Costin - NSR500 1994 Doohan bike

Got a customizing or restoration project? Post your progress pictures and updates here

Moderator: rztom

Message
Author
User avatar
wolfgangh
- - - - -
- - - - -
Posts: 1003
Joined: Thu Nov 17, 2005 5:37 am
Location: Vienna, Austria
Contact:

Re: Costin - NSR500 1994 Doohan bike

#31 Post by wolfgangh » Wed Nov 18, 2015 1:35 pm

Ciao Alex,
you made a point here. Actually when both cylinders were in sync and "suck" mixture at the same time the carbs would be too small most likely. I am not talking as an engine expert at all, just applying my common knowledge from school about physics and gas dynamics

racer38
Posts: 49
Joined: Sun Mar 14, 2010 10:30 am
Location: St Albans UK

Re: Costin - NSR500 1994 Doohan bike

#32 Post by racer38 » Wed Nov 18, 2015 5:22 pm

You're going to have to remove that Yamaha logo from the generator cover!!

Mick C
- - - - -
- - - - -
Posts: 149
Joined: Thu Nov 17, 2005 6:00 pm
Location: Wollongong, Australia

Re: Costin - NSR500 1994 Doohan bike

#33 Post by Mick C » Wed Nov 18, 2015 6:12 pm

Thanks for your positive comments guys...

Wolfgang, the cranks are 180 degrees, the same as standard RZ500....it would be an interesting theory to experiment with different phases when using a joint carb set-up. Ive never used it at all so I am looking forward to feb/mar when I hope to get this running. Im about half way through the titanium pipes and then its off to paint.

Ive had quite a delay trying to find some carbon/Kevlar material which is close to the HRC pattern. HRC get their own cloth made with a unique pattern through it and I think after 5 months of searching I have finally found something close. Im waiting for a sample then Ill order enough for 12 silencers. Ive got another 2 NSR's coming up so need plenty..

And racer.. its probabally a bit hard to see but Stan already has HRC engraved on the generator cover... Its not as defined as on the heads but is there!!

Cheers
Mick

racer38
Posts: 49
Joined: Sun Mar 14, 2010 10:30 am
Location: St Albans UK

Re: Costin - NSR500 1994 Doohan bike

#34 Post by racer38 » Wed Nov 18, 2015 6:29 pm

There's a guy in France who makes end cans with a similar carbon Kevlar mix. Ita got a lot more carbon in it than Kevlar so comes up quite dark. Good luck with the rest of the build. Going to be awesome!

Mick C
- - - - -
- - - - -
Posts: 149
Joined: Thu Nov 17, 2005 6:00 pm
Location: Wollongong, Australia

Re: Costin - NSR500 1994 Doohan bike

#35 Post by Mick C » Wed Nov 18, 2015 6:40 pm

Thanks mate....do you have link to the French guys stuff???

racer38
Posts: 49
Joined: Sun Mar 14, 2010 10:30 am
Location: St Albans UK

Re: Costin - NSR500 1994 Doohan bike

#36 Post by racer38 » Wed Nov 18, 2015 7:36 pm

Its Carbone&Composites Applications.

If you google that, it comes up with his Facebook page. He did the exhaust sleeves for the recent NSR500 build doing the rounds on the internet a few months back. It was using an 1989 ish NSR500 V4 engine.

Here's a picture

Image

Mick C
- - - - -
- - - - -
Posts: 149
Joined: Thu Nov 17, 2005 6:00 pm
Location: Wollongong, Australia

Re: Costin - NSR500 1994 Doohan bike

#37 Post by Mick C » Thu Nov 26, 2015 5:26 pm

Thanks racer....I should have the sample piece in the next few days. If its not close to the HRC pattern Ill get in touch with this guy and see what he can do. Id rather make all the parts myself, but if it doesn't look right then Ill just buy them from him. they look very good!

Heres a couple of pics of some electrical parts.....

This is the CDI box. It houses a Zeeltronic CDI. Ive used aluminium Milspec connectors similar to what the NSR had. The box is just folded/welded aluminium with a carbon cover..
Image

This is the power valve controller box. It has Hitachi and HRC connectors on it the same as the NSR. It is adjustable hence the little opening at the bottom which I have to make a small cover for.... I think this was a data logger box on the original NSR but putting the p/v controller in it works well I think...
Image

Not a great pic but this is where it sits on the bike. Im trying to keep cable layout the same as the NSR. The p/v controller goes on the other side but I haven't mounted it yet..
Image

Cheers
Mick

Mick C
- - - - -
- - - - -
Posts: 149
Joined: Thu Nov 17, 2005 6:00 pm
Location: Wollongong, Australia

Re: Costin - NSR500 1994 Doohan bike

#38 Post by Mick C » Sat Dec 12, 2015 5:08 am

The new cloth arrived yesterday. It is laid underneath the carbon tubes. The top tube is a custom one from Japan, the middle is 98 NSR500 and bottom is M-Max (I think) ....its very good guality but I don't think its close enough to original to use...bugger. Ill check in with the French guy and see what he can do!
Image

Made good progress on pipes..
Paper layouts
Image

Marked onto titanium and cut on bandsaw and finished on linisher
Image

Top pipes rolled and welded...
Image

Cheers
Mick

User avatar
Ax-Racing
Posts: 277
Joined: Sat Oct 24, 2009 5:11 am
Location: Modena (ITALY)

Re: Costin - NSR500 1994 Doohan bike

#39 Post by Ax-Racing » Sat Dec 12, 2015 10:15 am

Titanium :cool: :cool: :cool:
Alex

RuZty
- - - - -
- - - - -
Posts: 367
Joined: Tue Dec 13, 2005 12:39 pm
Location: Southern Ontario, Canada

Re: Costin - NSR500 1994 Doohan bike

#40 Post by RuZty » Sat Dec 12, 2015 1:58 pm

Ax-Racing wrote:Titanium :cool: :cool: :cool:
Image

rd84
- - - - -
- - - - -
Posts: 1618
Joined: Thu Nov 17, 2005 7:12 am
Location: Leicestershire, UK

Re: Costin - NSR500 1994 Doohan bike

#41 Post by rd84 » Sat Dec 12, 2015 2:29 pm

Hi Mick,

Nice project!

I thought the power valves weren't fitted because they interfered with the larger bore pistons ?

Cheers
Paul

User avatar
two-stroke-brit
Posts: 294
Joined: Wed Jul 24, 2013 11:07 pm
Location: Houston tx

Re: Costin - NSR500 1994 Doohan bike

#42 Post by two-stroke-brit » Sun Dec 13, 2015 3:08 pm

Mick C wrote:The new cloth arrived yesterday. It is laid underneath the carbon tubes. The top tube is a custom one from Japan, the middle is 98 NSR500 and bottom is M-Max (I think) ....its very good guality but I don't think its close enough to original to use...bugger. Ill check in with the French guy and see what he can do!
Image



Cheers
Mick

i thought they were "tarten patern" for a minute. :smt003
She might not be pretty but always a fun ride !!

Mick C
- - - - -
- - - - -
Posts: 149
Joined: Thu Nov 17, 2005 6:00 pm
Location: Wollongong, Australia

Re: Costin - NSR500 1994 Doohan bike

#43 Post by Mick C » Mon Dec 14, 2015 4:26 am

Hi Paul,
Power valves were always fitted, I think the original plan was to have them wired open. The customer wanted them to operate so Stan left the bottom pair movable and locked the top valves open. When I got the engine the customer asked me to get all of them working so I have made up all the linkages.. Ill put up pics of the new setup in the next day or so.
Cheers
Mick

rd84
- - - - -
- - - - -
Posts: 1618
Joined: Thu Nov 17, 2005 7:12 am
Location: Leicestershire, UK

Re: Costin - NSR500 1994 Doohan bike

#44 Post by rd84 » Mon Dec 14, 2015 12:37 pm

Mick C wrote:Hi Paul,
Power valves were always fitted, I think the original plan was to have them wired open. The customer wanted them to operate so Stan left the bottom pair movable and locked the top valves open. When I got the engine the customer asked me to get all of them working so I have made up all the linkages.. Ill put up pics of the new setup in the next day or so.
Cheers
Mick
Thanks Mick,

Cheers
Paul

Mick C
- - - - -
- - - - -
Posts: 149
Joined: Thu Nov 17, 2005 6:00 pm
Location: Wollongong, Australia

Re: Costin - NSR500 1994 Doohan bike

#45 Post by Mick C » Fri Dec 18, 2015 6:10 am

A couple of pics of the P/V linkages....

The bottom cyl was fairly simple as everything needed was still in place I just had to make the little lever arm, but the top had nothing as it was locked open so I had to work in the seals and make a few extension bushes etc for the little arm to sit on....

Trying to keep in the NSR spirit by having the pulley located between the 2 cyl banks. I was going to make a pattern for the mounting bracket and then have it cast in magnesium as per original bike but the bloke in OZ doing mag casting has gone out of business so it was just quicker machining one up out of solid. Ill get the pulley and bracket anodised in colours to match original...

Image

Image

Cheers
Mick

Post Reply