2002 R1 Project

[clintooo]

I bought Big Daves R1 about 2 weeks ago. I have been overseas the last 2 weeks so haven't had too much of an opportunity to do much to it as yet. Most of my time has been spent on ebay doing some procurement.

A few bad Iphone pics of the bike as I picked it up.

Damage wasn't really too bad. It really is a good advertisement for frame sliders, they really saved it. My original budget to get it back on the road was about $1200, so I will see if I can keep it down below that.

However, I have already blown that, as I bought another 2002 silver/black R1 off ebay. It was a repairable writeoff with only 26,000kms on it. So now I have two. Not sure exactly what I will do, origianlly I was thinking of making the 2nd bike the one I put back on the road and either wrecking or selling the 1st one as a track bike. I will wait until next week to see the 2nd bike in the flesh.

Pics of Bike 1 (Big Daves)

IMG_0282.jpgIMG_0281.jpgIMG_0280.jpgIMG_0279.jpgIMG_0278.jpg

[carbon-rod]

get some new ebay fairings and headlight and daves will be good to go pretty much.... oh and rearset

you could probably just about fix it up with under a grand!


Daves gearbox has had some work done to it not long ago and therefore could be in better condition than the unknown black one... Black one might be ready to suffer 2nd gear issues... who knows.

[clintooo]

a couple more pics

As you can see the damage is not too severe.

Two dents in the tank, and a slight scrape;
A new headlight
Repair or new mid and lower fairing
New nose cone
new Y piece
New brake reservior
some repairs to the bar ends, lever and brake pedal
Exhaust needs a bit of work.

[clintooo]

I have managed to get a full set of mids and lowers out of the states for $96. They look to be perfect from the photos. My company is paying the DHL for me, so it makes it a bit more economic. I have also picked up a blue nose cone from an eastern states wrecker with slight hairline crack. I was going to repair that and repaint it.

Tail section is minor and I will touch that up and repaint. The seat cowl also has a few boot marks on it (I presume) so I will repaint that when I do the tank and duck tail, and nose cone.

And if you are wondering, no that is not my lounge room I have a small workshop in o,connor with my father, that we use as a shed/come project centre. There are two old coffee machines behind that have been bumped in the project queue.

[clintooo]

Pics of bike 2

I cant quite workout what happened to it. Guy says the subframe is straight and the forks are too and that it is rideable. Not quite sure about that, given there is bits hanging off it.

But I will check it out in more detail, when it turns up and do an assessment of what is the best way to do it.

[clintooo]

Sorry wrong pics

Guys says subframe is straight, but I dont know, the tail light looks like it is off line, hard to tell with the smashed up fairing. but I will wait and see.

[clintooo]

is the 2nd gear an issue on these is it??

[carbon-rod]

ah yeh... .sweet if you can get oem fairings that would be good.... should be able to make a bit of monies out of it either way....

and knowing how to do your own painting is also good... if you gave it a sweet custom paint job that would definately bump the value..

[carbon-rod]

is the 2nd gear an issue on these is it??

yehh im not too mechanical but the pre 2004 models because the first gear isn't synchronised or something a rather it causes the dogs to wear out which causes it to drop out of 2nd gear... This happened to Daves one but I'm pretty sure they were all fixed up and possibly undercut to prevent it from happening again, don't quote me you might be able to find out more from him..

[clintooo]

The Akra pipe I have just about repaired. I managed to get the scratches out of the can with a flap disc on a die grinder and a few hours on a buffer. It is now a shiny pipe, rather than a satin look. Same with the mid pipe I have polished that up too.

however, there were a few slight dents that showed up on it. So what I did was grind off the weld seam on the back side of the pipe so it was flush and then polish it up. the weld seam is now pretty much invisible. I then pulled the two ends off and flipped them around so I have the back side of the pipe on the front. I found a guy in the UK who sells the heat resistant decals for $8 so I have ordred one of those. The strap though is going to cost me $50 though. So for $60 I saved the need for a new exhaust.

Does anyone have a spare strap they want to sell???

[carbon-rod]

ahh nice work...

[clintooo]

yeh I have all the painting gear. My last project bike I bought an ebay fairing kit and repainted the tank and wheels. I also like to restore old coffee machines and grinders. Last grinder I did in a two pack, which produced much better results than acrylics and is a lot harder, so I will do this in a two pack.

admittedly I always need to wet and dry alot, but time and patience and I can get good results.

My last respray, A Mazzer koney E grinder. I didnt like the original silver so went for a Lambo orange, it came up fantastic even if I do say so myself.

[clintooo]

Ok thanks

I might swap the gearboxes over then, Dave had said his had only done 5k since the rebuild of 2 through 5.

[Bunyack]

This thread makes me sad.

Make them pretty again Clint.

[carbon-rod]

Painting stuff is a good skill.. the orange looks good.. yeh if you are mechanically equipped and love effort then i dont see why you couldnt switch it over

[clintooo]

Yep, I think I will give it a go then.

I finished the exhaust tonight. Just need to put the sticker on and get a mounting strap.

It came up quite well, once I ground the weld seem off and polished it up, it is pretty much invisible. There is one slight dent on the top of the backside that wont seem to pop out. I was going to pull the packing out and pop it out from behind, but it was stuck in and I thought I would make a mess of it and then end up needing to buy a new set. It is basically right on the strap mark so I dont think you will even notice it from behind once it is hanging. It is no longer the satin finish, but I quite like the finish. It needs a bit of a polish to remove the final buff marks, but I'm pretty happy as I managed to salvage the exhaust, which I thought I was going to have to bin or sell off as a track exhaust.

Pic of what I started with, and the repaired product

[F2thaK]

fuck, nice work!!

[Big_Dave]

Wow, awesome job on the exhaust that looks amazing.

and just to confirm, yep my gear box was recently worked over was actually 1 to 5 that was replaced

it's great to see some progress already, looks like the bikes healing faster than I am

[clintooo]

I managed to repair the radiator on the weekend. The mounting bracket had snapped off the little studs that hold it in place. I took it to a radiator place and asked if they could weld it back on. They told me they dont fix radiators!!!, aparently they only put in new ones and didnt have a tig welder.

As it was just welding it to the top frame of the radiator and not any pressure containing parts, I decided to borrow a mates tig and give it a go. I avoided burning any holes in it, and just basically spot welded them together. A bit of Sikaflex adhesive around the edges to be doubly sure of my welding and it is ready to go back on.

Other things are progressing too, albeit slowly. I am trying to be disciplined and cleanup, repair everything I take off as I go, rather than my normal instinct to just pull everything apart and then try and sort it all out later So everything comes off, gets a short bath in turps and a little dance in my ultrasonic cleaner (if you dont have one, they are great, I just bought a cheap one off ebay, but I love it) then everything goes into little boxes and is labeled.

I decided to pull the headers off and give them a polish. Just as I was congratulating myself for getting all but the last stud out, I snapped it off in the exup valve side. But the headers are off anyway

Fairings from the states arrived too. so I will unbox them and have a look tonight. I managed to source a blue nose cone from Sydney, so that is on the way too.

Tank has largely been repaired, dent wise anyway. I was going to get a dent repair guy to come and pop the 2 dents out. But they wanted $120. I thought I would buy an ebay PDR kit for $50. But then on closer examination, there wasnt much to it. So I made up a slide hammer out of a bit of rod, got some roofing nails/clouts and put a 90 degree bend on them so I could gab them with my ghetto slide hammer and glued them on with the hot melt gun. A couple of goes with this and I managed to get both dents pretty much out, at least 90% anyway. Probably not as good as a PDR guy, particularly given I destroyed the paint finish, (but it needed repainting anyway). So a little bit of filler to cover the low spots and it should be good for respraying.

[HK31A]

the dent repair guy can he do it without damaging the paint?
and if so do you have his number?