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Thread: From Crash to Flash - Rebuilding my CBR600RR to be the ultimate track and street bike

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    Member Thunderbird's Avatar
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    From Crash to Flash - Rebuilding my CBR600RR to be the ultimate track and street bike

    I had been meaning to do a build thread for about 6 months as I remove the stock parts and turn it into a bike that will be just as good on the track as it would on the road. Over the last 6 months I have bought and added some aftermarket parts and some racing parts but 1 month ago I low sided the bike and have had to start again. Because of this I thought I would just start the build thread from now and detail the work I do on it to get it back on the road and ready for the track. Before I get into rebuilding the bike I thought I would give you a bit of an explanation of what happened leading up to the crash.

    This is what the bike looked like when I first bought it. It is a 2006 Honda CBR600RR that I ended up paying $8,000 for. It had done about 29,000km and rego was due, so after a bit of research on prices I was happy with this. The bike was completely stock except for a Two Brothers exhaust.




    I already owned a cruiser and the main reason I bought this bike was because I wanted to get into doing track days and eventually work up to racing in a year or two. I had completed a RAC Advanced Ride Day to help improve my skills on a sports bike and then I started to book myself in to whatever track days were available when I was wasn’t away for work. Things were progressing at a steady pace. I had a great time at my first level 1 Trakdayz and everything was running smoothly until the second last session of the day when one of the riders in front of me crashed at turn 7 and I got target fixation and lost my line. I made the conscious decision to run off into the sand not realising how boggy it was and once I hit it at speed I couldn’t control the bike and got slammed down pretty hard side ways into the dirt. The bike was fine because it was in the sand but my confidence was a bit shot. It ended up with a broken indicator, some minor scratches, and clogged up chain and sprockets.

    Over the next few months I completed an RAC Tunning Session which was a major boost in getting my confidence back because the track is slower but more technical, a Level 1 racecraft and another Level 1 Trakdayz. After my final Trackdayz I was riding quite well for my group (I still had plenty to learn though) and was ready to move up to group 2 Trakdayz. I booked in for group 2 and it was only 4 days away but it looked like the weather was going to be crap again so I also booked in for a level 1 racecraft that was 2 days earlier to brush up on my lines and breaking before moving up to their next level. Racecraft comes around and the weather is beautiful and I cant wait to get out onto the track. The first session was just a familiarisation session back on the track and we spent the whole time just sitting behind 1 of the instructors checking the track condition and looking for oil patches, sand and debri and turning markers.

    By the time this was finished I was so keen for the next session when we would finally have a chance to get out there and cut some laps at our own pace. Even though I have now done 3 track days I still wouldnt call myself a great rider and still had a lot to learn. I had been given several different pieces of advice from a few people and I wanted to try and incorporate these tips into my riding. I think the problem was I tried learning too many things at once instead of focusing on one aspect at a time. So we headed out onto the track and after a couple of warm up laps I decided to open her up and try and some of these new ideas. I only lasted 2 more laps before I low sided in the basin

    While Im not sure exactly why I crashed, one of the main parts was that I didnt put my knee out. I was having a few issues with the position of my new rear sets and just kept on trying to lean it over without my knee out until i low sided it at or just after the apex. Sometimes I have been told that it looks like that I try and stick my knee out to far like thats all Im trying to do so I was trying not to do it but I think that was a mistake. In the past having my knee down too hard has pushed me wide in the corners so thats something I have to work on some how. Looking back I think getting my knee down is a good indication for me as to how far I should probably lean as Im a heavy boy at around 100kg. I think if I try and lean it over to far and I dont have perfect body positioning I unbalance the centre of gravity of the bike and over I went. While not the only reason I think that was one of the main reasons as to what happened here and I went over to far and lost the front end. Another contributing factor could of possible been that I was off the brakes before I hit the basin and accelerating through it and without the front suspenion still compressed properly I didnt have the contact patch I needed and combined with my other issues contributed to my off.

    I am not an very experienced track rider and cant read what the bike is doing under me properly yet so these are only my thoughts and guesses. The only problem is there was no one behind me to see it happen and help with the explanation as the next rider didnt come past until after I had finished sliding across the track and had picked my bike up.
    I was fine with nothing broken just a little bruised and sore but my day was over after the second session. On the other hand the bike was a mess. Structurally the rear sub frame was twisted, the front fairing stay bracket was cracked, the right hand side rearset was flat like a pancake, and the right hand side handle bar and throttle tube were damaged. Cosmetically the front, tail, right side and bottom fairing were all destroyed, the clutch cover was all grated up from the road and my leathers and helmet were a bit of a mess. So this is what it looked like after the crash.







    To be continued...

  2. #2
    Inactive Member spun's Avatar
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    Unlucky bro....heal up, fix up and get back on the track
    "Continuous effort--not strength or intelligence--is the key to unlocking our potential." - W. Churchill

  3. #3
    Member Cbr Junkie's Avatar
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    Lol Been there done that on the same bike....not a bad bike to rebuild if you have any questions just ask!

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    Glad to hear your not badly hurt.
    Been there too.
    All the best with the rebuild.
    Riding - Living the dream...

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    Member Max Power's Avatar
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    OHhhhhhhh nooo that sucks mate!
    Quote Originally Posted by jasle View Post
    i have a new lover photographing me, she is thin, tall and yellow and she lives on stirling hwy. Its a pitty i didnt get her number but im sure she got mine....

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    Bad luck on that crash. Keen to see how the rebuild progresses.
    Quote Originally Posted by Gabe
    I will personally burn everything I’ve made to the fucking ground if I think I can catch them in the flames

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    Member pink bits's Avatar
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    hey hey,
    great to see you today, its been a while
    so i thought i would come check out the thread. you did a great job making it squishy!! hope its all fixed in time for your next track adventure
    Quote Originally Posted by Judge Dread View Post
    Now I'm gonna' have to wait for the next big blitz when they turn their attention to dangerously large aftermarket keyrings flapping around in the wind and affecting the balance of our bikes.

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    Member Thunderbird's Avatar
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    Thanks for all the comments. I think the crash was the best thing that has happened. I now have a chance to rebuild her with all this new gear. I have spent about $5,000 on new parts, its just a matter of waiting for it all to arrive.

  9. #9
    Member Thunderbird's Avatar
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    So I got the bike home and removed whatever fairings that weren’t already hanging off. As I mentioned the sub frame, fairing stay bracket, right handle bar and right rearset are all stuffed so I removed them off the bike. The forks seem ok so that is a bonus.




    Since the bike is out of action for a while I have decided to complete some of the jobs that were on my wish list. I have decided to get my forks re-sprung and re-valved so a set of Racecraft springs and gold valves are on their way from the US. I never like the fact that the swingarm was bare aluminium so I decided to get this powder coated. The clutch cover was damaged in the crash and its to expensive to buy a replacement so to fix this I filed the damaged section smooth, buffed it up and then sent this to the powder coater too. I needed to find a way to protect the bearings from the heat and powder without removing them from the swing arm and the clutch cover. After reading some other forums and chatting with a bloke in the US who does lots of swing arms it was suggested that I just sandwich the bearings between a couple of washers and have a bolt running through the middle to hold it all together. I removed the dust seals as I didn’t think these would survive the oven temperatures but each one was destroyed getting them out so 5 new ones would be required. I ordered the new seals and 4 arrived but not one of the ones for the swing arm. They have none of the one I need in Australia and have to get it in from overseas. I tried a few bearing shops to see if I could get a generic one but no one had any that small. After speaking to the bike shop it should be here on Monday. I really need this part as without it I cant progress any further and mount the rear wheel and remove the bike off the swing arm. While I was getting things coated I decided to get the exhaust heat shield done. The powder coater did an excellent job as far as quality goes but I wasn’t happy with the colour. I wanted it all to be done in matte black but it looks more like a semi gloss. This may just be part of the powder coating process and they may not be able to do it without the small bit of shine.






    To be continued

  10. #10
    Member shan's Avatar
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    Looking farward to see how it all goes.
    REPENT MOTHER FUCKER
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  11. #11
    Member Stephan's Avatar
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    Looks like your left tank mount copped one too...I hope, you ordered some GB racing covers to protect the pretty engine cover...!
    KRS racing Keevers Rural Service
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    Member Thunderbird's Avatar
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    Quote Originally Posted by Stephan View Post
    Looks like your left tank mount copped one too...I hope, you ordered some GB racing covers to protect the pretty engine cover...!
    Which mount? I didnt notice anything before, it could just be the way everything is sitting. The tank is unbolted and just resting on top. GB dont make engine covers for my year of bike. For some reason they decided to start on the07 model. I actually had a clutch cover that looks exactly like the woodcraft ones but I hadnt fitted yet (yeah Im and idiot). For the stator side I have ordered a woodcraft cover that replaces the stock cover and has an aluminum slider built into it. This cover is black so it will actually match the powder coated cover on the other side. It is being express posted from motomummy in the states so I am just waiting for that to arrive before I change the oil filter and put in the new oil.

  13. #13
    Member Stephan's Avatar
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    Quote Originally Posted by Thunderbird View Post
    Which mount? I didnt notice anything before, it could just be the way everything is sitting. The tank is unbolted and just resting on top. GB dont make engine covers for my year of bike. For some reason they decided to start on the07 model. I actually had a clutch cover that looks exactly like the woodcraft ones but I hadnt fitted yet (yeah Im and idiot). For the stator side I have ordered a woodcraft cover that replaces the stock cover and has an aluminum slider built into it. This cover is black so it will actually match the powder coated cover on the other side. It is being express posted from motomummy in the states so I am just waiting for that to arrive before I change the oil filter and put in the new oil.
    Ah, I see...the tank mount normaly gets a hammering when the bike overturns, just looked like yours did the same. Play on.........bugger with the Woodcraft cover, but that's the way the cookie crumbles...
    KRS racing Keevers Rural Service
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    Member Thunderbird's Avatar
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    Due to the way the rear sets fit onto the bike some of the covers and heat shields no longer fit. This now exposes parts of the headers and the rest of the exhaust. Because of this I have decided to clean up my headers and paint them black so they match the colour scheme I have decided to go with. I pulled them off and cleaned the up using 2 different size wire wheels. The main one fitted onto the end of my grinder and the finer one for in the gaps fitted onto my drill. Once they were clean I painted them with High temp paint in a matte black and after an hour when they were touch dry I put them on my BBQ and turned it on to cure the paint.
    BEFORE

    CLEANED


    PAINTED



    While I was doing all this 4 boxes of goodies arrived, its like its Christmas time. I received
    Kaneg head stem and rear stand
    2 sets of rearsets
    Keyless gold gas tank lid
    5 sets of tank pads
    Front axle sliders
    Frame sliders
    2 sets of bar ends
    2 sets of grips, 1 gold and 1 black
    1 set of swingarm spools
    2 fairing stay brackets
    HRC quick throttle kit
    Smoke windscreen
    1 set flush smoke led indicators
    1 set flush clear led indicators
    1 set of racetech fork springs
    2 sets of screen well nuts



    I also received a call from the bike shop letting me know that my final dust seal had arrived so I went and picked that up and I will install the swing arm tonight. While at shop I decided I would order a new battery tray as mine was severely cracked and pieces missing. I was going to try and get one off of ebay but there is none around. It will take a month to get here as there are none in Australia so in the mean time I will try and repair mine with some “plastic weld” expoxy.
    To be continues

  15. #15
    Member Thunderbird's Avatar
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    I decided on a matte black and gold colour scheme for my fairings after seeing another bike done the same way. So I emailed off some photos of the bike I like to the fairing company in China and they said they could do it and it was only going to cost US$355 delivered. Well they finally arrived the other day and I must say I am impressed. They only took 3 weeks to get here from time of ordering, packed extremely well and the quality seems quite good. There were a few minor problems like a small run in the paint near the mirror holes but it will be barely noticeable once the mirror is on and the rear wheel fender has one of the screw holes in the wrong spot but considering I wasn’t expecting a fender with the kit I don’t care. The kit came with all the pieces you would expect and some you wouldn’t. It included all panels, seat cowl, windscreen, rear wheel fender, plastic side covers, the little plastic vents above the exhaust and some heat shielding. All the holes seem to look good but some will need a little clean out because of paint but that’s to be expected. Below is a photo of the scheme I have chosen although mine will look a little different because I now have a black swingarm and black clutch cover but you get the idea.



    And here are the fairings that arrived. I just wish the bike was finished so I could put them on and see it in the flesh.






    To be continued

  16. #16
    Member GETAGRIP's Avatar
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    Looking tops!
    We are small and exposed, and probably moving too fast for our own good, but that's no reason not to enjoy every minute of the ride.

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  17. #17
    Member Algy's Avatar
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    whats the name of the fairing company you ordered from?
    Hungry Shark + Stupid Human = Full Shark + Dead human

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    Inactive Member spun's Avatar
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    Looks insane so far big fella...keep us posted !!
    "Continuous effort--not strength or intelligence--is the key to unlocking our potential." - W. Churchill

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    Member Thunderbird's Avatar
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    I have since put the swing arm, sub frame, rear sets and rear tyre back on. The battery tray is smashed at the back so I ordered a new one but as they dont have any in Australia I will have to wait a month for it to arrive. Because of this I have temporarily repaired my damaged one with some plastic expoxy. As I am away at work I cant do any more or post up any photos until I get home. I decided I didnt want the crappy plastic chain cover and rear fender so I have ordered carbon fiber replacements from Tyga Perfomance. I am also going to be ordering so ASV shorty levers. One to go on my Brembo brake master cylinder and one for my stock clutch. I didnt want odd looking levers on either side of my bike. I have also ordered a set of HID Projectors with Angel and Evil Eyes but they wont be getting installed until after I get the bike re-registered. Im just hopping my new switches that are required after I mount my quick throttle come before I get home on Wednesday.










    Last edited by Thunderbird; 18-09-2011 at 12:15 PM.

  20. #20
    Member Thunderbird's Avatar
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    EDIT Double Post
    Last edited by Thunderbird; 18-09-2011 at 12:16 PM.

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