
(http://i1213.photobucket.com/albums/cc472/manfredvonheyda/SONAVON012-1.jpg) (http://s1213.photobucket.com/user/manfredvonheyda/media/SONAVON012-1.jpg.html)
(http://i1213.photobucket.com/albums/cc472/manfredvonheyda/SONAVON003-2.jpg) (http://s1213.photobucket.com/user/manfredvonheyda/media/SONAVON003-2.jpg.html)
(http://i1213.photobucket.com/albums/cc472/manfredvonheyda/SONAVON186_zpsf71868c7.jpg) (http://s1213.photobucket.com/user/manfredvonheyda/media/SONAVON186_zpsf71868c7.jpg.html)
-
Aaaaarrrrrggghhhhhhhhhhhhhh - so, went to fit up my newly reamered K100 top yokes only to find that they are 5 mm or so narrower across the stanchions than the K1100. That'll teach me not to check thoroughly ! :dunno
SO, back to plan A. The K1100 top yokes are off to the machine shop tomorrow to have the ignition barrel plinth and other squitter removed and tidied up. :clap:
Then .................... OK, who hid my one off front wheel spindle ?? After 3 days of searching the garage, my shed and other likely places, my WIfe tells me she "put it in the sideboard drawer for safe keeping ". :eek:
-
On the bright side, she did know it was an important piece iso throwing it away [emoji3]
-
On the bright side, she did know it was an important piece iso throwing it away [emoji3]
Due credit ... I asked her if she "knew where my front wheel spindle was", and her reply wasn't "what's that" !!! :2thumbup:
-
Top yoke back now - the ignition barrel / lock was removed and the cast-in mounting post machined off.
Nice uncluttered look, exactly what I had envisaged. I'll prep the forks / yokes and get new RAM progressive springs fitted before the front end swap.
-
That's more like the look I had in mind. I'll get the front end painted next week ready for the front end swap when my bike comes out of starage in January.
(http://i1213.photobucket.com/albums/cc472/manfredvonheyda/shelbygraduationsept2014010_zps51b0bba5.jpg) (http://s1213.photobucket.com/user/manfredvonheyda/media/shelbygraduationsept2014010_zps51b0bba5.jpg.html)
-
Looking good. I very keen to see that turbo mounted.
-
Looking good. I very keen to see that turbo mounted.
That's still a year away - that's for the Mk2 Engine ! That's currently a very low mileage 1100RS bottom end which is sitting in storage.
I have an unleaded 8 valve head which I'll be fitting [ the 16V head was sold for a Mini conversion ! ].
The Eaton Supercharger [ M45 ] IS now definitely surplus to requirements [ for my Vanguard Hot Rod ] as I now have an M112 Eaton for that application.
As usual it will be getting the work outsourced - hopefully at mate's rates - that will be the major hold up, with the associated lack of funds ! I have the installation all worked out now, complete with mountings and the jackshaft. The blower is rated at 1000cc - 1300cc, and in it's OEM installation is very low boost. However, with the jackshaft I have the option to play around with drive ratios and the Eaton is safe to 10,000 + rpm.
I scored a couple of 2" SU alloy spacer blocks on E-Bay last month - I'll use one of those to get the SU intake [ to blower ] made up. Very conveniently, Mercedes / Eaton have placed the intake at the right angle for my application - and the same size [ 'ish ] intake diameter.
I'm having to move some of my stuff in storage early next year - when that happens I have a spare K100 engine that I'll use for the mule to mock up the blower. Somewhere in the same storage area I have various Nitrous Oxide fitments........................... :2thumbup:
-
All sounds beyond cool. As mentioned I really want to see this come to life.
-
All sounds beyond cool. As mentioned I really want to see this come to life.
Me too !!!!!! It's taken way too long for what was going to be a "quick makeover". However, it's in the home straight now [ Mk1 engine ] as it's mainly now fettling GRP panels, detailing and painting. Swapping the front end over / fitting wheels theoretically - a weekend job.
The Mk2 engine with the Eaton blower WILL be later next year, but hopefully I'll be getting some enjoyment out of the base unit.
-
Slight diversion has slowed me down - but a good outcome !
My Wife decided she wanted a lean-to type log store at the side of our house - a builder pal had some surplus poly carb roofing sheets and alloy beams - so, 2 days later a lean to running the length of the access at the side of our house - in all 30' up to our original "small" temporary lean to [ 20 years ago ! ].
Hmmmmm - what a waste of space - log store now in the old lean to, and the latest addition in the process of becoming a "workshop" !!!! That will allow me to work on smaller stuff away from my overcrowded [ ie - can't get in there ] garage and also some storage space which will release half of the space in my garage proper. The border with our neighbour is a substantial 6' high wooden fence - so that has formed the outer "wall" of my new man cave.
My pal who has ben storing the Kay suddenly announced he has a new mechanic / fabricator starting woerk for him - his main hobby is bikes ! He saw the Kay when he went for his interview - and immediately fell in love with it. So I'm hoping he will have time to carry out some small fab works and welding before I get it back to my garage for the front end swap over and the detail painting work.
-
And as a reminder, here's the Kay Fighter project.
-
Any new updates ?
-
Any new updates ?
I'm going down to see them next week and will get all updates, price, availability etc.