What! on the bathroom scales!!

Forks welded!

I have the greatest admination for what you are doing. Your forks are true to Norman Hossack in looks. That is the one weak point about the design - they don't look good to me. You had no choice; being constrained by the materials available to you (& Hossack in the original). Britten used carbon fibre & his forks looked great to me whereas the Confederate forks are similar but brutally ugly. The BMW cast aluminum are not pretty either. My favourite are the Vincent Girdraulic forged aluminum blades (not Hossack; a variation on conventional girder forks). I had a Vincent and stripped the stove enammeling off and polished up those aluminum blades - looked terrific. Like the Cyzsk (sp?). All of this is just comment & observation. Yours are going to look like what they are which is fabricated tubes. An honest design.

Did you have trouble with distortion of the steering stem bearing seats after the welding?

Thanks Tok! It's in fact a variation on Norman's design, as ball and socket joints are replaced with the head stock ( heavier but smoother stearing)

I'm sure I could fabricate a lighter version, but as I've never built anything like this before it's safer this way. maybe i could pretty it up with a bit of fork cowling?

The Kawa GT 550 headstock is heavy but functional - saved a massive amount of fabrication.

I'm really interested to see what difference this front-end makes to the handling with 15 degrees rake - it will probably be very quick? I have a GSXR stearing damper on hand if it gets out of shape.

Bearings went in fine btw - such a big piece of steel didn't suffer from distortion.

Here's another pic of the progress...

suspension linkage mount on wishbone needs moving forward.



'Fun' With the battery location.
You can see why I'd like to remove some of the rear cam cover.



Found a good location for the reg/rec

Page 8.22 of the workshop manual identifies that as the crankcase breather. A 'breather seperator' is bolted to the inside covered by a 'breather plate' torqued to 12 Nm with blue loctite. The rubber breather tube connects to the nipple on the front of that lump.
I assume you have taken off all the PAIR gubbins. Can you swop the front & rear cam covers around?

Fantastic Tok - that gives me an idea... I could re-locate the 'breather seperator' or make it 20mm shorter.

I'm leaving the PAIR system on until the bike's been though the UK MSVA testing - they do an emissions test

As to changing the cam covers around - there would be frame interference issues with the 'breather seperator' lump. good idea though

Scaring after operation on rear cam cover

OK I hope this works! plucked up the courage to remove an inch from the crank case breather lump. Hopefully the removal will only cause slight pulses into the airbox? A small expansion tank could be the fix for this.
There's now enough room for the battery across the frame, plus clearance for the fuel pump banjo and return pipe.

This Aprilia concept bike might inspire some ideas...



Looking good, RM. The frame is almost too sexy for the swingarm

Love the Aprilia Concept! Fork cowls like this would break the tube lines well, thanks Phantom!
My Radiator and oil cooler location are roughly the same location too.

First time sitting on the Hossack Viffer today!

Slightly aprehensive about mounting the bike - Wondered whether the handlebar position would be a long stretch? Bars are about 2-3 inches lower than standard and roughly the same distance from the back of the tank

Handlebar and front shock mount has now been fully welded (needs support struts like the front base tube)

Custom bolt and plugs to locate the stem clamps fabricated.

Stainless steel main engine bolt and front wishbone pivot bolts made

Still on target for the 1388mm (54.645 inch) wheelbase!

Here's the linkage
The red dots show where cross bracing needs to be added from one side to the other.
in each end there are bearing bronze bushes - a system like this requires zero slack in the linkage



3 Red dots to the left show the scissor pivot points



Dot to the right of the picture under the steering yoke marks the location of rose joint linkage to the forward pivot.



Now you’re probably wondering why i've included this extra linkage -surely I could attach the yoke directly to the forks?

Because the top wishbone pivot is further back than the handlebars - it would need link arms that could change lengths!
Plus if I used a scissor linkage from yoke to fork the ratio of bar movement to wheel turn wouldn't be 1 to 1! weird steering!
Also a rake of 15 Degrees also moves the headstock further forward - making a BIG stretch to the bars
Hope i'm making sense?

Cheers Seb!

Spent the afternoon measuring for all the stainless bolts needed to fix everything correctly, 61 so far. Interesting to note that the VFR engine bolts are M10 fine thread

ECU is going to be mounted behind the airbox and stock connectors for speedo/rev counter are redundant as I've bought a Vapor unit! should save a few more grams chopping the loom too.



Vapor Spec - Link

Sometimes - 'other' things gets in the way of bike building. So I thought it was about time I posted a little update on the bettle VFR.



Cooling system is now complete with silky silicon hose, stainless hose clamps and ducati 916 radiator.

R1 Caliper mounts added - parts for the earls hoses are waiting to go on.

Coils are mounted on a aluminium bracket on the left side of the frame between the engine and frame.





Don't worry the frame look squewd as it's unbolted for now. Crankcase breather on the rear rocker cover has been re-welded to miss the frame tube.

Airbox has been modifed to fit around the frame tube.
Front of the box is going to have 2 entry points for the ram air mod.



Finally standing back and admiring....oh yeah

Red Marque,

Nice job so far. Don't know about that radiator location, but like the effort.

May I make a suggestion for the rear, though.

NR replica

It would be killer.

Larry
VFRrider

Unless I get a radiator fabricated to go under the seat this seams to be the only option for now - i'd really like a wedge shaped one from a late GSXR would be slightly narrower and taper towards the base.
the 916 one was only $30

Tail fairings are really a matter of taste - i'm into the minimlistic look of the new fireblade and like integrated indicators like a gsxr1000.

the NSR tail is very cool especally the fin air intakes very ferrari!

Yes that's right - the riders he tried it on got used to the change very quickly. Interestingly the old Ner-A-Car has a 3-1 steering ratio on it's centre hub steering http://thekneeslider.com/archives/2007/10/...r-vintage-fest/

It's seams that most of the 'new' ideas have been done way before!

Thanks! I take it from your username you aren't the 'one' then?

Firstly i'm really no engineer! I started life with one of those father's who gave me technical lego and was a member of the Vintage Motorcycle Club!
I left school at 16 and went to the local college to do a foundation in art and design - went onto Central Saint Martins College of Art & Design in London to study honors Degree in Product design. Somehow after finishing (spending more and more time with computers) I've ended up as a IT Manager for an investment bank!
I had a lot of 'help' on this project but have tried to do as much as I can myself - I guess you could say I had a fair idea what to do, but only after reading Tony Foale's book and working with my now good friend from essex wheels and engineering.

As for a kit? who know's? I'm pretty sure that it 'should' handle well, i've even thought about adding a steering damper!

I can't wait to see if it works!

As requested a 'cockpit' view.

My, what a mess!



I've modified the standard oil cooler take-offs to except earl's hoses



Sanded down and painted the throttle body side plates Satin Black, will change out the standard bolts to stainless (shiny)



Didn't realy like the huge standard caliper so i'm modifying CBR600RR rear caliper to fit above the swingarm - should keep the dirt off and look trick.
I'd like to put the hose though the swingarm aswell

What you propose for the rear brake is novel. Like the front end is.
What I notice about your workshop is more how small the space you have created this in rather than how cluttered it is.

The other side...


Exhaust system is coming along, i've modifed the front down pipes to miss the radiator and cooler. Early cbr600 pipes have that same size header tubes

Stock pegs are a temporary solution until I finish the bespoke rearset design, also good to take measurements from for the rearset relationship to engine and swingarm mountings.

...Wonderful project. Reminds me of the Britten (in concept). Subscribing.

After much adjustment, fabrication and head scratching (standing and looking at the bike)

I've finally got around to the rearset design! way way back last year I decided that the stock 5th Gen footpeg hangers look disgusting...

The structural elements of standard 5th gen hangers are very good - especially using the swingarm pivot as a mounting point.
But as you know there isn't any adjustment! I've tried various designs trying to allow for some forward and aft movement - none of which look any good!

Here's attempt number 14 (left side rearset) It has height adjustment only - 3 positions at 36 degree increments.
Brake lever in this pic is shown lower than final design so that it can be seen against the hanger

Heal plate design is to be finalised afterward as 3mm plate aluminium can be easily fashioned by hand.

Would most apreciate you guy's input!

What?!? And here I thought you weren't posting because you were busy riding it already...

Looks good, do it up!

I know you love fabricating, but there are some real nice rearsets on Ebay for the NC30-35 or even the NSR series.

Larry
VFRrider

There very nice rearsets too..



Mounting on the 5th gen engine/swingarm would be interesting?

LH side with the brake! Yea I had a Triumph Tiger Cub and a Vincent Comet like that but things have moved on since then.

My mistake! it's supposed to be the right side! from what i've done so far - Do you think you could make these Tok?

Redmarque,

Very cool project. Good luck! Looking forward to seeing it on the road.

Quick question, where did you source the silicone radiator hoses? The 3rd gen hoses have been discontinued by Honda and I've been looking for a substitute. Currently I have something cobbled together with 4th gen hoses. But silicone hoses maybe a good solution.

TIA,

Roger

Thanks for the encouragement!

The hoses i've used are all made from straight sections and 90 degree beds from Ebay.

1" from thermostat to rad, 7/8 for the pump to cylinder heads and 1/2 for smaller bore stuff all joined with aluminium joiners and stainless hose clips.

If you need to get a straight pipe to go around a curve. I fabricated a hose cover from sheet ali - i'll find a pic tonight to explain better.
hope this helps!

Projects hossackviffer's going a bit slow recently (5 weekends in a row with my kids)

Meanwhile the both rearsets are in CAD.



I've mocked up the design in 10mm MDF board.
The 10 holes will be threaded for 6mm grub screws to allow the swingarm bolt to be recessed. Brake cylinder mount will be 6mm thick Ali.
I've sourced rear Yamaha R1 footpegs which will need to have a slot cut though the middle for the return spring.
Lever pivots will be bushed with bearing bronze to prevent wear.

I soooo want different rearsets for mine. Care to make an extra set

Your work has been awesome to follow, thanks for the report.

Yep totally agree 5th Gen pegs are grim!

Hopefully I will offer a group buy if anyone's interested after the first prototype set is made - i'll need to measure up on the 5th Gen rear master brake cylinder as this ones a CBR600RR one - also the banjos on the 5th Gen rear brake are hardlined to the Combined Braking System, so positioning maybe an issue.

Cheers Dude!

I'm lovin the progress mate.
I bet she thought she was going outside for a run.

You might have already said, but what color will we see that frame in? Or am I being too nosey now? lol

Frame and swingarm are going to be satin black - undecided on paint or powder coat? tank,bodywork and wheels in gloss black (always did like vintage bike look)
Was thinking of sandblasting and lacquering the engine once it's been for a test run, should make a nice contrast.

I've been labouring on the loom for some weeks now too , it's been completely stripped and shortened. Standard connectors are being replaced with waterproof ones like ducati use.

Wow just saw this AMAZING. Just bought a 5th gen engine the other day and was getting ready to start my own project but Hell if you maybe planning on selling frames I'll wait and just do the build up on my engine so it's ready for your frame.
I want one!!

Thanks for the complement!
Unfortunately I’m planning on a 1000cc V-twin version if this front-end is successful. Possibly in aluminum too. If you're still mad and would like to build your own PM me and we can discuss offline

Well sir, it's been a while... have you any updates for us to drool over?

and updates on the availbility of your awesome rearsets!

Finished yet??

To be honest progress on the hossackviffer has been very slow!

Life gets in the way of a good project!



I've had to cut and move the rear suspension mounting 25 mm left and re-weld!
Remake the frame - engine spacers
Move and weld on coil mounts
The steering scissor linkage has also been remade to allow for full suspension movement
Notched out the tubes in the forks to allow for greater turn on the steering lock
re-designed the rising rate front suspension linkage using a rear suspension dog-bone.
Replace front shock spring
and much more!

BTW I've put the rearsets on hold until everything else is working!

Hopefully I've got the time to get her running soon, as I've been made redundant last week!

Sorry to hear of your job loss

Going by the evidence presented, you certainly could be self employed as a custom builder, although under the current climate there may not be enough paying customers to make that viable.

BTW a giant spider appears to be mating with your V4?

It looks fantastic. Chin up, make the income priority 1, but keep at it on this, it's good for you

Thanks Phantom!

I'm not really worried about work yet as i've already got some part-time contract IT work lined up!

i've sand blasted the frame after recent mods them primed in black to stop it rusting. (also was fed-up at looking at browning steel!) I didn't think the financal outlay of powercoating was worth it yet. Tabs to hold the battery carrier, brake lines and bodywork mounts are still to be added. Once it passes the UK Single Vehicle Assessment and has a title the extras can be done.

Yeah bummer bout work, but good you have something else in store.
I love the black look, even if it's primer, gotta look after that precious metal work {bloody rust}
Little bit at a time Red... like Phantom says: Looks fantastic

Completely understand and thanks for the update on the progress!

I am so impressed with what you are doing, cant wait until its finished and your running aroiund on it, good luck on the job front so you can keep going.

Red,

As an IT manager working for an investment bank, I know how you feel, as being made redundant is the damokles sword that hangs over all of us in this economy.
Glad you've got something else lined up. Yeah, I'm a selfish bestige - I crave more progress on your build
It also amases me how you manage to find the time to do all this having the family and all. It takes me 3 month just to change my oil and fill tires with air...

Best of luck and keep'em updates comin!

I was an IT Manager of a small investment bank too - they joined it with 3 other businesses, hence redundancy
Ah! and I used to be a family man until the ex-wife did the dirty. Now I have my kids 9 and 4 year old every other weekend. So more garage time evenings and weekends.

Here's a close-up of the "bridge" (It reminds me of one) frontend.
Note the new scissor linkage



Big thanks to all VFRD for the encouragement!

Not sure what size tubing you used for the vertical part of the front end, but it looks like my idea might apply for you.

I found that the black plastic plug that goes in the top of the steering stem on the stock bike would fit as frame plugs on my VF750F frame. Might also plug the holes in your girder?

Hi Seb, that's a good idea - I thought I might turn up some black pvc on my 50's lathe to make frame plugs.

Off to look at your Vf750f post for other ideas now!

Thanks for the Firth Of Forth close-up

Amazing engineering - Paul Crowe at The Kneeslider loves this sort of stuff (he ran an item on Toro's blown 5th Gen), can I send a link to him? Or do you want to wait until you're a bit closer to finished.