RD500LC and FZR400RR project
Page 4
Updated : 19/12/2009 -> 01/01/2010
I've bought an FZR400RR type 4DX / 1993 in order to make a nice alloy framed RD500 for track day runs.
In
this page I will try to give news from my
project.
Last
step
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Photos (click to enlarge) |
Legend |
 
Gareth page |
05/04/2009 Decision on pipes : I've ordered pipes in kit from Swarbrick in the UK. |
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18/04/2009 The last upper cone must orient the silencer to the ground. Trial : 15° with 2 or 3 sections. |
      
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21/04/2009 Electric system building :
24/04/2009 I've removed the FZR400 ignition switch and will replace with a TZR one. I've swapped the 125 speedometer (180km/h) and the FZR400 one (220km/h). |
   
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25/04/2009 I've decided to change my mind on the airbox because I've a lot of electric stuffs to place. So I've decided to close the space behind the steering head and seal it with the front part of the tank. Thus, I could place the wiring loom connectors in the airbox, the coolant tank (maybe not a good idea if it gets very hot!!!). Template is cardboard. Pictures (from left to right)
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26/04/2009 Here is the realisation in metal sheet (later this could be in alloy sheet). After cutting and grinding I finaly got the "airbox" done (pictures 1-4 & 6). I think I could used the FZR400 ignition coil holders (picture 5) if the metal inside does not need to be grounded. A neoprene strip will seal the airbox with the tank (picture 7). Last picture shows the 4 ducts departures and the YPVS controler. Need to confirm this. |
  
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03/05/2009 Testing on how to make connections to the airbox. |
          
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08/05/2009 Bracket for all the electrics. |
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08/05/2009 YPVS servo mounting. To check if a little thermal protection is needed. |
 
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11/05/2009 Connection carburetor to airbox. Test with a PU duct ID 40mm to do some testing of flexibility. The PU is cheaper than the neoprene duct so this is OK for the first testing. |
 
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15/05/2009 The bike has a ignition key now !!!! Buy from YamBits (ebay) |
  
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17/05/2009 Trying to sort the CDI-Stator of the RD500LC with the TZR250 loom. Dedicated page : CDI |
 
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22/05/2009 Check the clutch cable routing. |
  Video
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24/05/2009 Design of YPVS cable to suite the TZR250 sevor and the new position of the servo. I've used old Exup cable from the FZR400RR . Will check if the RZ350 or TZR250 ypvs cables could do. |
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31/05/2009 Cooling ducting design using cardboard templates :
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04/06/2009 Design of hydroformed pipes. I'm still waiting for news from Swarbrick so then I'm back on pipe design. 06/06/2009 Good news from Swarbrick, shipping by the end of next week !!! I continue to work on my hydroformed pipes. |
    
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07/06/2009 Bought from autoperformanceonline Airbox : flexible neoprene duct (2m) and pipe joiners (x2) and the joiners will be cut in half and weldded to the airbox. Cooling : silicone elbows 45° and 90° in ID 22 and ID 25mm and an alloy tube in 25mm OD. |
         
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04/07/2009 I've received my pipe kit and it is superb. |
  
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05/07/2009 First test for upper pipes |
    
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07/07/2009 Shape with an angle of 5° or 10° 10° gives a better result. |
     
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08/07/2009 Shape for cone n° 2 with an angle of 15° Test for cone n° 3 |
  
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09/07/2009 Cone n° 3 and cylinder. Seems to go well, may cut this weekend!!! |
  
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10/07/2009 Complete pipe. |
         
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13/07/2009 Rear exhaust fabrication. Tackwelding is done using an inverter arc welding device with 1.6mm rods and very low curent to avoid holes. |
   
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14/07/2009 Lower pipe |
 
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18/07/2009 The 2 lower pipes are ready to get seam welded. |
  
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23/07/2009 My arc welding device has decided to breakdown so I need to find another solution to tack weld my pipe !!! So I decide to go to the farmer workshop to have the tack weld done. |
     
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25/07/2009 Reat solo seat, pipe and silencer |
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01/08/2009 Airbox test with the neoprene duct received from Autoperformanceonline |
  
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02/08/2009 I've cut the rear baffle cone at 35° in 4 sections and Ive tested to see how it goes. Not bat but I need to check as the two pipes are not exactly identical. I'll need to adjust. |
  
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04/08/2009 I finally get my stainless steel rear upper bracket. |
     
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29/02/2009 The pipes are ready to be seam welded and I've tackwelded the spring holders on the 4 pipes. |
  
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06/09/2009 Rear bracket final version. |
 
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06/09/2009 The left lower pipe is touching the gear lever so I cut it and well it the other way. |
  
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04/10/2009 First welding done. |
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15/10/2009 Upper pipes welded. |
    
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16/10/2009 Lower pipes welded |
  
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17/10/2009 Now the upper pipes are "almost" welded so I rebuild the rear frame. |
        
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18/10/2009 Rear frame continues !!!! |
          
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24/10/2009 Lower pipes brackets |
    
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24/10/2009 Rear frame. |
       
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25/10/2009 Reat seat brackets and pipes. |
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29/10/2009 Rear seat brackets |
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30/10/2009 Rear upper pipes spacing and bracket's pattern |
    
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30/10/2009 Rear seat brackets |
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31/10/2009 Baffle cones and brackets Lower silencers. |
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01/11/2009 Fairing and seat |
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01/11/2009 Lower pipes mounting bracket (CAD file to come !!!) |
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08/11/2009 CAD file version 2 to be printed in 1 to 1 scale. 09/11/2009 CAD file version 3 to be printed in 1 to 1 scale. |
    
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10/11/2009 CAD model of the joiner neoprene tube to carb. Last image with Oring seal. |
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11/11/2009 Stinger tube bent in order to reach the baffle cone center. Stinger tube welded for the upper pipes but finally with straight tubes. |
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12/11/2009 Measurements done on caburettor to dimension the joiner. |
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12/11/2009 Finished pipes, last welding to be done. |
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14/11/2009 The alloy plate is too small so it get too flexible... must be done in 5mm thickness plate. 15/11/2009 Gone for a tubed bracket. |
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22/11/2009 I've finished the lower pipe bracket and added a small plate. |
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06/12/2009 Finally, I re-do the bracket in stainless steel with turned parts, it will look better. 12/12/2009 Now there are finished... |
         
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13/12/2009 Starting triming the fairing to suit the engine :
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19/12/2009 Pipes finished |
 | 18/01/2010 Page 5 |