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Discussion Starter #101
Whipped up an upper fairing bracket using a spare stem nut I got from Bsgrimes, a threaded ball joint I picked up from Grainger, and some 1/4" aluminum rod I bent up and threaded.

mocking it up with some trusty bendy straws:


and now in aluminum:


I'm going to powder coat the stem nut and ball joint to make them blend in better but overall pretty happy with the result as the fairing is rock solid now.
 

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Discussion Starter #102
Per my other thread, installed new plugs, swapped coils for tt600 units and reprogrammed the ignitech per IRLmike and closteaus recommendations. Bike starts better (although still not perfect) but runs like a champ.

Took her out on a nice long ride up to the mountains with some friends, and even 2up had plenty of power and felt great in the twisties. The suspension soaks up bumps and the bike gives confidence in the corners. Braking too is significantly improved. My girlfriend, who had been a passenger numerous times on the bike prior to the mods, kept on referring to this as the "new bike," forgetting completely that it is the same bike.

I had been worried about the riding position with the clip ons, but happy to say that even after over 5hrs, my wrists and back are fine. Sadly, can't say the same for my neck since I keep on forgetting to take my scorpion helmet out of storage and once again had to ride with my hipster special which has the aerodynamics of a brick.

Still a few little issues to work out. My speed reading went out halfway through the ride so have to check that connection. Also need to figure out an iPhone mount and wire in my USB port.

Overall, even with the small issues that need to be worked out, I'm extremely happy with how the bike turned out. Like my girlfriend mistakenly thinks, it really does seem like a whole new bike and certainly a keeper. I'm looking forward to a lot of miles together and already planning some road trips for the summer.

ImageUploadedByMotorcycle1463369267.938389.jpg ImageUploadedByMotorcycle1463369286.683749.jpg
 

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Discussion Starter #103
guess I should update this thread even though I've started several others on various topics pertaining to the build. As per my several other threads, the TBS suffered a blown head gasket so will be getting treated to a rebuild to 955 specs and some other upgrades. Due to other projects and family issues, I haven't touched it since mid September, but figured I needed to get a move on it if I want to get it squared away by the spring.

A few months back, I picked up a 955i parts engine and finally got it torn down and the pistons and liners removed. Looks like a coolant leak caused some bearing wear and corrosion in the coolant passages. The pistons, rods, and liners are in good shape with little wear but the liners were a real bitch to remove. Used a tool made from several 3" PVC test plugs, a carriage bolt, and a scrap of 2x4 to remove the plugs. Cost about $15 vs the $250 for the Triumph tool. Due to ton of gunk around the liners, they were very frustrating to get out. I can't explain to you the joy I felt when that first one popped up.



started cleaning up the pistons


got the carbon off and inspected the ring journals for wear


Also, picked up some other parts for the build:
CBR1000rr Tokico monobloc calipers
NRC tail light
Daytona 3-1 header

Now I need to remove and tear down the 885 engine, inspect the crankshaft and get the measurements for the correct color code replacement bearings then get the upper crankcase to the machine shop to accept the 955 liners.
 

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Discussion Starter #105
got the motor torn down today. Was pretty worried what I'd find as I started tearing it down.

Valve cover off and looks good. Followed the factory manual sequence and everything came apart easily


once the head came off, things started looking much worse.


Sludgecity, pop: ME


cases separated and crank removed. Looking like a complete mess at this point, but all bolts were bagged and tagged or placed into cardboard templates


Where it stands now.

 

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Discussion Starter #106
Head boxed up and on its way to Joe at DWMS racing. After working it through with Joe, I decided to stick with stock valve sizes so the head will be getting: porting the intake and exhaust ports, opening and port
matching the valve seats, cleaning the combustion chambers, polishing the valves, and a competition valve job.

I'll be getting a custom Cometic head gasket at a to be determined thickness (depending on whether the head has to be milled at all).

Scored a deal on a rack of gsxr FCR39's at almost $500 less than a new rack from Sudco. Spacing is very similar to the TBS and I think I can lob off a bank and mess with the spacing to get it right. If not, at the price I got it, I can easily sell on eBay.
 

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Discussion Starter #107
My used rack of Keihin FCR 39s finally arrived. I picked up the set of 4 for just under $600 shipped figuring that it'd be worth a shot trying to rerack them to 3 and hopefully saving about $500 off the price of a new set of 3. They just arrived tonight so I only had time to take a few measurements and start tearing them down to see how hard it will be to rerack. So far it doesn't look like it'll be too much trouble at all.

For those who are considering doing this in the future, here are some measurements and comparisons:

spacing isn't too far off



 

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That's a good find. It looks like, to me, that the carb rubbers might take care of the difference. What year and model did you get those carbs off of?


Stay safe out there,
---Charlie
 

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Going by your pics, the FCR's are 40mm?
 

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ah, ok. That makes sense. FCR 39's vs Keihin CVK 36.
I just looked up the FCR 39's for 94-99 Speed Triple. 016-716 $1527.50 US.
They've gone up since I've looked at them last.
 

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Discussion Starter #113
ah, ok. That makes sense. FCR 39's vs Keihin CVK 36.
I just looked up the FCR 39's for 94-99 Speed Triple. 016-716 $1527.50 US.
They've gone up since I've looked at them last.
dealer price from Sudco is $1082 with plastic velocity stacks. Pod filter adapters are another $40/each.

I'm hoping to get these re-racked and possibly sell the 4th carb on ebay for parts for $100-150. If so, I'll be a happy man
 

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How do you get the dealer price?
 

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Discussion Starter #115
I have a friend who works for a shop with a sudco dealer account. Still, after the pod adapters and tax it would have been approaching $1300.
 

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Still saves you 225.
Funny, kind of reminded me of this:

 

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Discussion Starter #117
Got the upper case back from the machine shop this morning. After a few swings and misses with various shops, I called around to every car and motorcycle speed shop I could within a 100 mile radius and finally was referred to a local machine shop (7 min from my house) that did a great job. Two old salty brothers who don't advertise on the web but do a lot of work for local racers.





Head should be done and on its way back to me by the end of the week. :)
 

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Did the machine shop open the case up for the sleeves, turn the sleeves down for the case, or a little bit of both?
 

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Discussion Starter #119
Did the machine shop open the case up for the sleeves, turn the sleeves down for the case, or a little bit of both?
opened up the case for the sleeves. Plenty of material on the upper case for machining whereas the sleeves are rather thin. Each bore had to be opened 2mm
 

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Discussion Starter #120
Got an update on the head. Port work is done and the shop only has the valve job to complete before sending it back to me.

Before:


Progress:




Also snagged a new rear shock for peanuts on eBay. I've been running an '09 ZX6r rear shock which was a great cheap upgrade, but is a tad soft for my liking. Grabbed this Ohlins 46PRXLS off of a 05-06 zx6r so should bolt up with the same modifications as the current shock.



Update on other engine parts:
Cometic is currently making the head gasket and should be shipped out early next week.
Bearings and rod bolts should also arrive early next week.

Excited to get this engine back together already. :D
 
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