The strip down begins.
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Front shot.
I started this a few months ago and just posting now, trying to keep in sequence where possible. All parts have been on/off so many times gets confusing, but hopefully the thread can be followed.
NB: I'm using Turbosport for this as previously used it to log my Mk1 Escort build (Project Silver Fox on here somewhere), started off with the NSR forum, they don't seem too hot on modifying original kit (nuff said).
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Thats nice mate. Do like them an rare. Fancy a rs250 track bike.but too many other projects on the go. Keep us informed on this.
[/SIGPIC]CHRIS
WANTED MK1 2DOOR ESCORT COSSY OR XE MUST BE PERFECT AND FREEwell dont hurt to ask?
Some shots of the general nastiness of the condition. All to be stripped and cleaned!
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Soooo cold in garage 1st job was to insulate the metal door. Like a giant jigsaw.
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more nasty areas to sort.
My main brief is:
Re-build to a safe 'track day usable' standard.
Stiffen rear suspension.
Keep the bike geometry which should be good?
Remove weight where possible, without compromising strength.
Make as many of the parts myself.
Wrap in some later bike fairing.
This is the 1988 model which had the slightly shorter swing arm, so shortest wheel base and has the unrestricted ECU's (approx. 65bhp).
The full SP model of same bike was only 2.5Kgs lighter, by mainly using mag wheels. So would like to save 5+kgs if possible.
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De-gunking time. All hail the Dremil
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Engine shots. The yellow arrow shows the Torque Arm which links the swing arm mount to the engine and stops the engine from twisting when under load. The special bolt with super metric fine thread is missing and attempts to order through UK Honda spares have failed. Eventually made one myself.
Last edited by Mexico Spike; 21-10-2014 at 17:41. Reason: pic mistake
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V complex wiring on this baby so wont chop anything away yet, just strip back clean and re-tape. Also means can be put back to road spec if needed in the future.
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After many hours cleaning, needed a diversion to keep the project on track, decided to start my tail piece re-design. This part weighs approx. 8Kgs
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Bear with me,.... wanted a rough (full size) mock up to see what could be made. This is pallet plastic (like cardboard construction) easy to cut and shape but strong.
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After much shaping, trimming etc starting to finalise shape. I prefer the hole design but mates (the 2 I have) likes the slots!!
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After final design was cadded up, had lazer cut in 3mm aluminium. Then hand cut the middle, shaped and TIG welded into side sections. Approx 3Kgs finished.
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Also used this section to mount the silencers, made some lightweight brackets here.
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Swing arm out for cleaning (yes back to cleaning again)
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Cleaning turned into full-on deep polish,... many happy hours with the mop!
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Cleaned and painted linkage. Too bright I know but had tin of red smoothrite to hand!
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remounted old shock and linkage plates. These are pattern HRC dims which lift shock slightly.
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Stan shock in a poor state and needed replacing (£££). A popular upgrade is to fit a 1999 CBR unit. Had the machine down top mount width and make a bottom spacer, just about snug fit! Made some rough plates to mount for now. Aiming to lift rear end of bike min 20, max 40mm.
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This little fella needs to be working 100% so stripped down and sorted out. Had a fair amount of gunk and alloy corrosion so was well worth the time!
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A quick re-furb of the rear brake carrier and calliper. Will do this better later, just wanted a clean for now. Did end up changing pistons in calliper though as corroded (new seals etc).
This is my first owned Honda bike in 26 years of having bikes (always Yams and Suzis) and must say very impressed with the build quality, fastening type/size/strength, etc. The whole job seems much more thought out and put together better than most jap bikes. Might just be because it originates from a racing bike, but can definitely see a level of detail higher than most bikes I have worked on in the past (lots of jap crap and brit shit).
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The standard rad had a little bit if damage, tried to sort but too fragile. Wanted something slightly bigger so fitted a CR250 rad. Made own brackets to fit. Also lots of time messing with hoses to install, the only new bit if hose is from a Ford Transit!! The bottom hose outlet was cut off and turned 90 degrees then TIG welded back on. Now got a bigger stronger rad.
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Tackled a few engine parts, removing and cleaning/polishing. Biggest section is the right side casing.
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Needed new gasket and didn't want to spring for whole set. Gasket paper ebay £4.
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And refitted! Note oil pump blocked off with similar little gasket and home made alloy blanking plate (have taken out oil pump). Will run pre-mixed oil when running.
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Last track bike build: RD400 1979 with some period TZ bits. Handled a dream but aircooled engine very temperamental! Melted LOTS of pistons!!
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Back on (for now)!
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Thats coming alone nice. Be good to see it done mate.
[/SIGPIC]CHRIS
WANTED MK1 2DOOR ESCORT COSSY OR XE MUST BE PERFECT AND FREEwell dont hurt to ask?
After playing with rough bracket, drew up and cut lazer version to sort out bottom linkage. Clearance was tight with the CBR shock hence minimalist bracket. Plan to obtain a standard NSR shock at some point so can compare the 2 versions, all brackets are interchangeable between both set-ups.
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More inspiration for build,... not quite set up a 'mood board' like Clarkson!!
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Found this (top view) to help design final bodywork shape. Not exactly Ducati GP but something to scribble on (bottom view, with paint shop),.......
Last edited by Mexico Spike; 31-10-2014 at 14:39.
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Needed some info on wiring loom as having trouble keeping the smoke inside the wires,.... found this on web then spent some time colour coding to what I was finding!! May be useful?
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In true arse about face have started with the back end and working towards front,... looking at the state of front brakes probably a good thing though. Don't plan on upgrading I'm 10st wringing wet, just a full service should provide plenty of stopping power.
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Turned some new foot pegs. Wanted to keep the rearsets, but had some internal wear so machines out and re-bushed, now nice and tight, with just enough play not to stick!
Note new rear master cylinder to replace original tired item. Only a cheapo, had to cut rod arm down and rose-joint to suit short length required.
Last edited by Mexico Spike; 31-10-2014 at 15:10.
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After knocking over bike (owch) tied the bugger the roof!
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Bike has been dropped previously so some damage to levers, etc. Swapped out for these for now,... ok but not great!
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