93' ZX6 build. GSXR rear end swap. : Kawasaki ZX Forums: Kawasaki Ninja Forum

MrBubbles00482 · 02-02-2010, 08:47 PM

Name changed, gsxr subframe swap is finished. Please jump to page 7 for start of turbo and zx6r swingarm swap with extension.

Original bike

After fixing and paint.
4 broken body panels, not cracked, missing chunks
Full exhaust, no jetting

Front tire with a bubble in it

Shot chain and sprockets

Sitting at 11,xxx miles

And now, tear down. GSXR swap drops more then 30 pounds rough estimate. 15 or 20 just in the subframe.
2002 GSXR 1000 subframe
02' plastics, solo cowl, and seat.
Integrated tail light
OEM undertail
Air blade double bubble screen
Full spike bolt kit (fairing and windscreen)
Green SS front brake lines (back tire likes too locks enough already)
Soon...
Valve adjustment
Tires (Michelin PP2CT, running stinko's right now...

)

Pics

Took the rear end plastics and stuff apart earlier this afternoon.

Front end off

Parts table

Fender before

Fender design

Fender after

Did this a while ago. My belly pan was melted from the exhaust, so I cut it, layed about 15 or 20 2x8 squares of 1.5oz matt, soaked them individually and bam, cross bracket. Trimmed it tonight.

Close up

Got her naked on the rear end =]
Along with some sanding to get new paint on.
GSXR parts will be here tomorrow afternoon.

Then the top came off =]
Cleaned up and painted to match the anodized bars.

Base

Full rear end (minus undertail)

Frame off.

Frame on.

Mock up.

Tail

Electrical nightmare when i hooked the battery up backwards...lol

Melted the plug...

Radiator relocate and tail light wiring

Front lights had rash so I DA'd it out

VHT nightshade down, clear soon

Triple mounted after paint

One last check

Back down to move for paint (Tomorrow or Thursday)

tuscanidream · 02-03-2010, 03:34 AM

Looks sweet! I would clean up and strengthen where the subframe not bolts on. Makes me nervous. Maybe weld a square at the end of the old subframe and the new weld two outer tabs to slip over the old subframe?

Edit: I see that you cut and notched it.? I'd toss a plate on the backside where you cut it away weld the two together. Just my opinion.

Does the seat align with the fuel tank? Or is that just a wierd photo?

JBearSVT · 02-03-2010, 04:29 AM

I never thought I'd like seeing the ass end of a gixxer, but I suppose if it's still Kawi powered it's acceptable

I'm really enjoying this build, it's looking great!

MrBubbles00482 · 02-03-2010, 08:26 AM

Quote:

Originally Posted by tuscanidream

Looks sweet! I would clean up and strengthen where the subframe not bolts on. Makes me nervous. Maybe weld a square at the end of the old subframe and the new weld two outer tabs to slip over the old subframe?

Edit: I see that you cut and notched it.? I'd toss a plate on the backside where you cut it away weld the two together. Just my opinion.

Does the seat align with the fuel tank? Or is that just a wierd photo?

Those photos were before I moved it up closer to the tank, now there is about a 1/2~ gap between tank and seat, but i'll be doing something about that later, you'll see

The reason for bolting..I don't know how to weld, and don't know anyone that does...lol.

I figured, notching the new sub frame inside the old one would be strongest by bolting...I've been thinking about running another through the top to bottom. Bolts are grade 8, 1.5"x5'16's. Any bigger and I think it would take away to much metal. Also running one more through each mounting point from top to bottom, might comprehend strength my taking away to much metal at the mounting point.

TreyE · 02-03-2010, 08:53 AM

Looks like its gunna be pretty sweet, lookin forward to seeing it done.

Moscap87 · 02-03-2010, 05:51 PM

looks good. definitely interesting. only suggestion: powdercoat frame parts, not paint. otherwise good job so far

MrBubbles00482 · 02-03-2010, 09:18 PM

Quote:

Originally Posted by Moscap87

looks good. definitely interesting. only suggestion: powdercoat frame parts, not paint. otherwise good job so far

I would, powder coating would be a lot better, but I don't have the time/money for it.

I got all the plastics back down to primer, they need wet sanding and then they will be ready for paint.

Smalls · 02-03-2010, 09:33 PM

Subscribed!

Keep posting pics please :-)

MrBubbles00482 · 02-03-2010, 10:19 PM

Quote:

Originally Posted by Smalls

Subscribed!

Keep posting pics please :-)

Not to worry, I will as progress comes.

Watching a set of 03 ZZR600 forks on ebay right now, my left one has a hairline crack in the lower leg.

MrBubbles00482 · 02-04-2010, 07:17 PM

Just won a set of 2003 ZX6e (zzr600) 41mm forks for 48$. Straight and seals are still good.
Now I have adjustable pre load.

MrBubbles00482 · 02-06-2010, 09:43 PM

So I saw the guy that did the home made halo's on his 6.
I'm waiting on it to warm up, and LED's and resistors are cheap, so I figured ah what the hell.

MY bike only has one headlight housing and bulb, so it will be a cyclops, a green one at that.

Got everything out.

Baked the housing. 4 minutes at 250 split it right open (with the help of a screw driver.

Working on the reflective cuts.

tuscanidream · 02-07-2010, 07:16 AM

Sweet. Should toss a projector while you are in there :)

zaneyzrex · 02-07-2010, 08:54 AM

to each their own i guess..
but i would be checking to make sure someone didnt put a huge amp main fuse/or jump it with aluminum foil in your starter relay... shouldnt have melted the plug before blowing the fuse.....

MrBubbles00482 · 02-07-2010, 01:50 PM

Quote:

Originally Posted by zaneyzrex

to each their own i guess..
but i would be checking to make sure someone didnt put a huge amp main fuse/or jump it with aluminum foil in your starter relay... shouldnt have melted the plug before blowing the fuse.....

The plug had burn markes from before this problem just not as bad. The white wire which is the ignition wire had a break right after the plug.

The fuse problem was me. Upon the subframe swap, the battery had to be flipped around because the posts were hitting the mounting bolts for the new subframe. So I swapped the battery, and not the terminals...battery was wired backwards...mistake on my part.

MrBubbles00482 · 02-10-2010, 11:08 PM

03 forks will be here tomorrow

Upper fairing stay from a 97, straight and true 9.95$
Will be here next week.

There is a show coming up I wanted to get the bike ready for, BUT my parents are screwing me out of my tax return. If they claim me as a dependent (which they are) they get a $3,600 tax credit (which is good I understand that) but it makes me OWE 208$. If they DON'T claim me, then I would be getting 585$ back.

The thing is, they are claiming me, and paying my 208$ I'll owe....but that's it...I don't get anything else, which is pretty shitty in my eyes..as they say, "It's the lesser of two evils" even though they are pretty much telling me I'm fucked...and it's their fault.

I would be satisfied if they gave me the 377$ difference from the 208$ I'll owe..but sadly no they won't even discuss it.

JBearSVT · 02-11-2010, 04:01 AM

Apparently, you are younger than I had assumed.

Feel free to take that as a compliment.

AjZx6r · 02-11-2010, 12:10 PM

cool i guess. but i think your pissing money away, and i dont think id ride it, not sure how safe it would be at speed. Good luck, but i think u shoulda left it stock, and just rode it and saved up for a newer bike.

JBearSVT · 02-11-2010, 12:13 PM

I think maybe you're missing the point of this sort of project.

AjZx6r · 02-11-2010, 03:06 PM

Quote:

Originally Posted by JBearSVT

I think maybe you're missing the point of this sort of project.

Please enlighten me? im more worried for his safety

MrBubbles00482 · 02-11-2010, 03:45 PM

Quote:

Originally Posted by AjZx6r

cool i guess. but i think your pissing money away, and i dont think id ride it, not sure how safe it would be at speed. Good luck, but i think u shoulda left it stock, and just rode it and saved up for a newer bike.

What are you conserned about being safe at speed?
The new subframe?
Repaired plastics?
Front forks?

All the plastics are solid, I've been fiberglassing since I was 15, and I know how to get it to work with plastics. They are solid and trustworthy.

The subframe is full grade 8 hardware, and most subframes are bolt on now a days anyway. Granted the mounting points for factory bolt on subframes are stronger, but it's locked in good. I suspended the bike from ratchet straps to remove the swingarm for some cleaning, no bends, no giving or stress. All is in shape.

The forks are getting fully replaced with 2003's from the same bike. Good seals, no cracks. I've already inspected them. The font suspension is no problem anymore.

Quote:

JBearSVT
Apparently, you are younger than I had assumed.
Feel free to take that as a compliment.

How old did you think I was?

19 right now if you were wondering.

I'll be ordering transmission parts next week to repair second gear.
Should only need 2nd, 6th, and the output forks..if that. 6th seems to function fine, but I'll find out once I pull the motor this weekend, hopefully the drum is fine, but where it engages 2nd it might be worn.

New forks

Also.

Any concerns should be addressed more specifically. I don't understand why you are "worried about my safety". The bike was fully checked over before purchase. Brakes, frame (even the 2 re-welded spots), rims, and forks (crack was spotted). Everything that is known, is being addressed.

This bike will be one off. No other like it. MY own creation with a decent platform to build on.