Project Scope

I will elaborate on the full scope of the project shortly, so far, I've just made a list of the things that need to be done off the top of my head:

  • Paint wheels (rear and new rear)
  • Cut unwanted mounts off of frame, weld blanking plate onto frame, apply filler and sand smooth
  • Paint frame
  • Apply filler to hole in swingarm assembly
  • Paint rear swingarm assembly
  • Buy/fit new tyre to new rim. 
  • Clean up/polish engine parts (very long job!)
  • Re-assemble engine
  • Adjust valves
  • Paint valve covers
  • Machine up a spacer ring for starter to help engagement and hopefully get rid of the box of rocks noise.
  • Drill out pilot jets to 0.5mm
  • Drill out main jet to 1.32mm
  • Shim needles with 2-4 washers
  • Sync carbies
  • Fabricate frame mount for pod filter
  • Fit K&N pod filter
  • Buy/fit clip on handle bars
  • Fabricate mount for new speedo
  • Buy/fit new speedo (determine drive ratio first, think it's 2:1)
  • Fabricate mounts for lowering of headlight
  • Relocate fuse box from headlight shroud to underneath seat.
  • Modify top triple tree removing extra mounting lugs
  • Make 73mm fork spacers, fill forks with oil and re-assemble
  • Polish lower fork legs
  • Wet & dry upper fork tubes to remove rust
  • Fabricate mounts for front blinkers
  • Set fuel tank higher off frame at the back end so it's almost horizontal, fab new mounting for it
  • Cut existing wiring loom/make another simplified loom to tidy-up/minimalise wiring
  • Fabricate new battery housing and mount to rear subframe
  • Relocate battery to under the seat.
  • Add extra earth cables to frame (these bikes need them)
  • Modify rear subframe welding new support legs back to frame
  • Fabricate mounting plate for rear LED taillight assy & number plate holder
  • Fabricate mounts for rear blinkers
  • Fabricate/mold rear set pod from fibreglass
  • Fabricate seat and mounts
  • Cover seat with foam and fabric
  • Cut grind alloy frame support/peg mounts to remove spare hole
  • Get superbike footpegs and fabricate mounts to fit to frame
  • Rebuild front brake caliper
  • Fit new braider brake line and SS bleed nipple
  • Fabricate new exhaust pipes (2 into 1)
  • Fabricate new gear shift mechanism to suit new peg position
  • Fabricate new brake lever mechanism to suit new peg position
  • Strip paint off second fuel tank (1st one has too many big dents)
  • Apply rust remover and sealer treatment to inside of fuel tank
  • Paint tank, rear seat pod and headlight shroud
  • Paint switch blocks
  • Paint engine oil filler cap
  • Smooth and paint fuel filler cap
  • Polish rear shock air adjuster
  • Fabricate mount for air shock adjuster
  • Fabricate new mount for rectifier/regulator
  • Replace fuel lines
  • Fit new front brake lever
  • Refill engine oil
  • Refill final drive oil