butch-182
Killerteam Racing
Hello, I would like to introduce my project.
My intention is to build a super light sr track bike. I started the project a few weeks back, many ideas were thought over for a light weight, yet still optical friendly bike. I will race the bike here in spain - Jerez & cordoba hopefully.
Heres how the bike started life as:
Then after that again changed many things :
Engine setup
Malossi MHR Team II 7t
Malossi MHR Over-range
Stage6 R/T 85mm
Stage6 Torque Control clutch
Malossi MHR Wing Bell
PVL digital
OKO 28mm
Stage6 V-force 3
Top Nardo
RS24 / Bitubo ZZN
Yasuni c21
Here is a small preview of the progress:
I started with the frame, Cutting un-neccesary parts from the frame. As you can see the frame is not in too bad condition, surprizing as its from 1997.
Here you can see that I spent some amount of time preparing each weld for the prevention of rust in the future, there was some small peices of rust, nothing serious but it all spreads, So better now than later.
The frame is now complete and ready for the Anti-rust undercoat.
The start of the bodywork can begin. Here I spent some time fiberglassing behind the headlights, and the indicator holes. After some time of filling, rubbing back, filling, rubbing back and so on I got to this point.
After some hours of getting it how I wanted, I finally had the shape of the mould that I wanted to take. Here we can see the fiberglass setting on the front:
A close up of the front, you can see how it taking shape, had to work real fast! I wanted to keep the definition of the front, this was to be quite a challenge as the release agent would not allow anything to stick near it, constant attention needed to be paid. Going back over things 10 times to make sure nothing was lifting, nor out of place.
Overnight I let it set and waited to see what the first prototype would turn out like, you can see that the definition of the original sr front has came out perfectly. Exactly as planned.
The same princible was used to achieve the front hugger:
Obviously trimming is needed after, a second coat is still needed on the front fender, a second coat was added to the front hugger. The end product? Super solid, yet flexable lightweight hugger. The weight difference is excellent, I hope to save some kg's in the end. I will make a full weight comparison soon.
The finished project should look like something like this:
Obviously being in spain it can reach pretty high temps during the summer, when the bike will be used, so extra cooling is a nessecity. I had a full copper radiator hanging around, with some nice paint added we can see it came out quite well. Obviously being copper there is fantastic cooling properties. Small enough to fit behind the front wheel, yet not so large that its too bulky.
Origional radiator:
Thermochill pure copper radiator (excluding shrouds):
A comparison between the origional radiator and the Thermochill:
Took some time polishing one of the fork legs, still needs lots of work but you can see it is getting there:
I shall try and get some more pictures this weekend. The first coat of anti rust paint will be applied to the frame. My father found some great stuff in a local store, you can apply it through a paint gun so is suited perfectly. Not so cheap but top quality stuff. Will be building some more moulds this weekend also.
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