Tank with the gas cap bonded into place. Same resin used for making the tank, thickened with glass microballoons. Hopefully no one will ever try to remove the screws holding the gas cap in place... they aren't going anywhere!


cf reinforcement for the fuel pump mount. Will be bonded to the bottom of the gas tank with studs running out the bottom for the fuel pump to mount to.


The idle valve circled in red on the wrong throttle body. Tomorrow I'm going to the machine shop to do the work needed to put it on the right throttle body.


Plenty of clearance with the idle valve in place though. :thumbup

Aluminum is on its way for the rear sets. Bought enough to make 3 sets.

Last night I placed the cf reinforcement for the fuel pump in the bottom of the tank and set some studs down through the tank



Now waiting for ups to show up with the tank sealer so I can start sealing the inside of the tank.

So I'm sitting here shopping online for some polystyrene foam so I can start prototyping the air tank for the bike. Can't find it anywhere. Look out the window, and a box truck from Bob's Foam Factory pulled up to the neighbor's house. Guess who carries the foam I need?

I need to start visiting the site more.. 

Sealant showed up yesterday in the mail.





It'll get a couple coats with the halves separated, then a little added after the tank is sealed to coat the edge.

started working on the air tank today. This is just a rough shape for a plenum. Volume is about 3 times that of a single cylinder. This is the proper size plenum design for a forced induction application.

A whole lot more pictures to follow from today's work when I upload them off the other camera.

Been working on getting everything mocked up on the bike.


Was planning on using the space between the subframe rails to place the ecu, etc... but this didn't actually leave anywhere for the rear tire to go when the suspension compresses.

With the stock rear fender in place it's obvious I have a serious shortage of space.



I don't have any intentions on ever running a passenger on the bike, especially since I've shortened the rear subframe and removed the passenger pegs, so I'll make some room in the seat itself. No need for any foam for the passenger to sit on, so I'll make a carbon seat cowl and remove all the seat foam and supports below it, giving me a place to put the ecu.

A well stretched trash bag over the seat provides a nice smooth surface, protects the seat for resin, and separates easily after the part dries.


An hour or so later, covered in fiberglass.

So what do you do when it's too cold outside for the resin to cure but you have work to do?

Revert to your fort building days of your childhood!

chairs + blanket + space heater=


The FortOven





cf tank getting the two halves joined and the cf seat cowl curing

Are you going to make the seat cowl a solo seat design? I dont really like the look of some of the seat cowls on here, as they look like just a slip cover and I think if your gonna do that you might as well add a little different profile to it so that you can tell its there and not just a "hard seat"....    I know its more work but it sure does look a hellova lot better.

Quote from: Chanse on November 26, 2010, 06:52:11 PM
Are you going to make the seat cowl a solo seat design? I dont really like the look of some of the seat cowls on here, as they look like just a slip cover and I think if your gonna do that you might as well add a little different profile to it so that you can tell its there and not just a "hard seat"....    I know its more work but it sure does look a hellova lot better.

To start with, just a "hard seat", although this is on a corbin seat, which already is a bit more of a solo seat design, so we'll see.







I've been contemplating using an intercooler for my air tank for several month. Unfortunately, finding an intercooler small enough is a bit of a task. Finally got some dimensions on one of the smallest factory intercoolers available. This is from the mazda millenia. Apparently they run two small intercoolers.



Unfortunately, the size is still on the large side for a bike. So I made a foam mock up to see if I could find somewhere it could fit.



This is about the best place I can find. Not sure how I feel about it.



Also picked up some foam today to start working on an idea I've had for some time for making carbon fiber charge pipes for the intake. I made a little 4" long section to test it out. We'll see if it worked or not after the resin cures.

CF charge pipes? yes please!
So the new method works as it should.



From foam to pipe in about 5 hours... not bad at all.

put the intercooler under the rear seat cowl with some sort of ducting

Quote from: skirecs on November 27, 2010, 12:04:17 PM
put the intercooler under the rear seat cowl with some sort of ducting

Doesn't leave me much space for the ecu and other electronics

cant fit the electronics in between the battery and the air filter? thats where im planning on putting mine

if the IC is in the cowling you could have some good air flow, better than under the seat

also if im looking at your air valves right it will be compressing air out the front right?  why not switch the vavles so intake is in the front, exhast is the back, goes into the IC and then forward again to the IC, so it makes a loop?

Quote from: skirecs on November 27, 2010, 01:45:18 PM
also if im looking at your air valves right it will be compressing air out the front right?  why not switch the vavles so intake is in the front, exhast is the back, goes into the IC and then forward again to the IC, so it makes a loop?

I've considered switching the valves, but clearances on the front make flipping the valves around a bit difficult. Also, concerns have been brought up when I discussed the idea with others about the intake and exhaust port sizes and losing some efficiency there. I'm still considering it though.

Quote from: skirecs on November 27, 2010, 01:33:11 PM
cant fit the electronics in between the battery and the air filter? thats where im planning on putting mine

if the IC is in the cowling you could have some good air flow, better than under the seat

I think it'd fit

but there's really hardly any air flow back there. Major low pressure area.

The under the seat idea was more for just an air tank, not an intercooler.

Quote from: skirecs on November 27, 2010, 01:33:11 PM
cant fit the electronics in between the battery and the air filter? thats where im planning on putting mine

Lots of electronics to fit in there

cf pipes look like they'll work well



and a few more pictures of the seat cowl

i might have said it before... but I envy your fabrication skills.

Can't wait to see and hear this baby running.