Author Topic: Guzzi 1100 custom build  (Read 2677 times)

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Re: Guzzi 1100 custom build
« Reply #30 on: March 27, 2022, 06:34:55 AM »
I have agonised over the rear light / number plate arrangement…

No matter how I plan it, it just does not look right with the number plate on the back, So I am going for a side mounted plate. that leaves the rear light to consider… the rear of the seat is angled (more later) so I needed an angled plinth to mount the light I am using on… here it is, bar a good polish.

A new addition to the workshop is a bandsaw...  How did I manage without one all these years!  I modified the top and bottom guides so they have bearing supports and it works an absolute treat!




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Re: Guzzi 1100 custom build
« Reply #31 on: March 29, 2022, 10:38:36 AM »
One thing I always like on a build is a light throttle… in these days of EFI its easy to forget just how heavy some carb throttles were, always a balance of lightness Vs a throttle spring strong enough to prevent sticking, As I am using flat slides on this build I really wanted to use a pull / pull throttle set up, which would either mean a pair of splitters, or a dual throttle. that way I can retain the light springs. Try as I might I couldn’t find a dual pull / pull one so I have ended up making one! If anyone knows of a company that makes them… DONT TELL ME! here is the story in pictures…












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Re: Guzzi 1100 custom build
« Reply #32 on: April 01, 2022, 05:38:35 AM »
the wheels are back from the vapour blasters… they have come out FAR better than I expected, and I quite like the finish, so I will be leaving them as they are. just a coat of ACF – 50 should keep them looking good. the spokes are stainless and have also come up well. First time in MANY years I have put my own tyres on! they are tubeless so went on very easily. just got to get them balanced.




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Re: Guzzi 1100 custom build
« Reply #33 on: April 02, 2022, 09:11:02 AM »
seat next… I needed to bend the front to clear the tank bolt… So I made a former to press it into shape. I also made a tool so I could press some dimples where the rivinuts go, to raise the seat a little so the seat doesn’t sit directly on the frame rails…

Things don’t always go to plan… I decided to mount the rear light on the frame, and cover with a piece of alloy… which I did, but then realised that on full bump the tyre would hit the plate! I had designed the rear to cater for full bump, but promptly forgot! I realised I needed to mount the light on the seat base, but I hate wires showing… so I decided to make a conduit out of copper tube so the wires can be hidden under the seat cushion.

The seat is off to the trimmers today. I have not used this guy before… The girl I used for years to trim my seats left the company she worked for… the last guy I used was OK, but no where near her standard. So lets see what this new guy is like… Oh, and here she is in the daylight for the first time in a while…









Wildgoose Chase Moto Guzzi

Re: Guzzi 1100 custom build
« Reply #33 on: April 02, 2022, 09:11:02 AM »

Online Huzo

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Re: Guzzi 1100 custom build
« Reply #34 on: April 02, 2022, 02:15:46 PM »
the wheels are back from the vapour blasters… they have come out FAR better than I expected, and I quite like the finish, so I will be leaving them as they are. just a coat of ACF – 50 should keep them looking good. the spokes are stainless and have also come up well. First time in MANY years I have put my own tyres on! they are tubeless so went on very easily. just got to get them balanced.




Are they nice and true ?
Also, why not balance them yourself ? https://youtu.be/MbezuZa_hNY
It’s fun...!
BTW..
I did get the front better than that, but took the video to demonstrate the accuracy that can be achieved.
« Last Edit: April 02, 2022, 02:23:10 PM by Huzo »

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Re: Guzzi 1100 custom build
« Reply #35 on: April 03, 2022, 07:49:24 AM »
Are they nice and true ?
Also, why not balance them yourself ? https://youtu.be/MbezuZa_hNY
It’s fun...!
BTW..
I did get the front better than that, but took the video to demonstrate the accuracy that can be achieved.

yes, they were almost perfect!  that's a great idea! :thumb:  my mate has a wheel building jig I can use...  I will do that thanks!  :thumb: :thumb:

Offline Fodermonk

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Re: Guzzi 1100 custom build
« Reply #36 on: April 04, 2022, 11:04:22 PM »
Are they nice and true ?
Also, why not balance them yourself ? https://youtu.be/MbezuZa_hNY
It’s fun...!
BTW..
I did get the front better than that, but took the video to demonstrate the accuracy that can be achieved.

AME's balanced King Air aircraft wheels that way where I used to work, and they went over 100mph. I made my own compact version by bolting a couple of bearings to a small piece of angle iron (x2) and just clamp them to a couple of jack-stands. I've been doing this for years!

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Re: Guzzi 1100 custom build
« Reply #37 on: April 07, 2022, 12:34:53 PM »
no matter how I tried I couldn’t get the number plate to look right on the rear of the bike… so on this build its going on the side, which kind of fits with the look I want to achieve…


Offline EV Cali

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Re: Guzzi 1100 custom build
« Reply #38 on: April 08, 2022, 12:35:52 PM »
Brilliant work you're doing here Buzzer, wish I had your engineering skills to transform my EV into something better. Following with interest and based quite close to you in South Derbyshire.
 

Offline lucky phil

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Re: Guzzi 1100 custom build
« Reply #39 on: April 08, 2022, 04:58:25 PM »
Nice, looks like you won't be needing a side stand then. :thumb:

Ciao
If you're not living on the edge you're taking up to much room.

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Re: Guzzi 1100 custom build
« Reply #40 on: August 10, 2022, 12:02:38 PM »
Its been a while...  I tend to have the summer off from garage projects, holidays, days out, bike rides take over!  However I had a few spare days and thought I would make use of the warm days and paint the tank. It was badly damaged when I bought it, so I cut some holes in the underside and knocked the dents out. it takes an age to get it to shape, in fact as the metal had stretched, so I cut a 1mm slot in it, planished it, which closed the gap, and then welded the slot up! its nicely to shape, just the decals to put on now

Another little job was to redo the speedo… I want to keep this build as clean as I can and wanted a smaller speedo. I decided to use one of the cheap GPS modules which is just 55mm diameter. I made a new housing for it, and will finish the bracket off when I start the assembly. it been in the car for a week on test!








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Re: Guzzi 1100 custom build
« Reply #41 on: August 11, 2022, 09:59:01 AM »
All finished...  I always have my heart in my mouth on that last coat of lacquer over the decals!

I know a lot of people struggle with paintwork, its not that hard if you follow a process, so I have written a guide on my blog if anyone is interested...

https://jtccc.wordpress.com/projects-2/paint-spraying-at-home/


Online Huzo

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Re: Guzzi 1100 custom build
« Reply #42 on: August 11, 2022, 12:47:27 PM »
Why is there a decal on the back of the tank where you can’t see it ?
Won’t the seat rub it off ?

Offline Rick4003

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Re: Guzzi 1100 custom build
« Reply #43 on: August 12, 2022, 03:56:36 PM »
Hi Buzzer,

Very nice build and thanks for the write up regarding paint. Always good with some extra tips and tricks.
Moto Guzzi 850 T5 (850 sport) - 1985
Moto Guzzi Ambassador - 1967
Yamaha FZR 600 - 1996 - SOLD

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Re: Guzzi 1100 custom build
« Reply #44 on: August 12, 2022, 06:10:27 PM »
You have a lot of excellent machine tool skills, very impressive!

Bike is looking great.
48 Guzzi Airone, 57 Guzzi Cardellino, 65 Benelli 200 sprite, 66 Aermacchi Sprint, 68 Gilera 106 SS, 72 Eldorado, 72 Benelli 180, 74 Guzzi 750S, 73 Laverda SF1, 74  Benelli 650S, 75 Ducati 860GT, 75 Moto Morini 3-1/2, 78 Moto Morinii 500

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Re: Guzzi 1100 custom build
« Reply #45 on: August 15, 2022, 07:27:22 AM »
thanks for the comments guys  :thumb:

Out in the sunshine for the first time in a while… I am now happy with the look, and it now all needs to come apart for the frame to be tided up and painted silver (matches my other bikes!) I will be doing a mechanical rebuild at the same time.




Offline Calijackalbob

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Re: Guzzi 1100 custom build
« Reply #46 on: August 17, 2022, 07:42:24 AM »
In your obvious over inflated opinion...

Ciao

Great work. Wish I had your skills and tools in my garage! I tend to agree. If you are going to all the trouble to make new inlet manifolds, you might as well make them looked finished. You won't regret the extra half hour of or so work. But if you don't..... It will just look unfinished.

Offline Calijackalbob

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Re: Guzzi 1100 custom build
« Reply #47 on: August 17, 2022, 07:56:57 AM »
One thing I hated about the bike was the side stand… Just how agricultural is that bracket! I know its a great functional design, but its SO ugly!  so out come the angle grinder and it is no more!  In the loft (or as my wife calls it the spares department!!) i had a side stand off a 1994 Honda CBR 600…  it bolted straight on!  Just need to adjust the angle a little when the ride height has been set.  a job for much later on...




Looks great. If you go the route of clip ons, Check this out.





I used chrome "Washers," actually off the end of bar end mirrors, to hide the holes in the triple clamp on my Bellagio cafe racer. Only took about 20 minutes to strip and polish. Looks a million bucks.





Can't wait to see more of yours.


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Re: Guzzi 1100 custom build
« Reply #48 on: August 21, 2022, 08:16:45 AM »
Here is the speedo and warning lights finished, I am pleased with how this has come out, i wanted this to be as clean as I could… as with all electronic components I like to rubber mount them… so I have used some small grommets and spacers. The GPS speedo has a nice little feature which tells you which direction you are traveling in!


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Re: Guzzi 1100 custom build
« Reply #49 on: September 30, 2022, 06:26:30 AM »
Autumn arrives… Bike rides become less frequent, and the holiday and days out season slows down, so its back in the garage! the bike is now in the stage where all the fabrication is done and it all needs taking apart and cleaning and painting. Engine removal was quite easy with the removable frame rails and it was all soon apart and the engine and gearbox on the bench. I finished off all the welding on the frame and removed all the unused lugs to get that clean look, and sent it off to the powder coaters.




I will be doing a full engine gearbox and drive unit rebuild, mainly to vapour blast the cases. This of course means making a few special tools! First off was an extra long 32mm socket. I cut down a standard one and extended it with some thick wall tube.



next was a tool to undo the 27mm nut on the gearbox output shaft. you need to hold the shaft as well as turn the but so it needs to accommodate this. I used one of the spare Ducati wheel nut spanners I had laser cut years ago and bored it to shape on my new milling machine. Picture of that to follow!



next up took some thought… I needed to hold the shaft while I undid the nut. It would have been Ideal to use an old UJ but I didn’t have one… But what I did have was an old drive shaft. Out of this I made a stepped broach in the the lathe and then hardened it. With this I was able to broach a set of splines in a block of 10mm alloy, cut to fit a large spanner. It worked a treat!



finally, I made a tool to remove the castellated nut on the input shaft from an old socket, and a tool to hold the clutch hub from an old clutch plate. I think that may be it as far as special tools go!



I have been debating replacing my milling machine for a long time… but I have had it for almost 45 years and its like an old friend! over the years it done a lot of work, but its a 1929 machine and has its limitations! When my wife asked me what I wanted for my Birthday it was an easy answer! The old machine has gone to a good home where I know it will be looked after and used…



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Re: Guzzi 1100 custom build
« Reply #50 on: October 02, 2022, 03:24:10 AM »
I much prefer the look of the older round barrel engines...  so out came the angle grinder!



https://www.youtube.com/watch?v=-FLqOUEy0VA





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