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Discussion Starter · #2 ·
The first port of call was making the new subframe, I was never that happy with the shape of it all so chopped more off and made a start on bending some 1" tubing.

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I used some left over 22mm chromoly bicycle tubing for the plugs

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Made up some frame extensions to change the angle of the seat pan.

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Starting to look good

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Getting the new 22mm seat pan aligned
 

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Discussion Starter · #3 · (Edited)
To check everything before tacking, I needed to make some new shock bushings so I could fit the new shocks.

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I machined these out of Oilon.

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With the shocks fitted I could tack the frame together. It was the first time I could sit on the bike in several years.

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Discussion Starter · #4 · (Edited)
The old carbs and manifolds were shot and decided to go down the route of newer carbs.

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And so I headed over to ebay got a pair of mikuni vm30 copies, how good these will be? time will tell.

Next up was to make some inlet manifolds to suit.

Version 1:
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It was at this point I decided I wasn't happy with how they were going so set about making version 2 from a block of aluminium
 

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Discussion Starter · #5 · (Edited)
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Version 2 started with a large block of aluminium, which I cut up into the required size using a hacksaw.

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With everything measured and marked up I started by drilling the centre on the drill press.

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This allowed me to get everything centred on the 4 jaw chuck.

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I rigged up the tool post to mill the angles on the manifold and finished up the shaping on the linisher.

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Countersunk the holes and they're done. Much better.

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Discussion Starter · #6 · (Edited)
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Tonight I made a start on tackling the wiring harness, but a lot of the wires had gone brittle so the plan is to start from scratch with new wires. And that's the project caught up.
 

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Discussion Starter · #7 ·
Made more progress on the frame fabrication.

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I machined some new shock mounts from 16mm stainless steel bar.

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To ensure the shock mounts were parallel i welded the new stainless mounts to some 16mm chromoly 4130 steel tube.

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With the frame all tacked together I can now check clearances and make a start on the new wiring and get the bike started. I'll finish welding once everything is sorted and can strip the bike back down to bare frame.

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Handmade custom parts really do make the difference don't they? Nice work.
 

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Looking VERY good! I had originally planned to use shop built steel manifolds and straight rubber connectors as well but changed my mind and reused an old set of original rubber ones. Also like you, I decided to give a pair of the new knock-off carbs a try. They were a tad oversize (barely!) for the old intakes, but 10 minutes in the oven at 200F (while my wife was at work ;) ) softened them just enough to slip the barrels in. I've read everything I could find online regarding the carburetors and while the reviews all seem to expect inferior performance, the majority seem to praise them after actual trials. At least when new. :-? Longevity will be the test I suppose but for the price I decided to take a chance. If we eventually have to replace them, it was still a cheap experiment.

I like where you're going with the style. Looking forward to watching it progress.
 
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