GWS SPECIAL RT Build

2019-06-16T17:08:00.000+01:00

Some of the GRP alongside a part painted with Crystic primecoat and sanded back as a comparison.

I am very happy with the results so far and will be using this method on all of the GRP parts.

It's time consuming but satisfying when the work starts to pay off.

Bodywork Development

2019-05-06T11:57:00.000+01:00

Before I explain how I've done the bodywork I must also explain that due to lack of space and money open moulding is the only option open to me to complete the work.

The bodywork on the trike is GRP over foam formers. After much trial and error I finally decided to do it as follows. I used ply and foam to make the body panels up. When the former is sanded to it's final shape I let it rest for a few days and then cover it with aluminium tape

I then lay up the resin and matting over the former. usually two layers and allow it to cure for 12 hours. I then carefully 'pop' the GRP off the former. Any more than two layers it can crack, any less and it flops and won't hold shape while you back it out.

For large flat panels I laid 3mm core mat out on a flat surface and added resin. Once cured it's easy to mark out your panels and cut it with a slitting disk or hack saw blade in a jig saw.

I used bits of ducting to make formers for the side ducts, again covered in foil tape. Once they were off the former I uses screws and GRP paste to bond them to the sides. Once skinned over with a couple of layers of GRP the screws are removed.

As you can see I used the same method to build the dash binnacle and other body panels.
Even the dash panel is made to suit the job .

The front indicators are from the rear end of a VFR 750. I used the body panels as moulds and then trimmed the indicator pods to suit. I'm pleased with the results too and think it gives the trike a little more ' Grumpy'. When viewed from the front it can look a little angry.

The rear light pods are made up using cardboard tube taped together and then covered in GRP, the single pods are made the same way.

Obviously open moulding can mean a lot of filling and sanding but if you take a bit of time and make sure you spend the time working the matting and resin you can get a decent flat finish without having too much filler work. The last picture is of the front end after an hour or so of blocking with 40 grit and then gently flatting it with 40 grit pads on my sander.

Once the panels are flattened off properly I'll be paining them with two pack filler primer before flatting back for paint prep.

Walk around pictures

2018-07-02T11:59:00.000+01:00

I've had the trike back out to take pictures from a few different angles so I can use them to look at the lines on the trike.

I'll print a few off and borrow the wife's crayons (yes she has her own crayons) and do a bit of doodling to see what looks best before I do much more in respect of body panels.

Moving along

2018-07-01T22:24:00.000+01:00

As you can see its back on it's wheels again. I've been working on the bodywork on and off while other jobs are either waiting for parts or for engineering jobs that are outstanding.

As you can see I've decided to lose the bike plastics and subframe. I think I can make it a lot neater so it looks less like a bike rammed up a go karts bum.

Hand brake caliper.

As you can see the hand brake mount and caliper are now fitted on the custom made steady. We just have the cable to sort and the original rear caliper.

2017-11-06T22:54:00.000+00:00

Kliktronic Unit Mounting

I'm using a Kliktronic Gear Shift along with the paddle set in my earlier posts. Once James and I had figured the hole centres for the clamp mounting out it was a simple job to fabricate one from some 30x5 mm flat bar.

We then used a gear lever from a VFR 750 F and the rose joint from the ST welded together to sort the linkage out between the Klikktronic and the input shaft. Simple engineering, simple solutions.

I need to get some decent bolts for the mounting, the ones in the picture are just some I had in the garage. I'm almost ready to modify the rear plastics to accomodate the diagonals to the bike frame. The rear end should be done in the next few days health permitting.

2017-10-02T13:15:00.000+01:00

Steering wheel set up.

My steering wheel fitted with Kliktronic paddles, a button for the horn and a switch for the indicators.

I still have to get a high/low beam switch fitted with a new cable and socket to accomodate all of the switch gear I need on the wheel.

With the back injury the less I have to reach for switches etc will make it a lot easier to ber safe without causing any additional discomfort and allow me to have as much pain free fun as possible.

2017-09-25T03:56:00.003+01:00

My previous trike builds.

The first a little reliant I built with a mate, I learned a lot putting this together.

My gorgeous GSXR 750 WP, I rebuilt this bike after getting it from a mate in a very sorry state.

I had John Weaver build a trike back end for it when I couldn't ride it anymore.

It ruined a perfectly good sportsbike and turned it into a beast of a trike.

Eventually I had to give up riding with handle bars due to a back injury and thats what inspired the RT build.

2017-09-25T03:39:00.002+01:00

Dutton 1600 Mexico.

I still miss this little car. Rough as, but so much fun to drive. 100 bhp and a live axle makes for some interesting handling in the twisty bits.

If my trike is anything like as much fun to own and drive I'll be over the moon.

2017-09-24T17:09:00.000+01:00

Various stages of the chassis build.

You may notice some pictures with a rough CBR 600 that when sold on almost covered the cost of the 955i and sold for twice what it had cost me. The parts that i am not using from the 955i will also be sold eventually to recoup some of my outlay.

The 955i clocks have now been upgraded to a Koso Digital dash

2017-09-24T16:52:00.000+01:00

Bits and bobs.

Some of the parts I'm using on the trike.

Escort Mk V Steering column

Locost Wishbone kit

Wilwood Brake kit

Rally Design alloy Uprights with stainless top hats

2rike seats and headrests

Momo wheel with quick release and Kliktronic paddles and switch gear.

2017-09-22T14:17:00.000+01:00

Chassis Build Pictures

It's constructed from 25mm box section , 32mm tube and various thicknesses of steel plate.

I used Lowcost plans for the front suspension and mounting points. The alloy uprights, spindles, Gaz shocks and the Wilwood calipers are from Rally Design https://www.rallydesign.co.uk .

You can see the rest of the chassis in the following pictures. My mate James who has done the bulk of the welding is trying it for size. The roll over hoops are from a Porsche, it's cut and shut to suit.

The 955i was an absolute bargain for £450-00, it's a runner and sounds sweet. it'll sound great with the can I have in mind for it.

I'll be posting a few more pictures over the weekend with some more information about the parts i'm using, why i'm using them and the adventures with foam and GRP.
Two years in and about half way done.

2017-09-21T12:49:00.000+01:00

GRP over Foam.

I'm using GRP over foam to sculpt the front end bodywork on the trike.

It's a lot of work and takes ages but without the space to make moulds and store them I have little choice.

Once I am happy with the shape and it is glassed over the foam on the inside will be removed and sanded down to about 5mm and a layer of grp will be added to encapsulate the foam completely.

As you can see there is a lot to do as yet but I am hoping for a Spring 2018 debut for the trike and can't wait to get out and have some fun.

2017-04-18T18:08:00.001+01:00

I've not blogged for a bit but now my new trike project is about half way done i thought i'd add some pictures.

Over the next few weeks the trike will have the chassis painted and it will be put back on a set of wheels so we can get the cockpit and seats kitted out. I have all of the brake lines and a hand brake to sort out along with the clutch slave cylinder and fittings to buy as yet but once that is done I'll be doing a track session to see how it runs and handles.

Once that is all sorted it'll be time to sort a body shell out and get the lighting sorted as well as the mirrors.

HONDA VF-SRAD 750

2015-06-25T23:17:00.000+01:00

The VFR as it arrived at my shed, It's 25 years old, the plastics are all knackered at the rear end as is the left hand fairing panel but I have a few bits and bobs lying about so it'll be getting the treatment.

Standard is not something I can be comfortable with anyway so having to do the work is not really an issue

It's a bit crusty under the plastics but apart from the engine cases the corrosion isn't as bad as I first thought so I may just leave the engine in for now. The carbs need a good clean and it needs wheel bearings, tyres, chain and sprockets brake lines and pads and a lick of paint once the rear of the bike is finished off.

I've used a sub frame from a SRAD 750 and the plastics, I've also used some of the original Honda plastics and the two will be bonded together to create a new rear end for a single seat set up. This is not going to be used on the road much and will never carry a pillion while I own it. I have a trike project on the go for everyday use and the bike will be trotted out on one or two occasions a year.

I'll be adding to this blog regularly from now on and will also be linking my sound cloud account to it to link to pod-casts and the odd video.

Tomorrow I'll be getting more glass laid down so I can get it all dry before preparing for paint and a shine!

Rock on!

2015-01-08T12:37:00.002+00:00

https://www.facebook.com/MikeAustinsZX12R

Going Drag Racing!

Life after disaster?

2014-11-02T17:23:00.001+00:00

It's been a while.
Personal stuff and my health have been slowing me down but this week it changes.

I have a new ( to me ) lathe and mill arriving and the garage is almost set up for whatever Mikey and I decide to do in 2015.

Theres talk of drag racing, Mikey and I recently went to Blackpool to buy a ZX12 R for him to race. I'll be doing logistics and spannering on the bike. I'm not well enough to race so it's the next best thing as far as that's concerned.

Have a splendid week one and all

Getting stuff stripped down ready to clean and paint

2014-03-27T00:25:00.000+00:00

Been at it for a bit again today. Slow going , the fibro and sciatica are kicking my arse at the moment!

I've stripped out the front end and have a bit to do to get them ready to refinish. I have to get new top stanchion guides and I'm replacing the seals and dust covers. I could do with new stanchions but the pitting is not going to affect the stroke as it all seems to be at the top between the clamps.

It's almost stripped down to the bare bones now. I used to be able to pull a bike apart in a day, not as quick these days, I'm already into week two but It's coming apart nicely apart from some really seized swing arm pivots. I'm getting some new ones turned up and drilled for pulling when I need to lubricate them.

I had to drill the centre of the pivot for a 6 mm bolt, the one Kawasaki put in when they built it was off centre and only a 4 mm thread. The 4 mm bolts were just not up to the job so I did it my way. Which worked first time on both sides.

Home made puller from a bit of plate and a 6 mm bolt

The bike lift has made life so much easier and whoever had the bike in bits last did a decent job of making sure all the bolts would come out easy enough by putting a dollop of copper ease on most of them. Obviously some have thread lock on them to stop them vibrating lose but only the ones that need it.

I still need to remove the cooling system and get the carbs and air box off so I can get the engine out on the deck to start preparing it for a refurbish and paint. The frame is getting the same treatment before I start to put it all back together.

I need a few days away from it now to rest up and have a think about the rear axle. I could go the IRS route but it would mean two jigs for the wishbones and be a bit pricey so I'm going for the beam axle type that uses the swing arm pivot as a starting point to sort the rear axle out. I'll use slightly uprated shocks on the rear using the original mounting points.

I'm waiting on axle parts and will post pictures as soon as we have them. 20 years ago this would have taken me six weeks, I'll be happy if it's almost done in six months but next year should be all about riding it and less time in the shed!

More as it happens :-)

Buggering About With Bearings.

2014-03-24T01:46:00.002+00:00

I've had a manic few days with one thing or another so imagine my frustration at coming across the first seized bits on the strip down.

The swing arm pivots were stuck more than a very stuck thing. They are drilled an tapped by the factory but it's done off centre and only for a 4 mm bolt to go in.
The idea being that you'd bung a bolt in and pull the bearing out. I've had to drill and tap the centre for a 6 mm bolt and use a drilled steel plate to make a simple puller.

A bit of heat and a tap with the hammer before the application of a bit of brute force with a socket had the bugger out first go. I'll have to get a new set of bearings, the old ones are totally knackered but it's a small thing and on a bike this old I'm surprised I've not had a few more be a problem.

You can see the hole that the factory did and see how it being off centre may cause issues when trying to pull the bearing. I drilled it in the middle so that it didn't pull from one side and out she came.

Kay and I then spent some time cutting some steel to make a cradle for the bottom frame rails to bolt to the new hydraulic lift that my eldest daughter and her boyfriend bought me to save my knees and back.
Crawling around on a floor with my arthritis and nerve damage in my back is never fun and working at the correct height for me will solve a few issues and mean I hurt less after a shed session.

Kay got stuck in with the chop saw today and enjoyed it. She's really getting into building again and is saving to get the bits for her Baby Bobber sorted out so she can get it finished.

The Baby and her Bobber , I can't wait to get this done for her but she has to save and get some parts for it.

I'll grab some pictures of the new lift and the bearings tomorrow and update my blog later on.

More to come, it may take time but at my age I can't be arsed with rushing and think I may have finally learnt a bit of patience.

Rock on!

All Change At The Mad House.

2014-03-20T23:36:00.002+00:00

I've managed to secure a Kawasaki VN 750 shaftie at the right price and given that I've not had a ride for six years this year I've decided to put the RT project on hold and do a simple conversion on the VN with a swing arm type rear end. I can't do the RT to the standard I'd be happy with at the moment so will look at that once this is finished. It's not been abandoned, just delayed.

I've started to strip the bike down and will be going all the way so to speak. The bike has been laid up for a fair bit and the last time it was started was November 2013. Most of the work will be cosmetic apart from the back end and adaptions.
I just think it makes sense to change the wheel bearings, the corroded fixing and it definitely makes sense to clean and paint both the frame and engine. The exhaust is going to be wrapped so won't need too much work apart from being shortened about 4" to allow for the axle centre being in the same place as the bike running gear.

Happily up to now none of the bolts have stripped or snapped and I'm leaving things soaking a bit of WD into them overnight. Happily some of them still have copper ease on them and have been a doddle to deal with. I'm looking for an axle now , I have most of the steel needed for the rear end and rack so I have a lot to be getting on with while I save a bit of cash up.

It may mean less partying for a little while but once it's done the missus and I will be out and about as often as we can.

Jethro's been in occasionally to keep the blocks of wood in the garage company and to give me the odd sympathetic look and lick. The last picture is where I'm up to so far. Next time I have a go I'll be stripping the loom and cables and drop the fluids in preparation for dropping the engine for paint.

Watch this space ;-)

Rethink Time.

2014-02-11T15:20:00.001+00:00

I've decided to have another look at the chassis.
It's going to be way too heavy for the job I have in mind. I'm going to use what steel I have to improve the storage in the shed and then start again with some steel tube for the bulkheads, it'll look a lot tidier too.

More when it warms up and I can do a bit more than two minutes in the freezer.

Note to self, if you ever buy another garage ,DO NOT buy a steel one!

Slow Down.

2014-01-19T12:26:00.000+00:00

Just to update this blog.

I've not given up I'm just having to deal with some other stuff at the moment and will be back at it in the spring with a major re-design and better running gear.

Regular updates will resume in the spring!

Crazy days!

2013-10-22T12:28:00.000+01:00

On Friday the 11 October at about 1pm my mate Alan had a stroke in the garage while we were working on the trike. Happily I realised what was going on and got him an ambulance immediatly. Just over a week since his stroke Al is making a good recovery and has already been able to walk a short distance so I'm hopeful he makes a full recovery. It's a bit crap without his company in the shed but I've muddled on all the same.

As ever the lack of money has slowed me down, I'm waiting for some more 2x2 box to finish off the passenger side rails but I've managed to start in on the seat mountings, the tunnel for the gear shift lever and handbrake and the top dash rail.

I've got all the wheels now too, I'll sort some pictures of those next time I venture into the shed.
My mate Mick who sorted the box section out also delivered what his works deems as scrap. About 30kg of decent enough bits and bobs for engine and swing arm mounts, setbelt mounting points and a fair bit of gusseting and bracketery of all descriptions so it's not like I'll be bored but I'm hopeful that this will be a rolling chassis with seats and steering early nex year..

Thats when the real graft will begin, sorting the engine out, wiring, bodywork, lights and all the other bits and bobs needed to finish it off.

A bit more done

2013-10-10T17:34:00.001+01:00

Getting the rest of the steel later this month and then the chassis will be finished. Having a bit of bother with the engine though. Still not had time to turn it over and 3 screws I need to remove to expose the crank end have got bloody mashed screw heads.

The front of the chassis is going to have 1" box mounted on plates bolted to the front of the tub. This part will hold the lights and such. The bodywork as far back as the dash will flip forward on hinges for servicing and maintenance. The same at the back with the engine cover. The sides of the tub will have whatever we decide to use permanently riveted to the chassis.

Powder coat or paint? That is the question!

Sparkly things and time.

2013-10-08T17:56:00.003+01:00

Time it seems can be affected by the correct application of power tools.
Since we took delivery of a chopsaw on a loan the chassis has sprouted all sorts of new bits and bobs.

2x2 box used to take four passes with a slitting disc on the 4" grinder......... not any more, we are taking less than a third of the time to get stuff cut and into the chassis now.

The rear of the tub, it still needs the passenger side doing but it's starting to take shape.

The view from the rear of the welders rear and the back of the footpedal top rail.

The front with the suspension mount bulkheads tacked in place.

Lots of welding to do now, Aliens going to be busy for a few days.

Progress but now we are getting into the final bit of the heavy work and getting closer to doing the complicated stuff it's bound to slow down a bit. More as it transpires!

Onwards!

2013-10-07T11:34:00.000+01:00

I have a bit more steel, a big jar of decaff and roll ups!

It's time to get back in the shed, been a tough few weeks health wise but if I hang about waiting to feel better I may be long dead before this gets done. We have borrowed a chop saw so we can keep the cuts tidier and get them done in half the time. Hopefully Alien and I can get a bit done this week and get it further on.

See how far we get with the bit of steel we've been able to get sorted out. I did manage to get a fairly decent set of Ford rims for the front that will look the part once tidied up and painted.