RD500LC and FZR400RR project


Olivier PATROUIX

Updated : 20/05/2012

I've recently 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


18/12/2006
The tank has a ding and needs to be modified in the bottom.

 
 18/12/2006
I've removed the tap mounting and the fuel gauge. I could re-use them after the modifications. The tank will be cut under the tape and then bent for supporting the new sheet of metal.

 
18/12/2006
Cut tank.
07/10/2007
While the tank is opened, I remove most of the ding from the inside.
07/10/2007
I've bent the side of the tank to check how it goes.
I'll have a very good clearance for the upper pipes and the heat evacuation (good cooling).
RD500 FZR400 Tank RD500 FZR400 Tank 25/11/2007
I'm using some foam to copy the shape.
RD500 FZR400 RD500 FZR400RD500 FZR400
02/12/2007
Front metal sheet presentation.
FZR400 RD500LC FZR400 RD500LC 09/12/2007
Central part and from sheet formed
FZR400 RD500 FZR400 RD500FZR400 RD500FZR400 RD500FZR400 RD500 FZR400 RD500 17/12/2007
Moddeling for the rear part et ajustment of front part.
FZR400 RD500 FZR400 RD500FZR400 RD500FZR400 RD500FZR400 RD500 06/09/2008
Positionning of the petcock and the sender.
FZR400 RD500 FZR400 RD500FZR400 RD500FZR400 RD500FZR400 RD500 06/09/2008
Starting the bottom.
Thanks Philou.
FZR400 RD500 FZR400 RD500FZR400 RD500FZR400 RD500FZR400 RD500 FZR400 RD500 06/09/2008
Welding the front parts : tack welding
FZR400 RD500 FZR400 RD500FZR400 RD500FZR400 RD500FZR400 RD500 FZR400 RD500 06/09/2008
Welding the front parts
FZR400 RD500FZR400 RD500 FZR400 RD500FZR400 RD500FZR400 RD500 06/10/2008
Welding of the rear part with holes for the petcock and the sender
FZR400 RD500 FZR400 RD500FZR400 RD500FZR400 RD500FZR400 RD500 FZR400 RD500 11/10/2008
Welding of the central part.
FZR400 RD500 FZR400 RD500FZR400 RD500FZR400 RD500FZR400 RD500  26/10/2008
Test on the bike with the petcock and the sender.
Good clearance with the pipes and will let go out the heat.
FZR400 RD500 FZR400 RD500 08/02/2009
Heat gun paint removing
Sanding and ready to repair.
FZR400 RD500 FZR400 RD500 20/05/2012
First layer of white paint.

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