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GSXR 600 K5 tail conversion + quite a bit more in the end.

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Re: GSXR 600 K5 tail conversion + quite a bit more in the end.

Post by cabbie on Wed 26 Nov 2008, 23:45

No mate, no need for fibreglass etc, all it needs is the cowl fixing in place and a few adjustments to the bar I just made, I can adjust it down till it touches the cowl if need be.
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Re: GSXR 600 K5 tail conversion + quite a bit more in the end.

Post by alsieboy on Wed 26 Nov 2008, 23:46

cool digging
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Re: GSXR 600 K5 tail conversion + quite a bit more in the end.

Post by cabbie on Thu 27 Nov 2008, 20:10

Next job is the rear cowl supports.

I find making a cardboard template the easyiest way to fabricate parts like this


Then just lay it flat on the material and mark out the shape,
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Re: GSXR 600 K5 tail conversion + quite a bit more in the end.

Post by Jollygiant on Fri 28 Nov 2008, 00:29

Coming along nicely.

Your being a tad neater than i was for the conversion i did on my old blade.
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Re: GSXR 600 K5 tail conversion + quite a bit more in the end.

Post by cabbie on Sat 29 Nov 2008, 22:32

I got the rear mounts cut and fitted today, these will be tig welded later







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Re: GSXR 600 K5 tail conversion + quite a bit more in the end.

Post by 1992fireblade on Sun 30 Nov 2008, 09:04

Looking good cabbie!
The attention to detail is awesome. So much neater than mine. I just went at it with the grinder!
Although admittedly as I used the R6 seat subframe with the tail plastics it didnt need the fabrication.

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Re: GSXR 600 K5 tail conversion + quite a bit more in the end.

Post by griz on Sun 30 Nov 2008, 10:57

Top quality workmanship.... Great stuff, well done mate!
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Re: GSXR 600 K5 tail conversion + quite a bit more in the end.

Post by cabbie on Sun 30 Nov 2008, 14:38

Next up is the seat catch:

I'm using a nylon rod, I cut a flat in the rod and found a trailer strap anchor loop on eBay.





Next I turned down the ends to fit the hole in the cowl brackets



I made two small levers for the spring and cable



Here's the catch fitted, just need to make a cable holder



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Re: GSXR 600 K5 tail conversion + quite a bit more in the end.

Post by alsieboy on Sun 30 Nov 2008, 16:57

nice fabrication, well impressed sunny
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Re: GSXR 600 K5 tail conversion + quite a bit more in the end.

Post by 1992fireblade on Sun 30 Nov 2008, 19:15

You are a fookin` genious dude!
Attention to detail is quality.

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Re: GSXR 600 K5 tail conversion + quite a bit more in the end.

Post by wild bill on Sun 30 Nov 2008, 22:29

Get ya coat Cabbie.... You've pulled

Superb bit of work mate thumbup
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Re: GSXR 600 K5 tail conversion + quite a bit more in the end.

Post by mr pie on Mon 01 Dec 2008, 18:23

It takes me back to when I use to machine and fabricate, I was working at Renault F1 in Oxford two years ago, I walked into the workshops and the smell of swarf and coolant just hits you. all those memories come fludding back.

excellent work Cabbie.


Last edited by mr pie on Tue 02 Dec 2008, 00:21; edited 1 time in total
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Re: GSXR 600 K5 tail conversion + quite a bit more in the end.

Post by cabbie on Mon 01 Dec 2008, 22:33

Didn't get much time to play tonight so only managed to start the seat back plate.





I've also ordered some nylon block to make a new hump hinge, I don't like this set up, no one will be sitting on the hump so I don't need this heavy steel item.

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Re: GSXR 600 K5 tail conversion + quite a bit more in the end.

Post by mr pie on Tue 02 Dec 2008, 00:25

Hi Cabbie, just as a matter of interest, what do you use to cut your metal and did you use a folding press? I get a mate to do my bit at his work, he used a laser cutter and the end result is very good.
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Re: GSXR 600 K5 tail conversion + quite a bit more in the end.

Post by cabbie on Tue 02 Dec 2008, 07:37

mr pie wrote:Hi Cabbie, just as a matter of interest, what do you use to cut your metal and did you use a folding press? I get a mate to do my bit at his work, he used a laser cutter and the end result is very good.

I use the mill to cut the sheet and for the folding I cut a 2mm slot 1 mm deep along the fold line then heat the alloy with a blow touch and it folds real easy.
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Re: GSXR 600 K5 tail conversion + quite a bit more in the end.

Post by cabbie on Wed 03 Dec 2008, 21:52

Made a start on the new hinge, best way to do a job like this is transfer all dimensions to paper and cut out cardboard parts till they fit
Hinge closed

And open


Now I have the hinge bracket size I can improve the shape and cut two out


Closed


And open, I can always make some adjustments if needed later.
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Re: GSXR 600 K5 tail conversion + quite a bit more in the end.

Post by 1992fireblade on Thu 04 Dec 2008, 12:42

Genius!

What more can I say???

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Re: GSXR 600 K5 tail conversion + quite a bit more in the end.

Post by wild bill on Thu 04 Dec 2008, 23:38

I wanna to be your mate eyebrow

Top notch workmanship & fabrication thumbup
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Re: GSXR 600 K5 tail conversion + quite a bit more in the end.

Post by cabbie on Thu 04 Dec 2008, 23:49

wild bill wrote:I wanna to be your mate eyebrow

Find me a cbr 600 F4 front wheel and I'll be you're mate for ever, lol

I'm in Beckenham too so we'll soon be meeting up next year when the blade is back together

PS I need to talk about getting some wheels painted.
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Re: GSXR 600 K5 tail conversion + quite a bit more in the end.

Post by wild bill on Fri 05 Dec 2008, 22:56

As for the wheel i'll have a word with Russ & Bob @ Frank Dunstall M/Cs (Elmers End Green), he's got his finger in a few pies in the bike trade, used him for the best part of 25yrs, he might be able to help.

Flippin ell, your round here! For your sake don't give me your address or phone number, i'll be ringing you up for tips and advise all the time scratch

Best thing to do about your wheels is wait till after chrimbo, as soon as that's out the way i'll have a few extra quid and i'll get my wheels done, then you can see the quality of his work for yourself.

PS, i'm going to Dunstalls tomorrow, i'll have a word about that wheel, also, might be worth ringing Merlin M/Cs in Maple road penge, Nick has sh!t loads of sparesdown there.

Just a thought?
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Re: GSXR 600 K5 tail conversion + quite a bit more in the end.

Post by cabbie on Fri 05 Dec 2008, 23:07

Tell Russ & Bob to get rid of those Urban tigers out side the shop, lol

I'll give Merlin a ring tomorrow, thanks.

Back to the project:

I finished the levers


All looking good, might need a little alloy removed?


Started cutting the hinge bracket, I'll finish this tomorrow, it's a bit late to be milling, lol
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Re: GSXR 600 K5 tail conversion + quite a bit more in the end.

Post by wild bill on Fri 05 Dec 2008, 23:54

cabbie wrote:Tell Russ & Bob to get rid of those Urban tigers out side the shop, lol

They would never part with their Urban Tigers unless...
You pried them from their cold, dead hands.

What year is the F2?
These 1990 ones are on Gumtree, probably get the pair if you offer 50 inc tyres! http://www.gumtree.com/london/55/31809155.html
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Re: GSXR 600 K5 tail conversion + quite a bit more in the end.

Post by cabbie on Sat 06 Dec 2008, 01:30

I need to match this rear wheel, I think the 2005/2006 cbr 600F is a good match, I'm not worried if it's not a direct fit, I'll make up new spacers etc.
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Re: GSXR 600 K5 tail conversion + quite a bit more in the end.

Post by alsieboy on Sat 06 Dec 2008, 09:29

Those brackets are a nice touch, nice bit of fabrication....amazing project sunny
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Re: GSXR 600 K5 tail conversion + quite a bit more in the end.

Post by Guest on Sat 06 Dec 2008, 14:04

I 've got a VTR1000 front on my RRW?
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Re: GSXR 600 K5 tail conversion + quite a bit more in the end.

Post by cabbie on Sat 06 Dec 2008, 16:11

I got the hinge bracket cut, still needs mounting and pivot pin holes drilling.


Seams to be a good fit
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Re: GSXR 600 K5 tail conversion + quite a bit more in the end.

Post by cabbie on Sat 06 Dec 2008, 21:21

Made the pins from delrin bar, a washer and R clip to fix in place



What do you think about these to go on the tail section?

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Re: GSXR 600 K5 tail conversion + quite a bit more in the end.

Post by cabbie on Sat 06 Dec 2008, 23:02

So, here's the finished hinge unit


Mounted to the subframe to check for correct clearance etc


Pod fitted.


And here's the pod closed, perfect fit, i'll make the catch tomorrow
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Re: GSXR 600 K5 tail conversion + quite a bit more in the end.

Post by wild bill on Sat 06 Dec 2008, 23:51

Looks spot on to me mate.

Popped in Merlins earlier today for a chat'n'that, he said he has a wheel in black that'll do the job, yours for 50.
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Re: GSXR 600 K5 tail conversion + quite a bit more in the end.

Post by cabbie on Sat 06 Dec 2008, 23:59

wild bill wrote:Popped in Merlins earlier today for a chat'n'that, he said he has a wheel in black that'll do the job, yours for 50.

I'll call in Monday first thing, cheers my old China.
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Re: GSXR 600 K5 tail conversion + quite a bit more in the end.

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