Project GT500 hybrid

[nikfubar]

Well it's time to start my next winter project, I'm frustrated trying to get hold of an AC RD350 that's not going to cost an arm & a leg before I even start hacking it to pieces so I found a GT500 engine on ebay, so will build something around that.



This is one heavy engine, it feels like someone has emptied out the contents & filled it up with lead. Anyway stripped it down to a shell to make it easier to move around but it's still bloody heavy.



This is the frame I plan to fit it to, from a GS500.



Got a rear end off an NC29 gullarm which slots straight in, will need some suspension linkage modifications though.



Also got a complete front end off an NC24, not 100% sure if I like this but it will do for now.



So time to get the big hammer out & make a start.

[andygasgas]

If you don't use the front end I can give it a good home ?

[steeley]

nice start of a project there.yes gt500 engines are heavy.you can get them tuned up to poke a bit of power out from std.good luck with it.

[arrow]

One of the strongest 2-stroke motors to ever come out of Japan.

[markhoopy]

The T500 & GT500 made great production racers - plenty of poke hidden away in that heavy old engine!

[deltadave]

love the ideas will keep you bizzy good luck carnt wait to see it finished

[marsbar350]

this will be a watcher
phil swiv on the 2stroke forum put a t500 in an rgv 250 frame this year
good luck with the build

[marsbar350]

looking at the first pic
4 pipes putting oil straight into the crankcases
proper old skool lubrication

[billbott]

Watching this one.
With you on the weight of suzuki gt engines - my 250 is the same!!

[midlifecrisisrd]

Seen phils t500 rgv. Motor is huge so not surprised about the weight.

It will be a torquey mutha

Grinder, hammer and welder at the ready lol

Steve

[nikfubar]

Dec 1, 2014 13:13:13 GMT 1 headcoats said:

Not sure about the frame Furby but you do come up with the goods

I bought this frame because they are strong & rigid but mostly because it's steel & I can hack it around & re-weld it plan to cut off the back end & fit a single seat unit. Also it's good from a registration point of view ie: Suzuki GS500 frame with Suzuki 500 engine PLUS IT WAS CHEAP £35.00 for the frame & £60.00 for a dent & rust free tank, try getting RD ones for that

[dusty350]

I reckon this will make a great project. I love the look of those old 500 engines - barrels are huge, makes an Rd400 look small !!
Good luck with the build.

Dusty

[nikfubar]

Yeah seen the Kwikasfaki awesome but personally I really don't like the slingshot frame, I've no idea what it's going to look like until I try the engine in the frame but just had a quick measure up & found the down tubes are exactly inline with the exhaust outlets so that's gonna take some modifying if it's no good I'll just scrap the frame.

[muddyfox]

so it will be reg'd as a gs500 imagine if you didnt warn the next owner lol

good build!

[Paul H]

Interesting build, I will be keeping an eye on this one

[JonW]

always interesting to see what Nick does next! Im liking the sound of this one, all power to you mate!

[yamfan]

Dec 1, 2014 18:42:25 GMT 1 nikfubar said:

Yeah seen the Kwikasfaki awesome but personally I really don't like the slingshot frame, I've no idea what it's going to look like until I try the engine in the frame but just had a quick measure up & found the down tubes are exactly inline with the exhaust outlets so that's gonna take some modifying if it's no good I'll just scrap the frame.

Is it possible to create a Ducati style trellis "infill panel" that'll give the strength required and allow the exhausts to pass by it? Easier said than done though. Lol

[nikfubar]

Dec 3, 2014 14:44:43 GMT 1 yamfan said:

Dec 1, 2014 18:42:25 GMT 1 nikfubar said:

Yeah seen the Kwikasfaki awesome but personally I really don't like the slingshot frame, I've no idea what it's going to look like until I try the engine in the frame but just had a quick measure up & found the down tubes are exactly inline with the exhaust outlets so that's gonna take some modifying if it's no good I'll just scrap the frame.

Is it possible to create a Ducati style trellis "infill panel" that'll give the strength required and allow the exhausts to pass by it? Easier said than done though. Lol

Think I know what you mean Are you saying cut the down tubes off & then weld in an X shape, think that would look good. Have you got any pictures as an example of what you mean.

Started bolting bits on today, the engine is tight in the cradle so it's a good job one side unbolts.

[nikfubar]

Dec 2, 2014 21:46:00 GMT 1 JonW said:

always interesting to see what Nick does next! Im liking the sound of this one, all power to you mate!

Cheers Jon, got to do something to stop me brain turning to mush

BTW does anyone know where I could get my sprocket carrier machined down by 8mm that doesn't cost an arm & a leg

[yamfan]

I was thinking of a two horizontal bars with a series of x's, triangles, or bars like a ladder, with the exhausts passing through it but the dimensions might make it too tight. Your x idea sounds better, but I think I'd put a horizontal bar top and bottom to add rigidity though. Lovely job so far though matey.

[midlifecrisisrd]

Hey nik did you not put an extra frame rail in one of your ypvs projects that was a bit trellis ish

8mm is a lot to machine off. Lucky if you can get half that usually.

Can you not remove the studs and use countersunk bolts.

When I was going the gsxr wheel in the Rgv are I thought of mounting a disc on the sprocket mount then using a sprocket on the inside of it. Might let you away with less machining.

I tend to use a one man engineering shop near me. Helps he has bikes, nice old fella.

Steve

[nikfubar]

The wheel matches the arm so bolts are not the problem, I need to move the sprocket in to avoid hitting the frame & to line up with the chain tunnel on the engine, 20mm in total, could probably get away with 10mm offset sprocket then say 4mm off the carrier & maybe some creative welding with 2 sprockets need more booze & I will come up with an answer

[nikfubar]

Well things are moving on, all the engine mounts are fabricated & welded on, just need a few spacer tubes tacked into place. The engine sits quite nicely in the frame.



Also finished the linkage & shock mounts so now I have a rolling chassis.



Starting to take shape now.



I've got hold of a mint condition KTM seat so that's going to be cut & shaped to fit round the tank & the rear sub-frame cut off & re-shaped & welded to suit the seat. Lots of work but should look good hopefully. Also got some brand new Kawasaki foot rests, they are going to take a bit of thinking about as well

[steeley]

nice,i like that .nice project there.what pipes /and tune you looking at some thing mad or nice and laid back with plenty of grunt.

[nikfubar]

Booked in with Kenny @ TSA to do the pipes & will discuss tuning with him, thinking of making some reed boxes

[markhoopy]

Looks to be coming together very well .. and quickly too

[dusty350]

Wow, Nik, you don't hang about do you
Looking good so far. Did you decide how to get round the down tube/ pipe issue ?

Dusty

[nikfubar]

Dec 11, 2014 21:05:34 GMT 1 dusty350 said:

Wow, Nik, you don't hang about do you
Looking good so far. Did you decide how to get round the down tube/ pipe issue ?

Dusty

Think so once the spacers are in & the engine is bolted in tight to brace everything I will cut the down tubes one at a time & re-route them around the outside of the pipes.

[botty]

Great work. Watching this one.

[cinder]

I totally agree with the reed valve conversion, I thought about a whilst a go, decided to go down the same route with a H1, didn't go with the t/gt motor because of it's overall length. You have a good frame cradle to play with as it already fits. Good luck fella I'll be pulling up a seat for this one