General Category > Bike Builds, Rebuilds And Restorations Only
Guzzi 1100 custom build
buzzer:
To get the tank low, and get rid of the large pump mounting hole I had to cut the bottom out of the tank. easy enough with one of those 1mm cutting disks which I seem to use a lot of these days! I needed to make the infill patch and contour this to fit the hole. to make this easier I profiled it to the right shape by cutting some wood and pressing it to shape in the vice, then a bit of planishing to get it to the final shape.
The aim is to get the gap as small as possible to facilitate a nice weld. I used some 1mm mild steel plate which matches the thickness of the tank, so TIG welding is no problem on a low amp setting. I used a couple of magnets to position it before adding a few tacks all round. At this point I ran out of Argon... The last refill I bought was £65.. now its £104!
The outlet is made, but I need the filter fitting on the bike first so I can position it to get the pipe runs neat. Once this is welded on I can leak test.
buzzer:
I picked up the headlight and fuel filter brackets today... What a fantastic process waterjet cutting is! They were profile cutting a 150mm thick block of alloy while I was there! The jury is out on the brackets at the moment, but I am struggling to think of a better design
buzzer:
When i bought the bike it had a QD system on it… while I liked the concept, it was too big and heavy so I sold it on and decided to make an underslung exhaust of my own design. I wanted smaller and much lighter. I started with a mock-up of builders foam to get the shape and angles, and then moddled this in 3D. I did do a basic model on my iPad, but then found I had to pay to output it to a file! really frustrating! so I got my mate to do it and then had all the individual parts laser cut.
The baffle plates have staggered holes, which should quieten it down somewhat, but if not, I have a backup plan! Who knows if this will kill any performance? if I lose a few BHP so be it… but you never know!
here is a 1 min video of the process
https://www.youtube.com/watch?v=RgssU93IbPM
Huzo:
Damn…!
Although there’ll be a varied response to the styling choices, that is to be expected when producing art.
No one can fail to acknowledge your brilliance in turning a mental image into metal.
Love your work.. :bow: :thumb:
buzzer:
--- Quote from: Huzo on January 21, 2023, 04:32:03 AM ---Damn…!
Although there’ll be a varied response to the styling choices, that is to be expected when producing art.
No one can fail to acknowledge your brilliance in turning a mental image into metal.
Love your work.. :bow: :thumb:
--- End quote ---
Thank you :grin:
Apart from a polish the exhaust is welded up and finished. I didn’t want to have distortion and burn through when attaching the baffles, so for these I used TIG braze which worked quite well.
The slip joints are held together with springs and to hold these I needed to make some spring hoops. These are actual quite difficult to make to get the bend just right and to a consistent shape. I made a little jig to make these.
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