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blackout

Project FZ Supertwin

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blackout

 

1010172023.jpg

 

I started my winter project a little early this year.  

 

My head fairing is off and I will be installing 2017 R6 upper and lower race fairings from Hot Bodies Racing.  Tank and tail will remain mostly stock.  The main reason for leaving the tail stock is for the integrated tail light that looks so good and is needed for street duty.  While the bike will be tracked more next year, it will also need to be street legal.  

 

I plan to design and fabricate a cold air intake system utilizing the R6 front air intake hole.  Most likely a new air box will be fabricated.

 

A new fairing stay will be fabricated and I will move the instrument pod onto the stay this time.

 

This will be a slow moving thread as I will post as I progress.  You guys may witness some failures along the way, but that's part of the fun!  lol  The body work should arrive in 3 weeks.

 

Here is a link to last winter's mods....  

 

  

Edited by blackout
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stickshift

Sounds good, though I would question the work involved in designing a custom intake & airbox when you could just go down the proven route of a hordpower intake.

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blackout
13 minutes ago, stickshift said:

Sounds good, though I would question the work involved in designing a custom intake & airbox when you could just go down the proven route of a hordpower intake.

Very true.  But we have long winters here. :)

 

What I do is hard to explain, but I always need winter projects or my head will explode. lol

 

Many years ago, I built a custom Shelby Cobra replica from the ground up, even though I had a perfectly good FFR Cobra already in my garage.  Custom frame, suspension, spindles, brake setup,...   Raced it for 8 years.  

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blackout

I'm lucky to have access to a small milling machine at work.  I machined a new steering head saddle for the fairing stay.  My first design was not strong enough, it fatigue failed after 4,000 miles.  This one will be better.

1013171408.jpg

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Cruizin

Im looking forward to your build. This will be a good thread.

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blackout

This should provide a strong attachment point for the fairing stay.

1014171657.jpg

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blackout

A side view.  The rear collar is a standard 1.9375" aluminum collar from McMaster-Carr.  The front I made from 1 inch thick 6061 bar.

1014171658.jpg

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blackout

A little more progress on the stay.

1017170913.jpg

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blackout

I have the steering damper angled down to give more room for the throttle cables.  The cables move around a bit from lock to lock.

1017170914.jpg

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blackout

Body work came in earlier than expected.  Decided to size up the lower fairing first.  Kickstand clearance looks good.  Cutouts for the R6 engine will be filled in and the width looks pretty good so far.  The R6 engine is only 1.375" wider than the FZ07 engine.

1017172037.jpg

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blackout

Front view.  I need to cut clearance where the shifter is to lift the fairing higher and fill in the R6 engine cutout on this side too.  Filling the cutouts should be easy with fiberglass cloth and epoxy resin.  I use epoxy resin because it is compatible with polyester resin as well as epoxy resin, so no need to worry about what Hotbodies used.

 

1017172035-1.jpg

Edited by blackout

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blackout

I raised the lower fairing as much as possible.  The only part that I cut is shown in the pictures below.  This was clearance for the brake pedal.  It looks like I'll have about 5.5" of ground clearance.  That sounds about right.

1022171916.jpg

1022171915-1.jpg

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blackout

Kickstand fits perfect.  Nothing to mod there.  I have 4 mounting points figured out and will reinforce those areas with carbon fiber cloth.  I ended up using none of the R6 locations, so those will get filled in.

1021172050-1.jpg

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