This all started many years ago when I thought it would be really cool to have a 2 stroke engine in a more modern chassis and street legal.
A few ideas turned into the purchase of some parts and it began last year. ( i kinda went ADD on projects and the Bronco received no work and as a few of you noticed I fell off the face of the earth here )

I am stealing all this from another bike forum so as to not have to type it all again, please forgive me.

time frame was the weekend before thanksgiving when I made the trip south.

Enjoy......

It has begun, and is in full swing now.
Made the quick trip from Denver down to Albuquerque NM on saturday to trade my "too clean to tear apart" Hawk for another guy on the Hawk GT forums almost "too far to bring back" Hawk and a full race prepped RZ350.

Sunday after getting some much needed sleep after the 14 hour road trip on sat, I woke up, popped a monster energy and started unloading and making room in the garage.

decided since I cant afford(according to my mrs) a nice hydraulic stand I built me a wood one.
Redneck engineering at its finest.

Best part is since I am a pack rack it cost me nothing but some time. most material was wood leftover from my deck remodel last year.

not purty but will be nice to keep from being bent over for the whole time this project is happening.

Here is the new stand




with the Hawk up on it moves around quite easy and is 23" tall, I think it will work very nicely



here is the donor RZ



The Honda CBR600RR front end that will be sent out this morning and should arrive by xmas



I decided I had to fire up the RZ and take it for a quick spin just to get an idea what I was in for since Ive never ridden one.

Battery rigged from my SV, temp fuel tank.
added some water to the rad and fired it up.
main jets were a little big as it is jetted for 1600 feet and I am at 6000, so as soon as it started to come up on the pipe it started to fall flat but let me tell you this thing is going to produce some smiles when all done in the hawk and tuned properly for this elevation.
man I can't wait.






I told my wife i will see her in March sometime, and if she needs me to look in the garage

rear wheel HP should be about 65-70hp from the build sheet this engine has and I am hoping to have the weight down to about 275ishlbs.


Bike will retain its naked/fighter style with a large round headlight out front, it will have a single seat race tail either from A Honda RS125 GP bike or possibly a Honda RC211v moto gp tail with the exhaust routed either up under the tail similar to a Ducati 916 or very high with one on each side depending on what works out.

I think the frame and swing arm may get black powdercoat with the tank and tail sporting some honda HRC red/white/blue coloring with white powdercoat wheels.
at least thats the vision in my head, it may change 3 or 4 times before its done but that is where I think I want it to be.

example of HRC colors with a RS 125 style tail



the tear down.
have the next 6 days off so we'll see how progress goes.































some updates

Hawk engine pulled and rz engine stuffed in there to see how it fits.

Also dug my rashed RC51 tail from the rafters just to see how it looks.





Got some more work done last night.
had a bit of a slow start as a new toy/tool showed up and required some slight assembly.
I have a bench grinder, handheld grinder, files, and sand cloth but not a power sander, until now.

not the best there is but with the gift card my MIL gave me it came pretty cheap and so far works great.





this pic shows the series of engine mounts.

the front mount using the hawk bolt and spacers just slightly shaved down.
kinda crazy how well it worked.



this one is the rear mount, using the salvaged ZX11 "triangles"



here is the start of my bracket to grab the two 10mm holes under the engine.
bracket drilled



frame drilled and getting tapped
my small tap holder were too small so i regretably had to use a wrench, still works just way slower as its harder to keep straight.



1" square tube to mount under engine.
it spaces perfect to catch the rear frame mount with some flat strap.
the ends of the square tube will be capped and dont worry all the craptastic welds,
They will be cleaned up with a grinder and smoothed out to look clean even though they will never really be visible, it just needs to be done right.



tacked



welded





added some tube spacers to fill the gaps where the hawk engine holes used to be. allows it to be tightened without tweaking.
Please advise on the swingarm mount spacer, is it just a spacer or does that area have a function. IE- should it be a much larger peice of tube and maybe not aluminum?
I figured it just needed to be a spacer to keep the steel sleeves in the swingarm pivots but dont know?



Also I have been considering adding a bracket to catch the third hole in the zx11 mounts and having it welded to the frame. Not sure if it is needed for strength, but it can't hurt and will at least look to then be finished and will actually look like the braket was made for it instead of stolen from another bike.
Biggest issue is getting it welded as I dont own a TIG setup. Might see what the local weld shop would charge me to lay a few beads. It would need to be tacked as it is then remove everyting and take it to them just the frame to make their job easier.

here is the upper hole



and a quick rough example of the idea

weld the curved edge to the upper frame tube and then match the shape of thebracket on the bottom edge and drill it and slip a bolt though both of them



I think all in all it should be strong enough with what I have, and adding the welded mounts will make it a bit stronger and look more finished.

Updates:
got the cheaper upgrated shock, in a brown van as I type this. Fox TC.
got the rad mounted
Mag side cover cut down to squeeze in front of the frame by the CS Sprocket
replaced a bunch of bolts on the engine side covers as I was putting them back on
working on mounting all the electrical, cdi,powervalve controller and servo, rectifier.
pulled subframe off, getting ready for my hiperform to shop up any day now.
shortly after that I hope to have my tail.

going to see about swapping the 600rr front in there if I can get the hawk wheel to work in there for temp.(no tire on the 600rr front and dont want it getting nasty while everything else happens)

916 seat on stock stubbie




and gone








here are some updates.
got my subframe and tank and RC211V tail officially mounted.
lots of aligning, drilling and tapping.
got some rearsets bolted up.
fox shock is mounted going to wait til the exhaust is done to see where the reservoir will go.
some more wiring done (no pics)

also playing around with exhaust a bit, I originally planned to run duals under the tail kinda as pictured but due to the route I am choosing for the pipes the mufflers will need to be one off as the size isnt standard.

So this leads me to maybe running a 600rr or ZX6rr under tail that is off the shelf and have my pipe builder make me a 2-1 to meet that single 4 stroke muffler.
really liking the carbon Jardine RT1 with dual outlets kicking out at a bit of an angle. but it runs right at about $450-$500 just for that one piece and considering my custom pipes might be pushing the $2k mark with shipping and everything it is going to be one really expensive exhaust.

update as I know the cost,crazy as this is only the exhaust $2600 all said and done

I left out a bunch of boring details but currently my pipes are being built up in Canada, I am going to be running dual expansion chambers running into a single Two Bros Racing carbon fiber and black anodized magnesium muffler coming out under the tail.

There are a few pictures that are missed as they are not loading from my work puter, but here is the jist of its appearance before being sent to Canada for the custom Exhaust.

When that stuff shows up in about a month it is quite possible I will again disappear from here as all my attention will be on the bike project and getting it hopefully ridable by summers end.

here she is:

Thats going to be F'ing RAD!

Very cool project. You told me what you are working-on, but had no idea you were a full custom bike builder. Very cool project.

wow, that is a great project

you got some mad skills...........no wonder your Bronco is so nice

Those bikes are awesome!

We love bikes and scooters....here is my last project and Jonah's scooter. Not everyone's style but both are a blast to ride! Both were garage built in Greeley.

Donor:


Finished Bar Hopper:


Jonah's Ruckus:

Sweet bikes BFD - I wanna ride that Buell.

here's a picture of my ghost bike i got from batman.

[quote="BFD305"]
Not everyone's style but both are a blast to ride! Both were garage built in Greeley.


Finished Bar Hopper:
You are right not everyone's style.
Just as mine isn't.
The coolest thing about it though, is it is not cookie cutter like everyone elses and another builder can see what was done and appreciate it for what it is and the time and effort put into it.
Like all the custom touches, ie: the seat post shock..very cool.
and I am just guessing here but wind noise wasn't a problem on this one was it?
LOL straight piped torque monster

Jonah's Ruckus:
these things are huge over in Japan, I hear with some relatively minor mods they will haul pretty dang good.
Very nice gents

That bar hopper is awesome. It looks like it should be sitting next to an Ariel Atom. I really like vehicles that have everything removed that doesn't have an immediate purpose.

OK get ready.
Sit down and grab a tissue.

The Pipes are done.
and they turned out amazing.

Just have to send the check and wait for it to him to clear it then send it back and wait for it all to arrive.

enjoy

All I can say is...WOW

Holy crap, that's amazing.

are you actually going to put those on the bike...................

or hang them on a wall like a fine piece of artwork

Might just build the bike then put it on a pedestal, be afraid to damage it somehow

That exhaust is awesome. The work you have done is great. It's fun to look at the pics and see how it all went together. Going to be a sweet bike!!

The pipes are sick! Thats ganna be fun I cant wait to test ride it for you.

You better ride that thing and not just use it for a helmet rack.