General Category > Bike Builds, Rebuilds And Restorations Only
Guzzi 1100 custom build
buzzer:
As I wanted this to be different to the other builds, I tried several other tanks… I had an ST4 tank and a Monster tank that had too many holes to repair, so I cut these down… while I liked the ST tank, I couldn’t get the seat to tie in… I didn’t like the monster tank… So off to the bike breakers… he gave me the key to his storage unit... and said "say hi to the ghost!"
I walked around looking at the hundreds of tanks in there, discounting the plastic ones, of which there were many… the slope of the frame makes the choices limited... Nothing took my eye. Its a VERY old building though, and I have to say it spooked me somewhat being in there on my own, lots of creaking noises, and scuttling sounds which were probably rats... I didn't stay longer than I needed!
In the end I went back to the 999 tank I have used before. Another with some holes in the bottom where its rusted out.
buzzer:
While I love the look of a nice velocity stack they are not really practical for the road, hence while I make them for the photos I take, I like to use foam filters on the road. this of course means I need some suitable adaptors, which although you can buy them are REALLY expensive. these took a while to machine out of billet! I sometimes get asked where I get my material from for the lathe and miller. I am really lucky that there is a scrap yard locally that lets me hunt through the bins! They take scrap in from some of the aerospace companies so there are sometimes some nice bar ends in the skips. What is great about that is the bar ends are often etched with the material specification!
I don’t usually pay as I take my scrap in there and he writes the value in the back of his desk diary, and then as I take stuff, he takes the value off! he has done this for me for over 30 years! A few years ago I went in early in the year… he was no longer there as he had retired and I learned that his grandson had taken the company over. We chatted and I mentioned about the diary as I had a few pounds credit… The lad said he knew all about it and it was in the back of the book!
buzzer:
Time to start the fabrication of the back end. I decided to use some rose joints as I like the look they bring to a build. Experience has taught me to tack everything up first before welding fully! its going to be a very stubby back end, I have also used three 10mm LED as a stop and tail light. they are amazingly bright
buzzer:
Making the exhaust retaining flange out of 15mm alloy plate was quick and easy…
As an aside, that tin of marking blue is 50 years old, given to me by my Dad, along with one of my treasured possessions, a 0 – 1″ micrometre when I was 15 years old. Not much left in the tin now, but its still usable.
when I was a kid, I used some of that blue on the eye pieces of my brothers binoculars.. :evil: he still mentions it now!
The stainless steel collar however took an absolute age to make! I should have really used some stainless pipe, but its an odd size and I couldn’t get any that would fit, so I ended up machining it out of a solid piece of bar stock. I hate working with stainless… everything you do with it makes your life hard, just like the material!
buzzer:
I tried for a while to make a seat out of alloy sheet, and failed. the shape is just to complicated! in the end I decided on an alloy and glass fibre approach. I lifted the tank slightly so the finished seat will have some clearance, and then covered it with duct tape, followed by some tin foil to act a a release. This actually worked quite well! Cutting the foam to shape took a while and is a dusty job, but with the fan blowing on me and out the door it wasn't too bad. The key to using resin is the mix ratio... I used 2.5% as it was a cold day, in the summer that would have gone off in 5 mins! I will send it to the trimmer to do his magic... this is one of the few jobs I send out.
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