OzVMX Forum
Marque Remarks => Suzuki => Topic started by: Barra on February 09, 2013, 09:48:51 pm
-
Hi all,
as promised in my intro here's some picks of my beloved custom. As I explained it's not a true VMX resto I suppose, but it generates a lot of interest wherever she goes so that'll do me!
It's the bike I couldn't buy - one with the works that would do everything! Started in 1996. I was looking for the best chassis with the best motor that would fit all my pre prerequisites - MX, grasstrack, trail, hillclimb - even have motard wheels for her but not finished yet!
It is a '80 PE 400 shoehorned into a 1991 RM 125 with a few custom bits thrown in. The result I am really happy with. Doesn't do a thing wrong, handles like an arrow, roosts and vibrates!
I searched for several years to get just 'the right' bike and motor (best handling, weight, suspension, grunt, simplicity etc). Lucked upon a rolling chassis RM 125 and the PE was well, err . . . a primo one owner PE 400 with only 900 clicks that had been lent up against a shed wall all its life! Some will call it sacrilegious but I was just rapt to find the motor I was looking for and so proceeded to rip it out and begin my project :o :o ::) ::). The complete PE rolling chassis was picked up by some lucky bugger whom I cant remember the name - maybe he is on here somewhere???
I call it RE as its 1/2 RM and 1/2 PE, plus because it is a bit of an ongoing experiment it also stands for Retro Experimental! The 405 is again because its 1/2 400 and and 1/2 125! You will see it's got a few "funny' bits plus some you can't see. 'Plastics' are custom fibreglass. Suspension has been lowered 30mm and set up plushhh! (for old bones). The motor was totally stripped and only needed rings and rubber bits (seals) as everything else was like new! The barrel has been cleaned up somewhat ;), compression bumped up and ignition advanced a touch. Usually these mods go against the grain with these motors as they detonate easily, but she goes clean and hard! Have to run avgas though.
(http://[img width=800 height=600]http://i1308.photobucket.com/albums/s612/Barra11/Enduro_front_zpsb14ee09f.jpg
[img width=800 height=600]http://i1308.photobucket.com/albums/s612/Barra11/Enduro_rear_zpsc6ea93f3.jpg)
(http://i1308.photobucket.com/albums/s612/Barra11/Zorxt_closeup_zps899da255.jpg)
(http://i1308.photobucket.com/albums/s612/Barra11/Engine_rh_zpsb08e8aa2.jpg)
(http://i1308.photobucket.com/albums/s612/Barra11/Clutch_handlebar_zps2b85c345.jpg)
(http://i1308.photobucket.com/albums/s612/Barra11/Rhside_zps1f4bb1c7.jpg)
(http://i1308.photobucket.com/albums/s612/Barra11/Frdisk_zps411ac72f.jpg)
(http://i1308.photobucket.com/albums/s612/Barra11/Engine_lh_zps3c172188.jpg)
(http://i1308.photobucket.com/albums/s612/Barra11/Lhfront_angle_zps48ad301f.jpg)
(http://i1308.photobucket.com/albums/s612/Barra11/Above1_zpsb0f58ee5.png)
(http://i1308.photobucket.com/albums/s612/Barra11/LowriderturnRE405_zps9b1e2f47.jpg)[/img]
-
Two more! (i hope) photos not downloading . . .
http://i1308.photobucket.com/albums/s612/Barra11/Enduro_front_zpsb14ee09f.jpg[/img]
(http://i1308.photobucket.com/albums/s612/Barra11/Enduro_rear_zpsc6ea93f3.jpg)](http://i1308.photobucket.com/albums/s612/Barra11/Enduro_front_zpsb14ee09f.jpg)
(http://[img width=800 height=600)
-
I saw this bike at the last Classic Dirt at Barrabool and I must have spent as least an hour looking at it. The more I looked the more I liked.
I was (and still am) very impressed.
-
Great to see something a little different. Not keen on that shade of yellow but that tank looks like a work of art. Well done on a great project.
-
What a great bike, well done.
-
Just fantastic, a TRUE WORKS BIKE, hand made and one off, just amazing, we need more lateral thinkers like you mate, please please bring it to Classic Dirt in New South this year, I MUST SEE it in person. Sort of reminds me of one of the ATK from early 90's in looks, i'd like to do something similar using '84 125 with 400 PE engine, lowered is the go, nimble in the bush and low c of g for good mx starts, just lovely!
Kt
-
For someone who's generally a bit anal about everything being period correct, I really like this! ;D
I can appreciate the work that's gone into it and love how you've genuinely made something 'your own'.
Excellent!!
-
Just my kind of stuff. Amazing job on the tank.
-
I'm not into monos but that is fantastic! Wish I had half yr skill.
-
Thats just Faarrrrrkeeeennnnn cool 8) 8) 8) 8) 8) 8) 8)
-
That is awesome what clutch kit did you use? I have been thinking of putting one on my 400 I found that the standard 400 frame handles well enough that is why my project is pretty much all PE apart from the 84 cr250 front end.
Here is a pic of mine I have a 38mm mikuni flatslide that I have used on my other 400's and it was a big improvement over the stock carb. I also have a different ignition for the bike it is a powerdynamo unit so I have 12v lighting and get rid of the old cdi setup, I am also down Geelong way.
(http://i656.photobucket.com/albums/uu283/frostype400/D49A97EF-2CFC-41B5-8555-E7E6D8B44614-5459-0000120234F398F9_zpse23222bc.jpg)
-
It's also exactly the reason we need a 20 year rolling cut off in my opinion, it could be the first entry for Pre '95!
There should also be a rule for home builds that they have to be ridden by all of us, one of the nicest concepts i have seen, a bit out of the ordinary, maybe a "bastard bike" category is needed? AND if this is a "bastard bike" i want one!
Kt.
-
While normally this sort of bike goes against the grain for me i have to congratulate you on a great job .
You have managed to make it look right in every way 8)
Bloody well done it looks awesome :)
-
i like this bike to but love the suzuki s in the front rotor
-
"Just my kind of stuff. Amazing job on the tank"
Yeah thanks, the tank was a bit of challenge, never done anything like that before. My trade is woodgrubb builder but also an ex farmboy and my old man was a mechanic and my brother a fitter and turner so i've picked up a bit over the years. I also like to think I have a bit of mad inventer in me!
The tank is made from 2mm thick plate and has baffles inside to stop the fuel load surging around (I get ribbed over that one but it indicates how many hours was spent on this bike just standing there dreaming up cool ideas!).
To build it I started off by making a sheet metal template that would form the 'U' shape under section of the tank (like a big taco shell wrapped over the frame backbone). After mounting that onto the frame I simply wrapped the the whole lot with glad wrap and proceeded to spray on expanding foam till it was built up into a big blob (very technical stuff) ::) Then it was time to get the rasp out (maybe my woodgrubb skills helped here) and keep rasping till is was happy :P :o with the shape, making sure the seat fitted, full lock steering clearance was ok etc.
As I'm not even a sniff of a panel beaters peener; crucial to being able to achieve building this thing was that I knew it had to be formed from folded flat plate, there was no panel beating involved at all. Otherwise I couldn't have ever done it. All curves are one dimensional (but I did manage to get a bit of contour into the sides).
At the foam model stage I could see the physical finished shape so I could feel confident about the finished product being just right. Then the fun began with creating the metal work. The foam didn't have much strength but it was firm enough to fold 0.6mm aluminium plate over to form templates, which I trimmed to exact size. After making all the folded templates I flattened them out again and did the whole thing over again laying them out on the 2mm plate and cutting each panel to exact size. To achieve the correct curves I applied a range of bush mechanic skills involving experimenting rolling alloy sheet around various size oil barrels, blocks of 4x2 in vices, rubber mallets and ropes! ???
After a month or so of rooting around I ended up with a pile of funny shaped folded bits and pieces which were ready to weld together. Dad helped me turn up the threaded fuel cap fitting (those hoseless Acerbis fuel caps are the best!), sorted out the fuel tap mounts (reserve tap), made up a couple of 90 degree tube fittings for the fuel level sight gauge and all was ready!
I wanted the welding to be schmick, so I enlisted Gareth from B&B in Ballarat to stitch it all together for me. He did the whole lot in one hit on a saturday morning in between serving customers. I was rapt! I drove to Ballarat with a box of jigsaw pieces and came home with a brand new fuel tank! Boy what a relief when it fitted on perfectly!
Finished it off with some home made graphics. I got inspiration from early Yamaha logo, can't think which model it was? The Suzuki "S" I had to draw/replicate on my 'puter and then got a signwriter mate to cut it out. The rest is pretty basic really, just hand cut signwriter vinyl all covered with a thick clear protection layer, but the finished thing makes me happy :P :D
-
I have to agree that the bike is very well done and looks just right. What's the go with the gearshift shaft looking like it is located at the centre of the swingarm pivot bolt ? (Edit): Had another look and noticed the linkage down to the gearshift shaft.
-
i like this bike to but love the suzuki s in the front rotor
Both rotors are like that and lazer cut from bisalloy and then surface ground to 4mm thick. Front is 280mm. I have a heap of rejects laying around in the shed when I was experimenting (there's that word again) with different thicknesses and different grades of stainless steel etc., but settled on the bisalloy as it stays true under heat, has good adhesion (brakes are magic, as good as any modern!) resistant to rust.
As I already had the Suzuki "S" in my 'puter it was easy to give it to the lazer guys for them to program in. My discs are on file, if I ever need more I just have to go to them and say "cut me another one please".
Like the tank, my brakes also make me happy :o :P
-
I have to agree that the bike is very well done and looks just right. What's the go with the gearshift shaft looking like it is located at the centre of the swingarm pivot bolt ? (Edit): Had another look and noticed the linkage down to the gearshift shaft.
That was one of the very few compromises I had to make on the bike after it was built - but as it turned out I think it was an improvement.
Because the motor and frame were never made for each other, the footpeg position in relation to the gear shaft were way out of whack. The gear lever was standing uphill about 30 degrees and shifting gears was a bitch (getting false neutrals) as the gear lever in effect was rotating up and back (very awkward).
This required another standing and thinking session, with more ideas coming with each can of creativity stimulent. The idea of using the centre of the swingarm axle came to me when trying to work out a way of having the gear lever running parallel with my foot. I thought if the lever moved 'up' instead of 'backwards' it would make for easy upshifting. The pivot for the gear lever is pretty much in line with my ankle making for a nice 'parallelagram' type action. There is an adjustable linkage going down to a shortened gear lever to complete the set up.
This version is a bit rudimentory. I had to keep the pivot bolt small in diameter as didn't want to weaken the actual swingarm axle. Had no probs at all so far. I'd like to do another one using nicer materials. But it does work much better now like it should.
-
Interesting concept....a sweet lookin thang 8)
Did you do any weighing in :P
http://ozvmx.com/community/index.php?topic=14970.0
-
Outstanding Barra what a labour of love. I have been mulling over building a bastard bike for a while. You may have inspired me to get cracking. Again well done! Cheers Jerry PS Not taking it up to the Broadford Bonanza by any chance?
-
Who made up your pipe? did a nice job. Just looking again at the pics looking side on with that tank the bike is very WR500 like.
-
That is awesome what clutch kit did you use?
Frosty it's a Hebo unit supplied by a Trials supplier in Geelong. It was around $350 15 years ago. There are other brands available nowdays.
I couldn't believe how good it operates. Fits any cable clutch bike. Fully adjustable. Light as a feather, good take up and snicks into gear when cold with no drag! Perfect! One of the best things on the bike.
(http://[IMG]http://i1308.photobucket.com/albums/s612/Barra11/DSCN2534_zpsa21a713c.jpg) (http://i1308.photobucket.com/albums/s612/Barra11/DSCN2536_zpsa760f8b8.jpg) (http://i1308.photobucket.com/albums/s612/Barra11/DSCN2530_zpsf9a8f17a.jpg) (http://i1308.photobucket.com/albums/s612/Barra11/DSCN2529_zps3a0afed0.jpg)[/img]
(http://[IMG]http://i1308.photobucket.com/albums/s612/Barra11/DSCN2534_zpsa21a713c.jpg)[/img]
-
I love posting pictures . . . not. Last try.
(http://[IMG]http://i1308.photobucket.com/albums/s612/Barra11/DSCN2534_zpsa21a713c.jpg)[/img]
-
More power to ya Barra, creating a bike that's unique, neatly constructed and thought out and above everything functional. Bikes like this just rile those who don't get it which is yet another good reason for its very existence. Congratulations on the tank too mate....I'm a tig welder by trade and I'd be a bit hesitant of building something that complex.
BELOW: The sticker that's going on all of my hot rod bikes this season....it kinda fits this neat "dare to be different" little Suzuki too.
(http://i1112.photobucket.com/albums/k495/firko2/sticker_zps82f6a8ad.jpg)
-
Sweet ride Barra 8)
-
Who made up your pipe? did a nice job. Just looking again at the pics looking side on with that tank the bike is very WR500 like.
Thanks Maicoman. Its actually standard PE right up till the beginning of the reverse taper cone going into the stinger (PE pipe crossed over from that point but with my frame it had to keep going straight). I made the back end of the pipe including the muffler which is carbon case with stainless internals. Muffler graphics came about because my son Tom at that stage was just learning to talk and couldn't say "exhaust" so we used his word - "Zorxt pipe"!
I tarted the pipe up a bit by re welding all the seams (to get rid of the daggy jap welds) and coated the header with that cool HPC caoting used on dragsters etc. Stops the rust too. I did rip the standard perforated baffling out of the chamber as the inside diameter was so small like a torquer pipe, nothing like the RM 400's big chamber. Dont know if it helped any though as couldn't compare the two. I don't mind the slim pipe though, it fits in nice and snug.
BELOW: The sticker that's going on all of my hot rod bikes this season....it kinda fits this neat "dare to be different" little Suzuki too.
Like it!
-
Love your attitude Barra. Any other projects in the pipeline? J
-
Unfortunately no Jerry as all my time getting used / wasted still trying to stop an icon venue going down the gurgler. But that's another story for another day . . . . . . .
Would like to do something similar one day with a road going twin of some sort though! Then I can rumble off into the distance far away from the knobheads. :o
-
Thanks for the clutch info I will get one I was wondering how it would go if you have ridden with the standard setup the clutch pull is fairly hard.
I was considering doing what you did using another roller because I have other motors but then the one I have came up on eBay it is a 1980 model with a 84 cr250 front end it just saved me trying to modify another frame etc to fit.
I have a 98 husky wr360 but I prefer my PE400's once my current one is done it will replace the husky and I will just keep that regeod as a spare bike, thanks Michael.
-
I saw this bike at the last Classic Dirt at Barrabool and I must have spent as least an hour looking at it. The more I looked the more I liked.
I was (and still am) very impressed.
I must have been standing next to you Brent... I still have the pics from that day. It's a beauty!!!
If Suzuki would build it I reckon they would sell heaps of them. Who needs a bloody expensive, fragile 4-stroke... :D
-
all my time getting used / wasted still trying to stop an icon venue going down the gurgler. But that's another story for another day
Barra.....Barrabool? Lots of luck, that place deserves to remain as the best motocross track in the land.
-
I saw this bike at the last Classic Dirt at Barrabool and I must have spent as least an hour looking at it. The more I looked the more I liked.
I was (and still am) very impressed.
I must have been standing next to you Brent... I still have the pics from that day. It's a beauty!!!
If Suzuki would build it I reckon they would sell heaps of them. Who needs a bloody expensive, fragile 4-stroke... :D
The manufacturers do, if they were relying on selling engine parts for the 2 strokes they'd all be out of business ::)