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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 :punk
 

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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 :punk


2003-2004 frame is much wider at the front,so if he was using that frame it would require much less mods.
 

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Discussion Starter #26
Thanks guys. Definitely appreciate the comments.

2003-2004 frame is much wider at the front,so if he was using that frame it would require much less mods.
T.R.E. nailed it. The 2004 and earlier gsxr frames are much wider (and heavier). That's what really drove me to jump in to this. I've been replacing a lot of oem parts with titanium parts that I fabricated to make it as light as I can. I spent a lot of time trying to find someone who's done this swap with a 2005 or newer bike and haven't found anyone who has yet. It's been nerve wracking. There have been several moments when I started to think that it wouldn't be possible and my frame would be scrapped.

Sorry for the lack of updates, I've been traveling this week. I've got a ton more progress and pics to post when I get back home and settled in.
 

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This is going to be an epic project of heartache, joy, intense irritation and brilliant aftermath satisfaction.....

Cannot wait to follow through to the end...
 

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Discussion Starter #31
Thanks guys. Just wanted to stop in and say merry Christmas. I'll try to get a couple of update posts put up tonight.
 

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:punk 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
 

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Discussion Starter #34 (Edited)
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 lbs:punk Stay tuned guys, I didn't give up and go home.
 

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Trippy^ That odd to anybody else.
Trippy^ That odd to anybody else. :D
Nevermind the glitch fixed itself..i think.
165..... Eat a samich sir. :p
Welcome back.
 

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Discussion Starter #36
Trippy^ That odd to anybody else.
Trippy^ That odd to anybody else. :D
Nevermind the glitch fixed itself..i think.
165..... Eat a samich sir. :p
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.
 

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Discussion Starter #37
Thanks everyone for the positive feedback. Let's see if I can catch this thread up a little bit.

Next step is the front motor mount. Remember I had completely cut off the front motor mount arm, and cut out a °90 section on the inside of the frame to give clearance over the head. The head is wider than the inside of the frame, and sits high so it's a dramatic material removal. I decided to machine solid mounts that will insert into the frame channel. I used 0.750" thick 6065 aluminum plate. I coated it in dye Chem layout marking to scribe out some critical points.
[URL=http://s1373.photobucket.com/user/Robert_Wyper/media/My%202007%20gsxr%201000%20to%20Hayabusa%20engine%20swap%20project/IMAG0566_BURST002_zpsdr5hxahl.jpg.html][/URL]

I cut out squared off rectangular sections from the outside wall of the frame to create a ledge. I machined a shelf in the motor mount plate to mate with the squared ledge of the frame so that the mount plate sits flush with the frames outer wall, and continues inside the frame channel. Here's a test fit.
[URL=http://s1373.photobucket.com/user/Robert_Wyper/media/My%202007%20gsxr%201000%20to%20Hayabusa%20engine%20swap%20project/IMAG0591_BURST002_zpsoj87kg2n.jpg.html][/URL]

Good fit in the frame so back in the mill for the exterior and finish machining. I also have to relieve over 0.200" from portions of the back of the plate to clear the head. I "lightened" the plates similar to how I would on a custom firearm to reduce weight without losing strength. Here's a few shots of the left side plate, bead blasted to prep for welding. You'll notice the shelf I was talking about. The entire lowered shelf will be inside the frame. It's fitted to a near exact match to the inside wall of the frame. A little time consuming to say the least:banghead
[URL=http://s1373.photobucket.com/user/Robert_Wyper/media/My%202007%20gsxr%201000%20to%20Hayabusa%20engine%20swap%20project/IMAG0594_BURST002_zpszknizy79.jpg.html][/URL]
a ton of work on a manual machine. You can see the relief cut on the back of the plate in this shot.
[URL=http://s1373.photobucket.com/user/Robert_Wyper/media/My%202007%20gsxr%201000%20to%20Hayabusa%20engine%20swap%20project/IMAG0595_BURST002_zpsdyhozgop.jpg.html][/URL]
 

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Discussion Starter #38
Here is my motor mount plate test fit into the frame.
[URL=http://s1373.photobucket.com/user/Robert_Wyper/media/My%202007%20gsxr%201000%20to%20Hayabusa%20engine%20swap%20project/IMAG0596_BURST002_zpsmlsa1hy2.jpg.html][/URL]

Next I made the right side plate. The motor mounting points are in different positions on the right and left sides, so unfortunately I couldn't just exactly duplicate the left side plate. Here they are fitted and welded into the frame.
[URL=http://s1373.photobucket.com/user/Robert_Wyper/media/My%202007%20gsxr%201000%20to%20Hayabusa%20engine%20swap%20project/IMAG0617_BURST002_zpsoq4v2cgr.jpg.html][/URL]

In this pic you can see the large cut I made on the inside of the frame to clear the heads. That's still partially hollow/open between my plate and the inside of the frame. I'll be fabricating filler sections and welding them in.
[URL=http://s1373.photobucket.com/user/Robert_Wyper/media/My%202007%20gsxr%201000%20to%20Hayabusa%20engine%20swap%20project/IMAG0630_BURST002_zpsryybxy7i.jpg.html][/URL]
 
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