Hey all. I've had this project kind of thrown into my lap and I figured some of you may enjoy it. This has turned out to be a very challenging project. First off, I'm not a bike builder by any means. I'm a gunsmith and own a gun store here in Texas. I have a small machine shop with a nice tig welder. I'm doing all of the fabrication and machining with manual machinery. I got a too good to pass up deal on a 2007 gsxr 1000 with a roaring toyz 8" extended under braced 240 swingarm and rc wheels. The bike came minus motor. My friend and business neighbor George professionally builds 1000cc and hayabusa engines for formula 1000 and cart series race cars. He had a low mileage 2006 Hayabusa engine that he only had $700 in. As fast as that the project was born.
The bike
The hayabusa engine
My goal is a monster that plays like a litter bike in the twisties. The 240 kit has been replaced with an oem swingarm and wheels.....for now. George is going to be doing my engine build for cost of parts. He has an in house dyno. I'm going 4mm over on my pistons. The cylinder head is being sent out to be bored and dlc coated. The same with the head for porting. We are doing the weld up clutch mod, dual intake cams, valve job, and milling the block to turn the torque up. He's also doing all the fuel management / tuning and dyno work. Now all I have to do is make it fit and stay together.....
I had it pulled apart pretty quickly down to the main frame to take measurements
It was quickly obvious that it was going to be a challenge. The head of the hayabusa engine is 1.750 in wider than the inside width of the 07' 1k frame. The key to this build will be getting*the engine mounted so that the oil pan is as near to level as possible. The clearance for the valve cover will have to come nearly to the top of the chassis. None of the motor mounts come near close to lining up. Time to get the frame in the mill and machine out clearances.
For an idea of what I'm trying to pull off, here's the 1000 engine on the bottom and hayabusa up top.
The first thing I did was square up and true the bottom motor mounts. I will be making new motor mounts to weld on the tabs.
I then had to machine a clearance for the rear top motor mounting point, (that runs through the center of the frame)
Before-1
Before-2
After
Obviously I had to reinforce the frame. I machined an L shape .250" thick bracket mated to the frame, welded it in, then machined out the motor mount hub.
I also had to machine out a clearance to clear the top of the clutch. I completely cut off the front motor mounts, and cut 90° sections out of the inside wall of the frame to clear the hayabusa head and valve cover. That allowed me to drop the frame over the engine.
I lined up the top rear motor mount to use as the axis of the engine fit. That gave me the dimensions to make the rear bottom mounts that I'll be welding to the tabs I squared off earlier. The new motor mounts are positioned lower and further forward of the factory motor mounts.
With the Busa engine mounted to the new rear bottom mounts, it aligns with the rear top motor mount and levels the oil pan. With the top rear motor mounts being inset into the center of the frame, I wanted to fortify that. I turned 6061 aluminum tapered frame inserts to create solid motor mounting points.
Here they are inserted into the frame. Notice the cuts on the bottom of the frame above the clutch. I'll be addressing those shortly.
Top and bottom mounts with the frame insert in. It was important to line up the sprocket to clear the frame and swingarm pivot mount.
here's the frame inserts welded in.
Welded on the inside and out. Notice all the material I had to remove from the bottom side of the frame to get around the clutch that I mentioned earlier. I'll be covering that on my next post.
Nice project. If this is going to be anywhere near a daily rider,scrap the 1430cc pistons and stick to the proven 1397cc combo. 4mil on a Gen1 block doesnt leave much meat between the bores
Yessir' I want dependability. I was planning on running cp 84mm pistons, 1397cc at a 13.5:1 CR. I may have my data wrong as well. I'll run it passed my engine builder again.
We left off with that large clearance cut on the bottom of the frame above the clutch. The reason that I removed so much material there is so that I could add strength. I will be filling in with 0.750" thick aluminum. I can then mill channels in my aluminum fillers to clear the contours of the clutch without losing structural integrity.
I milled 6061 aluminum sections to the width and contour of the inside walls of the frame. Here they are, bead blasted and ready to weld in.
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Pressed into the frame
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Then welded up and sealed. I'll be milling channels to clear the clutch cover bolts later.
You just confirmed something I've been wondering about for a while...I met this young kid about six months ago, he told me he put a Busa motor into a gsxr 1000, and was clocked at 240 mph
When I thought about that for a second, I asked him how hard it was to do that swap...he told me that all the engine mounts except one line up....
I figured he was full of shit....thanks and good luck man unk
unk Good job, you will have a sled that will be as fast as Santa's when your all done! Merry Christmas!
Good luck with keeping the front tire down :biggrin
Sorry I've been MIA for so long guys. My old phone crashed. I lost all my passwords to get into here or photobucket:banghead I did manage to recover all my pics of the build so I'll be back on it here shortly.
The bikes come a long way. I should be shredding tires in just in time for nice weather. The frame is almost ready for paint. I think I'm going to do my own "superbike" type swingarm reinforcement in the name of why the hell not:lol my cylinder and head will be back next week. Bored and coated the cylinder 3 mm over. Using CP 84 mm pistons. Running a Gen 2 rotating assembly / crankshaft and rods for another 2 mm on the stroke, getting a little extra torque. On the head I went with a port job and valve re-work. Also running dual intake cams. I've done the weld up clutch mod as well. I also have these guys making an "airbox" for me that I'm REALLY excited about. http://catalystracingcomposites.com/i-18849456-99-13-hayabusa-air-box.html
It's going to allow me to tune custom funnels/stacks that are being used in race carts, giving a significant hp gain. I can't wait to get it on the dyno. I'll be posting the results. If it's anywhere near projected this thing's going to be a rocket, especially with a rider that's 5'7" and 165 lbsunk Stay tuned guys, I didn't give up and go home.
Trippy^ That odd to anybody else.
Trippy^ That odd to anybody else.
Nevermind the glitch fixed itself..i think.
165..... Eat a samich sir.
Welcome back.
Lmao. I don't know what happened to that post. I had to hurry and edit it. Even then I screwed the pooch, 175 not 165. My fat thumbs don't work well on my new phones little keyboard.