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Old 11-17-2009, 02:52 AM   #1
tripletom OP
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Joined: Jul 2008
Location: The Lower
Oddometer: 119
DR/SR hybrid to confuse the rivet counters.

Well, it's oldish, it's air-cooledish and that'll do for a start...
Will start off in here and see how it goes.
Ingredients-
1985 DR600 that was in good working order-



Then got lent out and returned with engine internals looking like this-





After a slow parts gathering and assembling the engine is nearly back together-

Head assembly with R/D Ti valve spring kit-



Wiseco +3mm piston, necessary due to bore damage-



Assembled head in background, new balance chain-



Got a Joy #209 race grind cam to go in, and a Keihin FCR39 on the way too. Will be building the exhaust system to a design based upon various books and an HRC design for the XR600.

I started playing about with a few parts and ideas...

Ex-Hawk Kawasaki BSB titanium silencer (I'll weigh it at some point, I reckon it weighs about 1500grams)



Old Raydot driving lamp-



Some ace bars I lengthened to go on the Trumpet a few years ago-



A seat unit that's probably older than me! Will be cut down and sectioned-



An old SR500 tank-



and a test of how it might look...



The tank is sitting high on the frame at the moment so I'm decided to cut the bottom out and remake it.I tried to see if the old Zed tank in the shed would fit instead. Paint has already been decided on.

I got bored and decided to try and see how the whole thing sat on the workmate. I stuck the FZR wheels and forks in, and then for shits and giggles tried out the SR rear mudguard ... It looks alright to me so far though..



The front forks were too short with the stock FZR top yoke so a friend is machining up a stepped top for me to give me more clearance.
I also got messed about with a filler cap, so ended up cutting the old mounts out and welding in a bsp female fitting. Had to slap some filler on to cover up the recesses, and it's not quite done yet. Got the gold basecoat on some of the plastics too.





Getting there...slowly.
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Old 11-17-2009, 06:29 AM   #2
thealien
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MMMMMMMMMMmmmmm nice thinking!! - is it going to be a DR Saturno like the one I eventually plan to build when I get tired of my supermotard?

[quote=tripletom]Well, it's oldish, it's air-cooledish and that'll do for a start...


and a test of how it might look...




I got bored and decided to try and see how the whole thing sat on the workmate. I stuck the FZR wheels and forks in, and then for shits and giggles tried out the SR rear mudguard ... It looks alright to me so far though..

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Old 11-17-2009, 09:53 AM   #3
Caddy82rats
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Nice setup
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Old 11-17-2009, 11:02 AM   #4
tripletom OP
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Location: The Lower
Oddometer: 119
No Saturno rep.
The idea is to build a bike that looks like it came from the factory, but was then tweaked a little bit by someone. But all in the early 80s style, as befits the age of both the bikes.
I want people to think it's an SR at first glance, then twig the 3-spokes, then the monoshock, then the suzuki badges, and be all "WTF?"
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Old 12-04-2009, 02:37 AM   #5
tripletom OP
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Well my top yoke has been made. Well chuffed.



50mm step to allow good ground clearance with the FZR forks. Pick it up tomorrow and can then start getting on with the bike finally.
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Old 02-22-2010, 06:37 AM   #6
tripletom OP
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Talking

Quite a lot has happened in a short space of time...
Now I have the awesome yoke from Al I am able to get it on wheels which meant I could see how much I needed to drop the back end.
Conveniently I am able to just drill two holes in the stock llinkages to drop the back down, and Hagon have responded to my query regarding a firmer spring for the Hagon shock on the bike. So today was decision day, does it go Bratty, or does it go OE+?
Well it's going OE+.

The seat unit I tried looked fine, but was just a little too long, so can go back in the shed for the TR1. Some picamatures then-

From the rear-



From the front ish-



and then from the side with me trying to work out silencer position using some twine-



It is stupidly simple and unbelieveable how the SR rear guard fits, the bloody bolt holes couldn't line up better. I've got a list of jobs for tomorrow; I need to cut off and move the tank mounts, prep the tank for paint, locate the second spare SR sidepanel I have so I can extend them both, and also drill the top yoke to mount the instruments. Thankfully Al has given me a couple of pilot holes already for that.
Chuffed. :icon_bounce:

I then spent a lot of time staring at the bike in various guises.



but decided to go with what I'd set out to do. I managed to drill the frame for the tank front mounts. Albeit in the wrong place. Never mind will have to redrill in the right place.



After fannying about staring at the bike for far too long and umming and ahhing I setled for what I'd planned and snapped a few pics.







Meh. More in maybe a few months...
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Old 02-22-2010, 10:52 AM   #7
eric123
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Looks good with the spoked wheels...
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Old 06-15-2010, 07:33 AM   #8
tripletom OP
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It's been a while...

But things have been happening. The bike is roughly on it's (new) wheels, and the bodywork is now wearing the 4th paint scheme.
I began building the frame up-



Fixed the bodywork on to see how it looked-



Then took it off again in order to fit the engine-





My list of things to do is now only 10 items long...
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Old 06-15-2010, 11:32 AM   #9
jings
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thats looking real nice whay are you going to do about a speedo
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Old 06-15-2010, 11:57 AM   #10
tripletom OP
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Using the original DR instruments, the top yoke is drilled at the bottom to take them.
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Old 10-11-2010, 08:25 AM   #11
tripletom OP
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Now with the exhaust system made up, and seat recovered-



I suppose I should do more to it...
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Old 10-11-2010, 09:00 AM   #12
Sniper X
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So far super bitchin! I love what you did on the paint. And everything else save for the weird bars!
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