RD500LC and FZR400RR project

Page 4


Olivier PATROUIX

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

Photos (click to enlarge)

Legend

Swarbrick Racing Swarbrick kit Gareth page 05/04/2009
Decision on pipes : I've ordered pipes in kit from Swarbrick in the UK.
18/04/2009
The last upper cone must orient the silencer  to the ground.
Trial : 15 with 2 or 3 sections.
21/04/2009
Electric system building :
  • TZR250 2MA wiring loom
  • TZR125 4FL dashboard
  • FZR400 4DX handle switches
All in working : lights, turn signals, horn... we did not know maybe she go back to the road !!!
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).
  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)
  • top view,
  • under view,
  • rear under view,
  • under tank view.
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.
03/05/2009
Testing on how to make connections to the airbox.
08/05/2009
Bracket for all the electrics.
08/05/2009
YPVS servo mounting. To check if a little thermal protection is needed.
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.
15/05/2009
The bike has a ignition key now !!!!
Buy from YamBits (ebay)
17/05/2009
Trying to sort the CDI-Stator of the RD500LC with the TZR250 loom.
 Dedicated page : CDI
22/05/2009
Check the clutch cable routing.
Video 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.
31/05/2009
Cooling ducting design using cardboard templates :
  • 25mm OD alloy tubing
  • 25mm ID silicone 90 & 45 elbow
  • 22mm ID silicone 90 & 45 elbow
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.
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.
04/07/2009
I've received my pipe kit and it is superb.
05/07/2009
First test for upper pipes
07/07/2009
Shape with an angle of 5 or 10
10 gives a better result.
08/07/2009
Shape for cone n 2 with an angle of 15
Test for cone n 3
09/07/2009
Cone n 3 and cylinder.
Seems to go well, may cut this weekend!!!
10/07/2009
Complete pipe.
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.
14/07/2009
Lower pipe
18/07/2009
The 2 lower pipes are ready to get seam welded.
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.
25/07/2009
Reat solo seat, pipe and silencer
01/08/2009
Airbox test with the neoprene duct received from Autoperformanceonline
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.
04/08/2009
I finally get my stainless steel rear upper bracket.
29/02/2009
The pipes are ready to be seam welded and I've tackwelded the spring holders on the 4 pipes.
06/09/2009
Rear bracket final version.
06/09/2009
The left lower pipe is touching the gear lever so I cut it and well it the other way.
04/10/2009
First welding done.
15/10/2009
Upper pipes welded.
16/10/2009
Lower pipes welded
17/10/2009
Now the upper pipes are "almost" welded so I rebuild the rear frame.
18/10/2009
Rear frame continues !!!!
24/10/2009
Lower pipes brackets
24/10/2009
Rear frame.
25/10/2009
Reat seat brackets and pipes.
29/10/2009
Rear seat brackets
30/10/2009
Rear upper pipes spacing and bracket's pattern
30/10/2009
Rear seat brackets 
31/10/2009
Baffle cones and brackets
Lower silencers.
01/11/2009
Fairing and seat
01/11/2009
Lower pipes mounting bracket (CAD file to come !!!)
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.
10/11/2009
CAD model of the joiner neoprene tube to carb.
Last image with Oring seal.
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.
12/11/2009
Measurements done on caburettor to dimension the joiner.
12/11/2009
Finished pipes, last welding to be done.
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.
22/11/2009
I've finished the lower pipe bracket and added a small plate.
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...
13/12/2009
Starting triming the fairing to suit the engine :
  • clutch case
  • water pump
  • kickstart...
19/12/2009
Pipes finished
18/01/2010
Page 5

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