Guzzi 1100 custom build

[Huzo]

That is just beautiful…

[buzzer]

Here is the finished final drive with a new bearing and seals.

[buzzer]

The engine is now back in the frame, a nice and easy job with the removeable bottom frame rails…

[Pescatore]

Beautiful shine.
Are you keeping it all silver?

[buzzer]

Beautiful shine.
Are you keeping it all silver?

the tank is orange, like all my builds...





I didn't want to use the frame as a breather as it can rot them out, and rust partials can drop down so I am told...  so I decided to make a new breather the vent the crank case and also the heads.  Here is is...  will it work?  Who knows, we will see!!

[buzzer]

Two jobs today...  first was to make a paddock stand.  I hate the universal ones as they are very difficult to get a bike on one on your own..., and often not that secure.  this one positively locks onto the wheel spindle, and when its on the lift I can clamp it to the top so its nice and secure.





The second was to make some bushes out of bronze to take the play put of the clutch lever as the hole had worn oval.  I drilled it out and made some over size top hat bushes.  Finally, here it is on its wheels!





https://www.youtube.com/watch?v=NoiBIyf7MYY

[buzzer]

I pondered for a long time on the throttle arrangement for this bike… I wanted to keep the pull to open, pull to close for a couple of reasons… First, its safer… manufactures didn’t go to this arrangement for no reason as bikes evolved. Second, it means you can have much lighter return springs, which in turn males the throttle much lighter, particularly if you are going for a quick action. . A light fast action action throttle feels like you have 20 BHP more!

I couldn’t find a 4 cable throttle anywhere, so I ended up making one from scratch…

[buzzer]

I needed to make some brackets out of alloy tube, but of you squash the ends in the vice it looks crap… so I made this little die that profiles the ends round which also make them stronger.

[Huzo]

I needed to make some brackets out of alloy tube, but of you squash the ends in the vice it looks crap… so I made this little die that profiles the ends round which also make them stronger.

It would be a privilege be apprenticed to you.
You are the true embodiment of someone who actually “ builds” a bike…

[Canuck750]

I needed to make some brackets out of alloy tube, but of you squash the ends in the vice it looks crap… so I made this little die that profiles the ends round which also make them stronger.

That die press is brilliant! I was wondering how to get that shape on some tube brackets I need to replace on a bike. Thanks for posting this idea, your work is top notch!

[Huzo]

I would like to see a sub thread set up entitled…
“Roper says, Canuck says, Buzzer says..”

Roper for mechanical advice
Canuck for restoration advice
Buzzer for specialist machining

The deal would be, no arguments or immediate removal of post. Questions yes, but if you don’t value the advice don’t open the thread.

[buzzer]

I would like to see a sub thread set up entitled…
“Roper says, Canuck says, Buzzer says..”

Roper for mechanical advice
Canuck for restoration advice
Buzzer for specialist machining

The deal would be, no arguments or immediate removal of post. Questions yes, but if you don’t value the advice don’t open the thread.

I am always happy to help 

I made a speedo housing earlier in the build, but I was not happy with the result, so I tried again...  this one is better...

turning the dome took some doing! I have rubber mounted it as I always feel electronics need it…

https://www.youtube.com/watch?v=vVhAJ0GDwlE

[buzzer]

I wanted to add some custom detail onto the bike, in particular on the valve covers... So I tried the technique of etching alloy...  have to say it worked rather well!  Oh, and although those indicators are small, they are amazingly bright!

https://www.youtube.com/watch?v=TJBqAuzCvzI

[Huzo]

Ok…
Where have you been hiding all this time, that is absolutely brilliant…

[buzzer]

Ok…
Where have you been hiding all this time, that is absolutely brilliant…

Mainly on the Ducati forums.... 

Onto for me what is the most enjoyable part of a build...  the wiring.  I have a process for this I stick to.  First I draw out the wiring diagram in Microsoft Visio, and colour code the wires. Then I order the wire in, which is quite cheap and any connectors I need.  So often the standard of the electrics is what make a bike trouble free in the future.  I then build the loom actually on the bike, circuit by circuit, wire by wire, which I hold temporarily in place with some Velcro cable ties.  When its all in place I use that braided sheathing and close the ends with heat shrink tubing.  it make a neat job.  Rather than connect the main battery leads up, I use a fly lead with a 10 amp fuse just in case I make a mistake.  I crimp, and if needed solder every joint.  I have rubber mounted the coils and put them on an alloy heat sink.  I also like to make my own HT leads out of solid copper lead, so I can get them to fit perfectly...

I have also used up the last of the Tygon fuel tube I had in stock...  Its 8mm ID and I am unable to source any more without buying a large quantity, which is really annoying.

[Huzo]

I built a Rob North BSA A65 years ago and it worked out nicely.



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But where I hit the wall a bit was the wiring.
When you say you laid out the circuits one by one, I can readily see that logic, but when I did that, I found that I was duplicating a lot of positive wires.
 How did you determine whether to run a dedicated positive to perform a given function, or just tap into one that was already there ?

[buzzer]

I built a Rob North BSA A65 years ago and it worked out nicely.



[/url]

But where I hit the wall a bit was the wiring.
When you say you laid out the circuits one by one, I can readily see that logic, but when I did that, I found that I was duplicating a lot of positive wires.
 How did you determine whether to run a dedicated positive to perform a given function, or just tap into one that was already there ?

nice build... 

that's why I like those fuse boxes in the picture... one positive wire to it, and 6 out to the various components.  also one earth to it, and 6 out.  it keeps it simple 

[Huzo]

nice build... 

that's why I like those fuse boxes in the picture... one positive wire to it, and 6 out to the various components.  also one earth to it, and 6 out.  it keeps it simple 

Oh ok.
That would have simplified things, I did not know of them.

[buzzer]

Here is the finished wiring… and the final diagram of which I am always happy to share a full size version. Its one item that is always nice to pass onto the new owner when I eventually sell on...  Imagine fault finding without it!   I like to use the braided sheathing rather than the hard PVC stuff of old. I see that many cars and bikes now use it. Its a bit fiddly but if you touch the end on the soldering iron after you cut it, it stops it fraying. Another nice advantage is if you need to pull one or two wires out, you can do by just parting the strands.

[buzzer]

the footrests/and levers are now finished… I pondered how to do the brake light switch and then came upon this neat hydraulic one which bolts onto the union…

[buzzer]

here it is finished...  just waiting on a small part to get it running, which is very frustrating!

[Kildareman]

here it is finished...  just waiting on a small part to get it running, which is very frustrating!

Absolutely gorgeous. 

[Huzo]

I cannot remember seeing any better ground up project, that was actually “ built”.
I love the absence of plastic.

Behold…!
Moto Guzzi Metallo….

[buzzer]

thanks for the complements guys!

So its start-up time…  I had a good spark, but I wasn’t sure if it was on the right cylinder as I hadn’t made a note on the coils… so it was a 50% chance it would start…  It did!  It quickly settled to a nice tick over, but I had to shut it down as I am missing the “0” rings off the sensors and they leaked oil.  I have been waiting a week for them, bloody Royal Mail strikes!

With any fresh engine build I have a routine I stick to that has served me well over the years…  first thing I do is remove the oil switch and pump oil into the engine.  I use a plastic pump up bottle for this.  This primes all the oilways, fills the filter, fills the oil pump, and oozes out of all the bearings.  I prefer this to engine building paste, which I am not a fan of…  I do use a smear of it on the cams and followers though…

The other thing I do is screw in a pressure gauge.  I was pleased to see that it immediately shot up, which is always a relief.  This has saved me a couple of times in the past…  Once when the pressure relief valve in a new oil pump was stuck, and the gauge went off the scale…  the other time was my fault when I put an oil pickup pipe joint on wrong, and the joint itself covered the pipe hole…  started it up and initial pressure then nothing… that gauge is a lifesaver!

[Pescatore]

Beautiful head turner.  The exposed frame gives a sense of power.

[buzzer]

well how annoying is that    I noticed the section of one pipe was going blue...  checked it and its magnetic!  looks like the supplier mixed in a piece of Mild Steel in with the stainless!  Oh well, new piece is on its way

[Huzo]

well how annoying is that    I noticed the section of one pipe was going blue...  checked it and its magnetic!  looks like the supplier mixed in a piece of Mild Steel in with the stainless!  Oh well, new piece is on its way

Son of a mongoose….!!! 
You’ve the patience of a saint, I hope old mate picks up the cost there. Your bike is so distinctively unique, it will always be yours even if you sell it.
I wish like hell it didn’t have to get that great big yellow licence plate hung off the arse, especially assymetrically.

There must be a way….

[Huzo]

I would like to see a sub thread set up entitled…
“Roper says, Canuck says, Buzzer says..”

Roper for mechanical advice
Canuck for restoration advice
Buzzer for specialist machining

The deal would be, no arguments or immediate removal of post. Questions yes, but if you don’t value the advice don’t open the thread.

I’ll add one to that.
Kiwi Roy says…(electrons and subduing their sometimes errant behaviour..)

[buzzer]

well this build comes almost to an end, I am sure there will be some snagging to do, but that can be done in Spring when I can ride it! I will post a video of it running as soon as we have a nice day. Here is is with the last couple of builds I have kept as I liked how these ride!

Its time to start the next Build… I have another Multistrada at the back of the garage which I will wheel out soon and make a start on that… this has some nice parts on it and should make a great bike, not sure on the style of this one yet, I guess it will evolve over the coming months.. Have to say I have really enjoyed the Guzzi build, a refreshing change to Ducati’s as the next one will be Ducati number 10 build!

So apart from a video at some point its goodbye from me and I hope you have all enjoyed my ramblings.  Unless of course any of you are interested in the Ducati build, I could always continue it onto this thread.

[Huzo]

I could watch you build a garage door and still be interested.
Your craftsmanship is worth witnessing in any application, please don’t go running off. I just hope you are not put off if someone tries to copy something you’ve done.
I like how your colour choice defines the creation as a “Buzzer build”. I would christen that lovely bike the “Moto Guzzi Metallo”…..