Club 80-90 Forums

keep on with the updates tom

neil

Thanks for your comments Lads, same to Richard..much appreciated..No worries on the udates more to come in the next couple of days...Got to get my cordless first..11hrs left on ebay..first its head down time..sleep off my night shift..
Catch you all soon
Tom

Managed to get a few hours in yesterday.
my mission for the day - Battery and housing it - fit the the Silencer - fit the Header Tank

I recycled the diesel battery tray I had..I gave it a clean and spray over. I was hoping to plant it on the side of the engine bay. After several attempts of trying to convince myself it would fit I admitted defeat and went for option B.
I decided to house the battery in the offside vent hole. A tight squeeze but managed. I had to change the air intake vent hose (grey) to a smaller diameter(same diameter as the air filter intake)(black).
I took a flick of the bits and my new cordless..£36 on ebay..works a treat.

Here are a flick of the corner sections I used..

Here is where I am putting my Battery..I drilled a hole ready for the clamp and fitted a -tve cable


just make it out!


Everything back together..

another angle

Got to work at fitting the silencer...
a little gasket and gooch



After a while I managed to fit it..made a slight hash at the back..but its fixable.

I then started on the Header tank and the big bracket I mentioned earlier. I also recycled the second diesel air filter bracket..I had an idea toying arond and I wanted to try it.

nicely mounted

Then this happened....



and incase your wondering about height...I am lower than the Carb (highest piece) but higher than water pump and thermostat..It might look a bit rough and ready...I can deal with that at a later date...I am looking for something that will work for now..and this will..

Left to do..
Secure header tank and strengthen supporting bracket.
Finish off connecting coolant pipes.
Mount the ignition coil.
Oil-sparkplugs-fuel-coolant-ATF Fluid for Carb
Wiring up-refit the gear lever arm-clutch fluid and bleed.
Patch a couple of holes. Stich the back up- form a raised hatch
At some stage hopefully turn the key and start her up...
Thanks for looking
Tom

what bike is that can off ?
We'll hear you coming

Hi Aidan
The one fitted is from a Susuki GSXR 1000 (k3)..I have another one slightly smaller in length from a Susuki GSXR Streetfighter. Neil said it would sound fruity..the silencer recomended in the conversion instructions is by all accounts really load..Neil said it used to set off car alarms. Not sure if he is still having that problem. I can't wait to hear what it sounds like..
I will at a later date have to bend the down pipe section from the engine..just to allow the silencer to fit a little more elegantly ...do for the time being .
catch you soon
Tom

hi tom good to see you have made some progress, with regards to the silencer, i used a plate as you have done, but i welded it on to the down pipe directly, my thought process was strength and it blowing from any joints. i also set it back on the down pipe so that i could mount the silencer further back in side the engine bay.



this was taken mid way through the job, ie i finished sceam welding the plate after the photo was taken.



you should also make up a hanger for it, i made it from some 20mm angle iron, i dont have a pic but i can take one for you if you like.

neil

Hi Neil

Thanks for the pics and the tip on the weld..I will get that done at a later date..I know slight adustments are needed, bending the down pipe down and left by around 30mm will allow the top part of the silencer from missing the very botom of the van..I could push it out a little further..I reckon it would look pretty once I've done...eventually when I get it outside my gaff I will have a major play around. Regarding the hanger..I was thinking about fitting it to the large newly named header tank bracket... Its solid enough to take it..

I plan to visit again next Tuesday..got to get work out of the way first...I am hoping to finish off the coolant side..slight mods and gentle repairs.
Iv'e been looking at the electrical side of things..I've been checking out the loom I got from sweden...I do have questions keep cropping up..But I'm waiting until I get the other bits sorted.....

Tom

good to see its getting there..

my volvo crewcab is tucked in the back of my bit of barn, must get a battery on it and run it up.
my exhaust is loud enough with a standard car exhaust box on it so im sure that will have a hummm to it once its up and runing

As an occasional passenger, I can say that Neil's exhaust set-up is in no way load or obtrusive, in fact I'm amazed at how quiet it is for a single-box system. It's beefy but not rasping or harsh.
Maybe that's because it's in a DOKA so the sound doesn't travel through directly to the cab, like in a van?

this is the hanger that i made for the silencer, it is not that clear on the photo but it is mounted to to the same lip as the engine bar is mounted too.just bolted using 2 m6 nuts and bolts on the chassis lip. strong and simple,



once yo are up and running and start refining every things look at investing in a proper mount for the header tank.



keep up the good work and stick with it. if you have any question drop me a line

neil

Thanks Neil...I plan to cut a cardboard template of the lower part of the header tank on my next visit. I have some scraps of metal and a mig welder at home..never used one before..I guess now is the time to start practising. I appreciate it's a bit naff looking ...I like using my imagination and I kinda get a buzz out of finding and using random recycled bits ..all part of the fun of doing a conversion...

Tom

ref your battery

have done the same on my autohomes , but cut the diesel battery tray so its just a tray and bolted than in .

can still get the battery in and its nor resting on the shelf floor.