rdstars nearly finished.....99.9% there...

[rdstars]

I've been promising myself a rebuild for my rough roller Hybrid for a number of year's so one late afternoon a few months ago I pulled it completely apart. I knew it had a few issues that showed up on track at Llandow last September. my man cave is in a complete mess and nothing has been cleaned for the quick photos.

Basic spec is as follows:

RD350 F2

Frame braced all around the bottom cross member around the shock links and also from swingarm point right up to the head stock incorporating the upper section of the frame, also to this a fair few of the stock rubbish welds have been beefed up a bit. GSXR750 K model rearsets. Expansion bottle moved to where the oil tank used to be located.

Rear end is Honda VFR400 NC30, powder coated bright silver with all the factory castings removed, custom spacers and obvious mods to the frame to fit. Wavy disc and braided line from Wezmoto.

Front end is ZXR400 H forks, yokes and clip'onns, KR1s wheel, CBR954 Calipers, ZZR600 Discs, CBR600 02 Master Cylinder and clutch leaver, shorty leavers, Vapor dash, RD headlight replica, original switchgear, Braided lines from Wezmoto. Obviously custom front axle and spacers for it all to fit together.

Engine is RD350, 31k carbs, Martin77 Port/Clean up job ( very nice port work from Martin and would recumend him, top guy ) single layer head gasket 0.85mm squish, stock crank, TZR Reed block modded centre stopped and 3mm reed spacer, foam filters, stock ignition for now ( probably invest in Zeal ) Modded Powervalve controller so I can set my open and close times, TSA design pipes to my spec built by me ( Kenny sure knows pipes ) EBC HD Clutch Springs, RWHP I dont care as I just want it running nice but estimate mid 60. RD350LC flywheel side cover, Clutch window mod 10mm Lexan. Oil pump ditched.

Stainless new nuts and bolts used where I can but also used allot of older nuts and bolts to give it a usable look / daily rider if that makes any seance ( not a show bike ) ( costs to much money ) All the Powder Coating was done by RPA Bristol Powder Coating. Paint I was going to do myself but for this one I just could not take a chance and bottled it, it is in the hands of someone else who I am hoping and praying does a real good job, going to be Black with N2 decals, I have given him free rein on straight or metalic and even pearl Black so not sure how it will be, he did have in mind Subaru Black Metalic Pearl but not sure if he can get his hands on it.

Well all that may have bored you all so I wont beat around the bush any longer and just post a few photos over the various stages........It's not perfict but it all works so far and most done by me as I don't see the point in building something if your not doing the work yourself, just buy one done if that's the case.

How she was as a rough roller:



Got my frame all welded up:



Re'built and painted the motor all new seals etc:



Some Powder coated bits:



Frame Powder coated:

















A bit feather on:










































Next update will be running with body work on ( Hopefully )

Cheers

rdstars

[flames]

lookin very spunky dude.i take it with all that bracing you intend to ride hard.lol

[47x]

would"nt it be because of the weight of the single swinger,they are VERY heavy.theres a lot of extra pounds on there from stock!

[lcolin]

What finish have you used on all the silver bits? I like the look of them.

[rdstars]

The extra bracing I feel is needed because of the stiffness of the modern parts and the RD frame is know to flex a fair bit, Also because duel down tubes just look the nuts.

The silver bits, swingarm, fork down tubes, side covers are Bright Silver with Clear powder coat. The other silver bits, bottom of the forks, rear sets, cross over tube were done with Plastikote Silver.

Reason for going silver powder coat and nothing fancy is to try and keep a period look to the bike, almost like it could have left the factory like that, if that makes any sense.

[chamber66]

That looks fantastic

[busaash]

very nice , like the frame bracing too ;D nice to see it completed

[billbott]

Kelvin, that looks well smart. The frame is a work of art.
Whio did the powder coating?

[rdstars]

Jul 19, 2012 15:49:04 GMT 1 billbott said:

Kelvin, that looks well smart. The frame is a work of art.
Whio did the powder coating?

RPA Bristol Powder Coating, there side line is specialising in Motorbike Powder Coating, visited a few places local and was not happy so took a trip over the bridge, was far from the cheapest but they undercoat, colour and clear over it all. Went above and beyond what I asked from them and there preparation masking was great.

[47x]

have you there number.

[rdstars]

Jul 19, 2012 17:48:28 GMT 1 47x said:

have you there number.

www.bristolmotorcyclepowdercoating.co.uk/contact.html

Almost everyone who I spoke to at the VJMC told me that is who they used.

[peterlc2]

That is very nice, love the frame too, only thing is red frames go faster than black ones

[andyo]

the double downtubes look fantastic a top mod. i also like how you have left the left and right engine covers silver for a change it gives it a striking look. i would be very pleased with the result if it was mine.

[tommo]

mint job

[rdstars]

Ops Sorry this update is not finished and running but just picked up my panels and got work in the way of finishing it off, just need two or three days to get there.

I am pleased with the paint, that is about 99% there and the reflection is great with no orange peal effect that you see on so many new paint jobs. The decals well I'll give them a 98% as there is slight mistakes ( I can cover it up with a small tank pad ). BUT it was a someone who deals with cars, he told me NO! to fitting decals BUT stubborn me insisted that him fitting them would be a better job than I could do. Done in 2k straight black with decals also covered in 2k clear.


Some photos, I've done nothing to make them look nice but some natural light would have done the trick but to late now.

[rdstars]

Well today she breathed life,,,,,,,


,,,,,,,,,,,,,,Not without some blood & tears.........


Carb's leaked a little, got it started and then they leaked allot,,,,,,,Must have forgotten to tighten the drain bolts

Sorted that out and would not run right,,,,,,,Carb Slides in the wrong carbs

After pissing around and the bracing does get in the way of working on the carbs got the bike running, smoked evenly each side and rev'ed quite cleanly with no setup.

Small issue, before started over the last week or so loosing slight water, about 10-20mm in the filler, no obvious signs of leaks or water marks, oil looks fine and compression is even each side. Could be a bit of air in the system as I've not even bled it yet but water leak is not the end of the world if it is that.

It sure is nuts when trying to keep things clean and clear how much crap gets over things.

Well 99.9999999% done, will update soon and get some decent photos done.

[rdstars]

Day off to do a few things and TYPICAL Brittish weather,,,its Peee'ing down. Cannot get it out to do any good photos, take it for a quick once over or anything.......

Some poor photos of roughly where I am. Just a once over needed round the block, Mot & some decent photos.










Just need a day to myself with it being nice, I'm not holding my breath waiting though.

[leaky]

She's looking mint Kelv'.

[chez]

looks nice but treat your self to a new number plate

[rdstars]

Cheers Leaky, Yup chez will be putting a nice small plate on but Mot first

Ran into a small problem, heard a rattle, clunk, tick boom...............

.............Worse thought,,,,Piston/Crank Something I done wrong,,,,,, Pulled the top end off and all is well. strange, pulled the flywheel off and a washer got stuck in there with the stator,,,Ahhhhh

Also slight fuel leak from the tap, so new Base gaskets and tap sealing washers on order. End of next week now and she should have the niggles and top end sorted & back on.

[rdstars]

No real updates but managed to get 5mins dry weather and spare time to get a breath of fresh air:

[billy]

Sweet! I love that last pic.

[rdstars]

Had a few more niggles but managed to give it a quick run, Throttle cable needs addressing as it keeps sticking open and clutch slip.

Strange thing is left cylinder was missing, could not figure it out and was sure it was carb issue so I did something a little different...... Put on my PJ Carbs all stock apart from 380 MJ and ran them open.....................................

.......................On a quick run it was amazingly crisp bottom end and pulled hard through out the power, nice kick without being like a light switch.....
............But instantly the clutch slipped..........And still managed to lift the wheel without trying.

Martin77 Port work and setup advice is spot on and Kenny's design of the pipe works well.

Considering I did put new EBC springs in, clutch slip and how my arse dyno felt should be mid to late 60's rwhp.


So just Throttle and Clutch to sort out:

FZ600 Friction plates maybe?

[phil]

Great job mate bet you are well pleased a real head turner!

[bare]

Nice careful work.
Just out of idle curiosity: can you remove the rear wheel without removing at least the end cans?

[nikfubar]

Jan 1, 2013 22:31:24 GMT 1 bare said:

Nice careful work.
Just out of idle curiosity: can you remove the rear wheel without removing at least the end cans?

I can ;D


I fitted a set of new clutch plates & HD springs from Norbo & no hint of clutch slip

Nice job BTW looking well smart

[rdstars]

Jan 1, 2013 22:31:24 GMT 1 bare said:

Nice careful work.
Just out of idle curiosity: can you remove the rear wheel without removing at least the end cans?

Nope not at all but it is still simple enough, 2 springs at the front and a bolt at the rear, few mins and its off.

Going to go with some EBC HD Friction plates, with the EBC HD springs that should hold it hopefully. Just got to figure out the Throttle cable, think removing the oil pump cable is causing it to twist, move around and holding on slightly.

[copper99]

Thats a beauty mate, stunning build.

Nice to see one in that colourscheme too.

[wheeliecrazy]

Lovely :-)

[Yogi]

I want one,classy build,best hybrid I've seen