New project under starters orders!

[north996]

Hi all,
I finally started my 748R build last night , the weather is so sheeeeite that I might as well get my bike fix by twirling some spanners in my garage rather than riding one in the piddling rain! Below are a few tasters of what's going to be included in the 'mix'. The motor is a 996 corse lump circa 147 at the rear wheel last time on dyno but that was with a very restrictive std airbox arrangement and a semi-sensible rev ceiling. It's now going to use a 'shower' type single injector set-up, all enclosed ala 748R (but the bodies are bored out to 54mm) so we'll see if this makes a difference. This is the reason I went for the 748R frame as it is the same configuration as the 'Foggy rep' otherwise known as the Kyalami frame with the lowered rear tube for the big airbox but much cheaper.
Chassis wise it's getting a 1098 ohlins front end inc monobloc Brembos, magnesium rear arm, ex-Reynolds rear Ohlins shock, corse billet rocker arm and BST carbon wheels.
Bodywork is all carbon - 996R side fairing panels/bellypan with a Casoli single headlight endurance top fairing, Corse carbon tank and seat unit all painted to perfection by Ray Ketchen.
Other bits of techno-porn are the Brembo brake and clutch masters, Translogic Dash, STM slipper clutch, carbon headlight holder and nearly forgot the full 60mm Akrapovic exhaust system!
It's taken me a couple of years to get it all together at reasonable prices but the other night I figured I had enough parts to get started, should be ready for Spring next year!!
Apologies in advance for the 'other' non-Italian bits on my shelf in the garage, my secret shame is that I'm into R1 Yams as well That's me out of the closet now and some derision is coming my way I fear!!

<a href="http://s439.photobucket.com/albums/qq111/chrisair1/?action=view&current=24052009329.jpg" target="_blank"><img src="http://i439.photobucket.com/albums/qq111/chrisair1/24052009329.jpg" border="0" alt="Photobucket"></a>

<a href="http://s439.photobucket.com/albums/qq111/chrisair1/?action=view&current=24052009336.jpg" target="_blank"><img src="http://i439.photobucket.com/albums/qq111/chrisair1/24052009336.jpg" border="0" alt="Photobucket"></a>

<a href="http://s439.photobucket.com/albums/qq111/chrisair1/?action=view&current=24052009338.jpg" target="_blank"><img src="http://i439.photobucket.com/albums/qq111/chrisair1/24052009338.jpg" border="0" alt="Photobucket"></a>

 

[bobsyeruncle]

some tasety looking kit there....should be awesome when finished. Just make sure you don't fit any R1 parts in error:lol2:

 

[north996]

Some progress!

Finally got a rolling chassis completed last night, should be a simple enough operation in theory but the reality of fitting a load of Corse parts to a street 748R frame is quite different!

Had to modify loads of bits but we're there now!

I've hung the bodywork on temporalily to see how she'll look (and to reinstate some of the enthusiasm that has been drained from me in getting the compatibiliy problems sorted out) but she's looking good, IMHO, and I'm raring to go again.

Front end (1098s front end, Galfer discs, BST wheel)

Rear end (Mag arm, Corse Ohlins, BST wheel)

next up is fitting the loom, changing from a P8 to a 1.6 for a twin to single injector conversion (going shower type) so the engine loom will have to be changed. Then Engine is complete all I have to do is fit some pretty dress-up bits (carbon belt covers, silicon hoses and Ti fasteners) and slot it into its new home.

Will update when there's more progress folks.

 

[marklwhittaker]

very very nice!!!

 

[Mach 1]

Looking brilliant m8, must be on line to be the lightest 748 ever!! :thumbs:

 

[drewV2]

Tyres are really dirty

 

[BruceCampbell]

Looks awsome!!!!

 

[bigchunk]

Its getting there mate!

 

[north996]

Tyres are really dirty

I had to leave the dirt on the tyres to stop it floating away

 

[drewV2]

I had to leave the dirt on the tyres to stop it floating away

ah - good thinking, It would never have occured to me , I would just have cleaned them then had to spend money on tying it down. seriously good looking though, some really nice stuff there

 

[north996]

ah - good thinking, It would never have occured to me , I would just have cleaned them then had to spend money on tying it down. seriously good looking though, some really nice stuff there

Cheers bud, the majority was bought from fleabay gathered over the last 3 years or so. I'm tight as fcuk so I don't part with my spondoolies easily unless it's a bargain

I think it'll stand me around 8.5k by the time she's done (not too bad when you consider that the mag-arm would have been 4 grand on it's own new!!! )

Started on the loom tonight - I never did like spagetti!

 

[north996]

Latest update

Latest update!

She's coming along fine, the story so far,

Highs:
Finishing mods for mag arm final fitment
Fitted GBM rear race calliper
Found a rear hugger that’ll fit mag arm with minimal mods - a nice Harris item.
Fitted Marelli dash
Fitted carbon headlight holder
Modded headlights for single ‘endurance’ look fairing
Fitted Engine to frame
Completing mods and fitting 1098S front end
Fitted Brembo brake and clutch master cylinders
Mounting twin Brembo reservoirs on the top yoke ala ‘Moto GP’ style! (not in pics)
Got all the parts for the 748R injectors/airbox conversion together - cheers Eddie!
Matched 748R inlet rubbers to 996 Corse engine
Trial fit of carbon tank - clears the overhead injector assembly fine - phew….!
Modded 748R airbox for oversize Corse air tubes
Ordered airbox entry filters from Australia - suitable for big air tubes (allegedly!)
Ordered 748R coils
Fitted wiring loom.

Lows:
Realising that I have to machine the mag arm again after I’ve had it Alodined and painted.
Not ‘computing’ that ‘Mag arm = 19mm longer = original nearly new chain too short’
Realising that bigger mag arm needs a tiny AP calliper at £500+, so modded arm for a GBM item.
Remembering that fitting engine on your own is still a frustrating task despite buying an allegedly super-dooper engine cradle!
Damaging powder coating on frame when crappy cradle tilts over
Despite getting all the major assemblies for the overhead injector conversion for a good price, putting all the niff-naff and trivia parts together removes £260 from my toy-fund.
Finding out the 748R has special coil mounts for the lowered rear frame rail and then passing out after hearing they’re £50+ each (for a flat plate of metal)!! Got a pair of complete 748R coils on the ‘bay for £44 
Finding out that the lovely satin black engine cases I have had saved for this project for ages are not compatible with the Corse engine so I’ll have to get the existing ones refinished.


Current show stoppers are:
Waiting for coils to arrive so final fit of 748R airbox can commence.
Waiting for engine cases to be done.

Pics below

http://i439.photobucket.com/albums/qq111/chrisair1/DSC04755Medium.jpg

Next instalment after Christmas, I've got a hell of a busy January so I'll have to pretty much finish her over the festivities (if I can stay sober long enough!)

Till next time folks....................Chris

 

[Chiz]

Stunning.
Cannot wait to see it finished & polished up.

 

[brian91cfr]

Very nice project, whats the problem with the mag/arm and the
rear brake is the standard caliper to big ?.

brian.

 

[north996]

Very nice project, whats the problem with the mag/arm and the
rear brake is the standard caliper to big ?.

brian.

Hi Brian, the Mag arm is alot broader than the std item, where a std item has a 'wrist' at the point where the hub section tapers down to a narrower beam section, the Mag arm doesn't taper at all, it stays the same breadth as the hub along it's length.

The problem arises from the chain adjustment using the eccentric action, the picture in my post is of the hub at it's lowest point with no chain fitted so there is a lot of room between hub and caliper. After the chain is fitted and some of the adjustment is taken up, the caliper will naturally move inwards towards the hub due to the eccentric action, but there is not enough room to adjust the chain on the eccentric hub with a std caliper fitted. The Caliper just abutts the arm before the correct tension is reached. Even with the GBM item fitted (a good bit smaller than the std Brembo) I had to machine a notch in the casting to allow the caliper to clear during chain adjustment.

The other problem was with the billet rocker arm you need to fit to maintain the correct suspension ratio. The one I got was from a factory RS which has a lot more meat on it than the item you get with the road bike mag arm kit but the RS has a different frame with more space in this area so I had to make a template and machine it a little for full clearance through full travel in the 748R frame.

Sounds like a pain in the ass! but to me, dealing with all these wee hurdles is what I love about building a 'special' or 'bitsa'

 

[north996]

Woohoo!!

After 10 months of 'challenges - various' with the 748R9961098 hybrid 'thingy'........she's nearly ready!

I've just got to pick up a pair of RS airtubes from a buddy and plop them in, then MOT time!

(Which incidentally is a complete pain in the ass when you have a Corse coolant header tank fitted as it sits right over the frame number )

Here's a taster, I'll take the time to post a load more pics and a final spec later in the week.

Later peeps.................Chris

 

[990Glen]

Looks mint mate. Some serious hours gone into that. Kudos.
Would love to have both the time and dedication to try a project like that.
Only managed a few supermotos up to now. Nothing this involved.

 

[north996]

Latest update,

Project 748R/996/1098 Desmo'hybrid'thingy moves under it's own steam!

Don't cheer quite yet, I managed 600 yards from my garage en-route to Eddies for it's first MOTand got taken out by a myopic old c**t (a word I hate and only use in anger but this old gipper fully deserves it!) in an ancient Fiesta.

He came barrelling out of a side street 15 feet in front of me and down I went trying to avoid him. He didn't see me at all and is probably completely unaware that I was sliding along the road behind him! At one stage the front wheel of the bike was underneath the car as we went along and the 'Fiesta' badge was about 18" from my visor.
He carried on oblivious to the carnage left behind, I jumped up with intention of giving chase but one of my sooper-rare Corse carbon clip-ons was buggered.

Called Police who helpfully informed me that it would have been better off for me to have hit him as then it's a more serious (and provable) incident apparently!

Managed to get bike back to garage and survey damage:

Carbon 998R side panel scuffed to hell and worn through in places
Carbon Casoli seat unit scuffed
ValterMoto rearset snapped
Corse carbon clip-on broken
Brembo brake lever bent
Mirror scuffed
Hoping that my carbon headlight housing is ok but fairing mount is suspiciously wobbly (fingers crossed it's just loosened in the impact!)
Dainese jacket sleeve logo now reads Du.....ati!

Knee black and blue!

Not too bad in retrospect as 2 seconds later I'd have had my whole left side taken out! Bloody annoying all the same as it'd taken 18 months to get this far.

Called Ray the painter today and he's going to try and place his healing hands on the panel unless I can source another 996R or 998R item from somewhere?

Will keep you updated if I ever get the thing to Eddies!!

Chris

 

[Pict]

Absolutely gutted for you

 

[CJK]

Sickening Chris

 

[Chiz]

@@@@ing hell. Gutted for you matey.. I know how you feel lying by your pride & joy & knowing its going to cost you time & effort to get it sorted.

 

[miloVanMultistrada]

It's bad enough dropping a 'normal' bike due to someone else, but when you've poured so much time and effort into it, it must be sickening . Hope you can get the bike sorted quick and your injuries get healed quicker.

 

[bobsyeruncle]

Sh!t!

Sorry to hear this mate.
I take it there were no witnesses?

 

[north996]

Sh!t!

Sorry to hear this mate.
I take it there were no witnesses?

Nope

Quiet back street in Edinburgh unfortunately.

 

[davief155]

bummer mate sorry to here this

bike looks amazing aswell

 

[monster_998]

Nope

Quiet back street in Edinburgh unfortunately.

Unbelievable, the old codger is still free to take out someone else Did the polis even speak to him or is he still completely unaware of the carnage he's caused?

Gutted for you, especially after all the work you put in. Hope you can get it fixed and on the road soon.

 

[PaulV]

FFS ....... Really don't know what to say....good luck with all the remedial work to get it back to it stunning best again.

 

[mbg]

I'm so sorry to hear this after following the rebuild from the start. Hope you will soon be on your way again for that MOT.

 

[Steviec]

Bad luck mate hope you get all sorted soon .bike looked mint & will do again

 

[molenz]

@@@@ man,
I wish you well, a good recovery.
I can't imagine after that work
But as you say it could have been you
Better luck and take care man
Molenz.