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Discussion Starter #1
Hi all. After joining this forum a few months back I figured its about time i started a build thread :)

Just before the new year I picked up a new project... 86 GSXR 1100, far from complete! But it has come with a 91 gsxr 1100 swingarm, srad forks, some B12 wheels and a custom subframe for a more modern gixxer tail piece. The swingarm still needed some axle spacers and the forks required a different upper bearing... both now sorted. The subframe will be binned for a new one.



The plan is to build a monocoque tank/tail unit, custom exhaust (home made), remove shock linkage and relocate upper shock mount for direct fitment with alternative shock (possibly er6). I’ve recently picked up a bandit 1200 motor for it too, which i plan to get vapour blasted as some point. The engine will remain stock for the moment with plans to upgrade later.

So, tank progress so far...

First a cardboard mock-up





Next I dismantled and measured my cardboard mock-up to then recreate the parts in Solidworks. I then flattened and exported the parts into our (work) sheet metal software, where i then programmed the parts to be cut out of a sheet of 18 gauge stainless steel. I was originally going to use 2mm aluminium but the steel was half the price, our machinery at work is limited on the tooling i can use to punch 2mm ALI so I’d have had to cut all the parts manually! Plus I’m much better at welding steel :p

The design below also shows the battery location based on a 12-cell anti gravity unit and a channel to hide the wiring. What it doesn’t show are the tank baffles, which will be added later. Also, the plan is to have the tank pivot at the headstock to gain access to battery/underseat area.



Parts punched...



Next I went about bending the metal. The zero radius bends i put on using the bending machines at work, but unfortunately work didn’t have the tooling to bend the larger radius bends i needed so i had to improvise at home! Fortunately a had a couple of used disposable argon bottles that worked a treat.





Unfortunately, this weekend, I only got as far as tacking one side of the tank before running out of Argon but am pretty pleased with how it looks so far...



 

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Progress has been slow but I've finally got the rear suspension sorted, and the tank/tail mostly complete.





and this is the plan for the exhaust now I've relocated the shock...



 

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UPDATE... (It’s been awhile!)


I picked up a cheap bandit 1200 engine, cleaned it up abit (but not alot!) and have it in place so i can make the mounts.

I’ve had to have the sprocket carrier machined so the wheel can sit central.



I finished off the tank/tail shell and have also made the subframe. The 2 pieces are now connected via a hinge and supported by 2 mini gas struts. These will lift the shell from 45 degrees to vertical but are mainly in place just to keep the shell safely in its vertical position whilst access is required.





Im also playing around with ideas for holding down the front of the shell. Quite liking this style of latch either side, bit of a feature. Thoughts?



I’ve also made the fuel cell, well, almost... i ran out of gas! This has a channel for wiring and a flush fitting fuel cap. Once welded, Il be filling it with foam baffle cubes. The tank will hold approx. 13 litres.













Ideally i would have liked to make the shell from either carbon fibre or aluminium, and the subframe + fuel cell from aluminium too. But as i can only weld steel and wanting to do as much of the build myself, i opted for what i can weld. Perhaps once the build is complete il learn to weld aluminium and remake the parts.

Anyway, still lots to do but its definitely starting to take shape.
 

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I finished off the tank/tail shell and have also made the subframe. The 2 pieces are now connected via a hinge and supported by 2 mini gas struts. These will lift the shell from 45 degrees to vertical but are mainly in place just to keep the shell safely in its vertical position whilst access is required.
Interesting idea, that's pretty trick.
 

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Really cool project, and some seriously nice fabrication! Looking forward to seeing where this is going, keep posting! Like the latches at the front of the tank, looks "race-y"
 

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Hi, if you want your exhaust to follow pathway indicated , try to get a gsx-s750f sump pan, it has a better shape to allow paired headers on each side
 

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Hi Guys, Hope all is well :)

I’ve been struggling to find time to work on my build as of late, but managed to get on in a bit more over the last couple of weeks.


I found myself a rear brake caliper and had some custom spacers made up to make the B12 wheel fit.







And I got going on the exhaust too. I decided against making the full system, figured the headers would be too much work for my amateur welding skills! So I purchased some Black Widow race headers, which are very nice indeed. Then proceeded to make the exhaust back from that. I purchased some 304 tubing and some pre-bent mandrels to suit. The mufflers however, I made and rolled myself from flat sheet 304. They were a b***h! But overall happy with what I’ve achieved so far.













 

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Wow! I am amazed at your skill and imagination! Truly amazing project!!
 

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So, since finishing the exhaust I’ve done very little else! It’s been a hectic last few months and a pricey one too!

As funds are still too short to purchase any of the more important components (carbs, electronics, ignition etc) I thought I’d get a bit of paint on it. Wheels, bodywork and headlight/gauge housing. I also added some fork guards that I had originally made for the sv, look alright I think.

And I made a mounting bracket and some end caps for the Mocal oil cooler I has previously purchased. Really happy with how that turned out.

















 

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Black gloss spray finish is nice.
Whats your process to paint?

Spray can? Proper paint spray with air?
How many layers? Any undercoat?
Clear coat?

Finish with car polish?
 

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Discussion Starter #20
The exhaust is magnificent.
Takes me back to lobster back welding - did you gas or tig weld the sections?
Looks like tig
Thanks, yeah I tig welded it.

Black gloss spray finish is nice.
Whats your process to paint?

Spray can? Proper paint spray with air?
How many layers? Any undercoat?
Clear coat?

Finish with car polish?
I actually just used Simoniz Tough Coat Gloss Black! Gave it a few coats, flattening between coats. Its not had a polish yet but will be getting one before its all finished.

The tough coat goes on really well, fills any blemishes and is a bit more resistant to scratches etc. No need for primer either. Love the stuff! shame they dont make it in other colours
 
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