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Project The Yamaha R4 (Glacially Slow Project)

Discussion in 'Other Projects - Other Bikes (non 250's)' started by maelstrom, Dec 20, 2014.

  1. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    Somebody moved this to the project section. So now the jig is up and I will have to post something.
    :confused:
    Anyway, the goal is to make an R4 loosely based on the Yamaha R7 OW-02 and using my FZR400 as the starting point. I have a build page here http://litetek.co/R4/R4_Project.html but it is just a work in progress.

    This is what an FZR400 3TJ1 looks like.
    [​IMG]

    And this is what an R7 looks like.
    [​IMG]

    The plan is for a half fairing. I was going to buy an R7 unit and hack that up but I ended up buying an early R6 race version so I can fit round headlights. Seat is based on the R7. Radiator is going under the seat. The instrument cluster, from an R6, is the same as the R7 except for the white face, and there is a page on that here http://litetek.co/R4/Guide_R4_InstrumentCluster.html

    [​IMG]

    Electrics are being changed a lot. Rewiring with Tefzel coated wire and lots of new components.
    Ignition switch is an RFID by MotoGadget (the blue thing is the key).
    [​IMG] [​IMG] [​IMG] [​IMG] [​IMG]

    Electric water pump to replace the binned mechanical one. Shindengen SH775 reg-rec. The fuse boxes are Cooper-Bussmann (only took me 4 months to find them), completely waterproof and can hold micro-relays as well as fuses (nice). Headlights are 90mm Hella. Still have to buy the electronic control unit for the pump/fan and the GPS speedo sender.




    As part of this project I have to get rid of the wings on my 400. Now I am sure that some people think they look good. I am very happy for you. But for me, the word hideous springs to mind. In any case they are not in keeping with the final goal.

    [​IMG]
    Cut, cut and cut.

    Need to have something level.
    [​IMG]
    and the laser level comes in handy for that.

    Keep cutting with a little bit of welding thrown in. Welds aren't perfect yet. I am still getting the hang of my new machine, and I have the wrong tungstens. The pulse setting is wonderful.
    [​IMG]
    Laser line shifted up to new lug. Note slight gap. :)
    I know you are going to say "Why didn't you do multiple cuts?" actually I did, just not enough. Anyway it will come out fine. The back section also includes a lug for the lower part of the new sub-frame to attach to. There are four pieces of the old cast wings that go together to make this.

    [​IMG]
    Nearly halfway there. I sat the tank on just to see where it sits. Maybe finish it tomorrow if I don't run out of gas (tiny little bottle in the background).
     
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    Last edited: Feb 21, 2016
  2. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    Sharks with Frickin Laser Beams!

    One of the problems when you bin everything is that it is very hard to align all of the new bodywork and mounts that need to be fabricated. In my case I have nothing left to attach anything to.

    So I mounted a cross-hair laser to the ceiling. This is one of the more expensive versions. The $20 jobbies will not maintain a fine line over any distance.
    [​IMG] [​IMG]

    I use a plumb-line hung from the ceiling to align the laser vertically. It is very sensitive, so I recheck the alignment of everything before I weld or fix something into final position. You can see in the image on the right it looks like the line is not running down the centre of the bolt. But it is just the left-right alignment that I need to reset (rotate the bike clockwise). Notice how that same bolt is not centred in the lug, thanks to Yamaha for that one.
    cheers
    Blair
     
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  3. GreyImport

    GreyImport Administrator Staff Member The Big Cheese Contributing Member

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    Mr Green ...I finally got you out of the closet with this one ..... :dance2:

    awesome project :bowdown:
     
  4. Grasshopper

    Grasshopper Well-Known Member Premium Member Dirty Wheel Club

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    Nice work! Should be an awesome bike...
     
  5. Fox McScrooge

    Fox McScrooge Well-Known Member Premium Member Contributing Member

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    What sort of welder is that you have there Blair? I've been thinking of investing in something a bit better than my caddy. Mainly because I'm entertaining the thought of getting a plate alloy boat kit and I definitely want to make a new camper trailer out of alloy. I've been lead to believe that a 250amp MIG is the go for alloy?
     
  6. Moo

    Moo Plodge Racing!!!

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    subbed :)
     
  7. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    @Fox McScrooge
    It's a Chinese AC/DC TIG. It is the new version (new body anyway) of the 200P which has been kicking around for a long time. They are sold as all sorts of brands but they are all the same thing. Sure it is not a Miller, but I am impressed for the money and I won't be using it that much.
    [​IMG]



    For that sort of job (the boat and trailer), I would go for a mig too. TIG is too slow. 300 amp might be better, you might need the extra grunt. You can use a normal push mig with the teflon liner but the secret is to make a tripod on wheels, or overhead gantry, and hang the unit up in the air. That is how they used to do it at Clark boats. You want as close as possible to a straight line between the spool and the handpiece. The feed line also needs to be as short as you can use. There is no compromise on this, any bends in the line and the wire will melt straight back up into the handpiece. I used to use a Cobramatic when I worked at Lloyds Ships in Brisbane. Those things are seriously wicked and priced to match. The other thing is that if you need to do pipework for the boat you will need also need a TIG.
     
    Last edited: Feb 26, 2015
  8. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    I knew it would be you :minigun:
    Oh well. Some more motivation to get something done can't be a bad thing.
    cheers
    Blair
     
  9. Tim_

    Tim_ resident nutcase Premium Member Dirty Wheel Club Contributing Member

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    i was actually wondering how the CBR would look with the R6 front end lol..

    inspiring you are my good sir
     
  10. Fox McScrooge

    Fox McScrooge Well-Known Member Premium Member Contributing Member

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    Thanks Blair. I've been considering a unimig inverter that will do mig, tig and stick. I've done a lot of stick with steel over the years but never welded alloy. I've heard its quite a bit harder? I've heard about needing the Teflon liner and different rollers so you don't crush the wire. The tripod is something I never would have thought of. You think it's worth getting a seperate wire feeder?
     
  11. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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  12. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    Baby Steps

    My electric water pump bracket arrived today, so time to see if it fits correctly.
    [​IMG] [​IMG]
    I drew this up a few weeks ago and had it 3D printed in nylon. Fits perfectly with no clearance issues so now I can go ahead and get some silicon hoses.
    Now I know what you're thinking. Why didn't I just fabricate one from aluminium? Because the electrical plug housing and lower part of the pump body are wider than the section where the bracket supports the pump, I had to stretch the nylon over the bottom of the pump to fit it. This was just luck as I had no idea if I would be able to do this. Davies Craig recommend that you can support the pump by its hoses, but I chose to err on the side of caution.

    The oil pump has to be taken out from the other side of the engine and have the end of the shaft cut off. It used to drive the mechanical water pump, and it is not a good idea to leave it as an unsupported shaft.

    [​IMG] [​IMG]
     
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    Last edited: Jan 13, 2015
  13. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    The R7 comes standard with Ohlins front and rear. Something that I will definitely not be doing :)
     
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  14. cal

    cal Well-Known Member Premium Member

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    wish i could fabricate parts! bloody well done :)
     
  15. 2smokeRonin

    2smokeRonin Active Member

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    OW02 R7 is one of my favourite bike!
    Love this project.
     
  16. risky

    risky risky

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    aluminium welding is a breezewith the right gas and more than 180 amps. the more amps the better but you need a good respirator or even better an external air supply as the fumes get pretty strong. as i get older i get wiser and pay for alloy welding- reason is you do not live without lungs.bit like playing russian roullette.
     
  17. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    Well thanks for all the encouragement guys.
    It is not going to look identical to the R7. I have tried for too long to come up with a workable solution to the fairing issue but lights and screens for the R7 are very difficult to obtain, so I am thinking of using an early R6 top and grafting round lights into it. Sorry, but those enormous diamond shaped things just don't do it for me (anyone notice the headlights on the 2015 R1).
    [​IMG]
    These are 90mm Hella. Some serious illumination.
    That is my photoshop mod by the way, not an AirTech option. :)

    Edit: Have bought the fairing and the lights so this will go ahead.
     
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    Last edited: Feb 26, 2015
  18. Tim_

    Tim_ resident nutcase Premium Member Dirty Wheel Club Contributing Member

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    i was meaning fairing lol... i just finished my suspension upgrade lol
     
  19. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    @Tim_ I think your Honda looks brilliant just as it is. I wanted to buy a CBR400 NC23 but couldn't find one.
     
  20. Tim_

    Tim_ resident nutcase Premium Member Dirty Wheel Club Contributing Member

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    Oh it was more a thing i would like to mock up my R6 front fairings to the blade and see how she looked... would never attempt that... Im still learning all about suspension set ups now i have the adjustments..
     

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