Building a 7/11 racer

[BenjaminDG]

Did get a AC/DC Tig welder rather cheaply (made in china) and started making some tig welds on an aluminium plate.

Looks okish to me.

rather tricky compared to mig/mag welding or using electrodes.











Now i can make small pieces of aluminium that will replace the heavier steel bits like frame for holding the windshield, my oil cooler bracket, coolant bottle bracket,....

[nuke421]

practice makes perfect on that deal, looks like your china made welder has plenty of power to get the job done looking at your first welds.

[BenjaminDG]

It has 200 Amp.

http://www.lasexpert.nl/WSE200P

Bought it for 500-600 dollars including foot pedel (for adjusting amperages manually).

[BenjaminDG]

Started with finishing the new intakes in the topfairing.

Old



New



Larger intakes which are positioned to get as much wind as possible.

[BenjaminDG]

Bought a yoshimura TRS full exhaust from a gsx-r 1000 2002.







This complete exhaust only weights 5-6kg, it also features the duplex system

Header spacing looks allright for the 1100 head only the overal width of the exhaust is 3cm narrower then 1100 exhaust so i need to stretch it out a bit.

I also made my first aluminium producht which is a new bracket for the oil cooler and coolant bottle.



Weights 165 gr which is 300gr lighter then my other bracket.

[Sabba]

Nice find...will be interested to see it fitted.

Good wrk on the bracket too...these old girls can stand to loose a few pounds!

[BenjaminDG]

Here is the mock up on my new exhaust.

Fits allright, the exhaust is made out of stainless steel and not titanium

But stainless steel is better to work on, less fragile.













Groundclearance is also good, atleast 13cm.

Should fit nicely after some minor modifications

I am thinking of fitting the 750W bellypan so that i can move the collector a couple of cm's up towards the engine?

[Sabba]

So the 2002 GSXR 1000 exhaust is pretty much a bolt on to the 1100?

Good info...

[BenjaminDG]

Pretty much is not how i would put it.

This is not the stock system from a gsx-r 1000 2001-2004.

Its a yoshimura trs which has thicker exhaust pipes, the stock system may be even better to fit and most likely a bit cheaper then this 2nd hand yoshimura.

Stock headers are from titanium BUT titanium is harder to work on.

More fragile and difficult to weld (you need tig and argon gas on both sides of the weld to create a oxygen free condition).

Even so the stock system headers may weigh 1kg less then the stainless steel system but the stock mufflers weights more then the yoshimura one so there are no weight gains compared to the trs system.

But with some heating and stretching and some modifications (need to modifty the flanches and reweld the duplex tubes for example) it will fit.

Will do this in the course of this week and weekend.

[BenjaminDG]

Finished the new windshield bracket in aluminium.

Quite a pain in the ass to get all the angles, heights right and to make sure i clears all other components from the gauges.



Weight: 200 gr

Stock: 450gr

Not impressive but with my new brackets i already saved 0.5kg.

Total weight saving with the parts i will fit this week or next week is around 7.5kg

2 new brackets
1 gsx-r 1000 exhaust
removal of the radiator fan

[BenjaminDG]

Finished the topfairing so its ready for paint.











As you can see i left the opening for the indicators open on purpose.

Becaus i will drive this bike on the road for testing so i need to make it road 'legal'

[Adamm Bomb]

The top fairing looks much cleaner than before. Good job.

[BenjaminDG]

Does any know if there are lights avaible for track fairing?

I tought of putting 1 light in front like the ducati 999 or 749.

[TJS]

You could sell alot of those....if you could mass produce that fairing!

[BenjaminDG]

You think there are some who want state of the art ram-air fairing for their 750 or 1100W

But who knows if my airbox really pressurizes and there is enough intrest i guess i could replicate these.

If i can still have the motivation to use filler and sandpaper 10 times in a row to get the fairing smootly.

[Sabba]

Nice work Ben

[BenjaminDG]

Leaving the front fairing for now becaus i proably will modify the intakes a bit so that all the planes are even.

Oh and sand bending the exhaust tube didnt work well

So i will cut and reweld the pipes by hand.

Is easier to fit when i can work on the bike instead on a workbench.

So i started by making/modifying my own race tail.



There will be a new section attached so that i can hook it up on the tank and on the lower bracket where the carb covers are bolted to.

I welded 4 little brackets on the subrame to hold the end tail there.

I probaly will work on the shape of the end tail aswell to make it similar like the tlr1000 end tail.



Note that the endtail flattens out towards the side to provide downpressue?

Looks a reversed double bouble design.

[BenjaminDG]

Modified the exhaust to fit the 1100W engine.

Sand bending didnt work out well so i rewelded it, needed to fabricated new sections aswell.



Ground clearance looks good to me?

Now i need to make the duplex canisters and modify the link pipe towards the mufler for better fitment.

[BenjaminDG]

So i have decided that i dont need to modify the frame for my ram-air.

I will place the intake pipes in these positons.

Starting from the middle of the top fairing for best intake speed/pressure.








I will replace the stock fuel tank with a homemade aluminium fuel and modify the airbox (larger) for the new air-intakes.

Also making a resonator tube.

Aluminium fuel tank will have a fibreglass shell on it to protect it and house the intake tubes.

Intake tubes will be also made out of fibreglass.


Started by modifying the front fairing again (version 5 by my count).







Oil cooler will be repositioned, proably below the radiator.

[Sabba]

Originally Posted by BenjaminDG

Ground clearance looks good to me?

Now i need to make the duplex canisters and modify the link pipe towards the mufler for better fitment.

Agreed, looks okay. Are you trying to replicate a Yosh Duplex here?

Want me to post some pages of the Duplex section from the '94 Yosh catalogue?

Good call on not cutting the frame, I dont think that would have ended well...

You will be a master at fibergalssing by the time this thing's done...