Steves Project

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

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Ade SYM
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Location: Lecicestershire

Steves Project

#1 Post by Ade SYM » Fri Aug 26, 2016 5:07 pm

Hi All,

Got to know a local guy to me on the forum who liked some of the bikes that I had made and asked if I could make him a YZR500 Replica. What a challenge I thought, so started something for him.

I had a few spare parts hanging around so started to pull them all together to see what could be made for him.

I thought a good start would be the RZV Alloy frame which I had spare along with a very nice set of crank cases I got (Thanks Paul) and luckily I had all the engine component's to create a good motor.

A quick call to Daz on the forum and the engine was collected and completely rebuilt with new bearings, cranks overhauled, a couple of new piston and a full set of rings etc. Went to collect the engine and it looked great, many thanks to Daz, really excellent service, and communications when he was building it, loads of photos of the work as he was doing it and overall a really hassle free service and a very competitive price. If you want an engine doing he is your man!

Married the engine to the frame:

Image

Had a nearly new set of R1 Yokes and forks from a cross plane and a new stem was made to fit the RZV Frame:

Image

Swingarm is a RS250 re-worked to fit the RZV frame:

Image

Shock is WP with remote:

Image

The wheels are fairly special and again I had spare from a project long back. Marvic - Magnesium - 17 inch and a 3.5 rear wheel which fits a 180 tyre great:


Got the oil tank fitted as Steve did not want to run premix:

Image

Also had a alloy oversized radiator that fitted well:

Image

Got everything powder coated once I had the rolling chassis and engine in situ along with the front and rear sub-frames and put everything together.

An Aluminium Tank was sourced:

Image

Fitted a completely refurbished set of standard carbs with billet adaptors to hold the Pod filters:

Image

Fitted R1 Digital clocks

YZR500 Fairing front and rear are ready for fitting and all brackets have been prepared for fitting

Rear sets ready for fitting along with rear master cylinder

Just got the remaining parts finished for the bike so the electrics can be started and then the fairings can be painted.

Been in contact with Steve along the way and changes have been made as needed, but not so many as I have made to my own bikes which is good news for me.

The bike is going to be painted as per this video below which is the first bike have built:

Image

Hopefully it will be ready in a month or so and it can then go to its new owner, which is good for me as he is local to where I live and gives me another person to ride out with! Its been interesting making a bike for some one else as you automatically want to make what you like, but you have to take into account what the buyer wants without doing what you want to do all of the time!
Really enjoyed it so far...

Will post further pictures of the bike as it comes on further.


Ade

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jackson.40
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Re: Steves Project

#2 Post by jackson.40 » Fri Aug 26, 2016 5:53 pm

You have been busy Ade!

Bike looks fantastic :cool: :cool:

Retro racer
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Re: Steves Project

#3 Post by Retro racer » Fri Aug 26, 2016 5:54 pm

Hi Ade

Great thread, this bike looks awesome.

Lucky lad this Steve

AndyT
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Location: Port Douglas, Australia

Re: Steves Project

#4 Post by AndyT » Fri Aug 26, 2016 6:33 pm

Another brilliant looking build, mate you don't hang around

Ade where did you get the rad from
Cheers
Andy
There are holes in the sky where the rain gets in, but the holes are small, thats why the rain is thin

My rides
RZ500
Kawasaki 1969H1
Kawasaki 1970H1
Kawasaki 1972H1
Kawasaki 1973H2
Kawasaki 1972H2
Kawasaki Z1300

Ade SYM
Posts: 487
Joined: Wed Sep 15, 2010 4:48 pm
Location: Lecicestershire

Re: Steves Project

#5 Post by Ade SYM » Fri Aug 26, 2016 6:58 pm

Hi Andy,

I got it with a number of parts that I purchased some time ago and always thought it would come in handy sometime!.

Its really close to the standard radiator but is slightly wider which gives a bigger bore so hopefully a little better cooling.

Thanks for the comments

Ade

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Smoker
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Re: Steves Project

#6 Post by Smoker » Fri Aug 26, 2016 7:09 pm

Sounds like most of the bike was built from spare parts you have lying around. You must have an amazing stockpile of cool parts! :cool:

How long does a build like this take you from start to finish?

Excellent work and thanks for the inspiration!

Ade SYM
Posts: 487
Joined: Wed Sep 15, 2010 4:48 pm
Location: Lecicestershire

Re: Steves Project

#7 Post by Ade SYM » Sat Aug 27, 2016 5:21 am

Smoker wrote:Sounds like most of the bike was built from spare parts you have lying around. You must have an amazing stockpile of cool parts! :cool:

How long does a build like this take you from start to finish?

Excellent work and thanks for the inspiration!
It was started in the New Year - February or March I think so around 7 months on and off.
I had to wait for a couple of key parts which were out of my control which caused significant delay with the project.

Regarding the parts I think once you have built one bike your a compulsive parts collector as I am always thinking what could be done next and when you see something nice that may work you cannot resist the purchase!

Ade

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Ronnie
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Re: Steves Project

#8 Post by Ronnie » Sun Aug 28, 2016 5:46 am

Fantastic Ade! How on earth do you find the time! :grin:

rd84
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Re: Steves Project

#9 Post by rd84 » Sun Aug 28, 2016 12:28 pm

Nice work Ade !

Cheers
Paul

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Re: Steves Project

#10 Post by trix » Sun Aug 28, 2016 6:22 pm

Hi Ade
Looks cool as always. I'd be interested in buying a set of the pod adaptors if you have an extra set available, please pm me.
What filters are they?

Thanks
Emerson

Ade SYM
Posts: 487
Joined: Wed Sep 15, 2010 4:48 pm
Location: Lecicestershire

Re: Steves Project

#11 Post by Ade SYM » Wed Sep 13, 2017 3:39 pm

Hi All,

Made really good progress on Steve's bike in recent weeks and i am now on the last little bits to complete the bike.
The Dry build was completed and then stripped and Everything was then painted and put back together.
I put some "New Type" of Rearsets on the bike which i was going to use for my own next project but i got convinced to fit them onto this one! The bike had a bespoke wiring loom built along with a new set of clocks. The engine has been fully rebuilt and is running standard carbs so will be very reliable. It has been started and runs well but will benefit from a rolling road day to get it just right, which Steve has already planned for.

I convinced Steve not to have the holes in the front of the fairing for the lights as that was a little mistake on the Abe rep i did for myself, but the lights are all in position if needed in the future so an easy retro fit if it is decided to do. I took the bike down to Illusion Race Paint a couple of weeks ago to get the fairings prepared and then painted in the same Abe Colours as my own bike. Collected it today and it looks as you would expect a YZR500 replica too look! IMO the Alloy Tank looks amazing and fits the bike really well along with the rear seat unit and front fairings (again should have kept it for myself!)
I am hopeful Steve will like it when he visits tomorrow night to confirm the final details he wants on the bike.

The bike should be ready by the weekend dependant on me getting the rear lights, seat, number plate board and a few other items completed so i will have room at long last. I will put a few pictures up of the completed bike with the fairings on and off so you can see the whole bike once i can find a new method of doing do (Any help with this would be good)

Thanks Ade

Ade SYM
Posts: 487
Joined: Wed Sep 15, 2010 4:48 pm
Location: Lecicestershire

Re: Steves Project

#12 Post by Ade SYM » Sat Sep 16, 2017 8:50 am

Ade SYM wrote:Hi All,

Made really good progress on Steve's bike in recent weeks and i am now on the last little bits to complete the bike.
The Dry build was completed and then stripped and Everything was then painted and put back together.
I put some "New Type" of Rearsets on the bike which i was going to use for my own next project but i got convinced to fit them onto this one! The bike had a bespoke wiring loom built along with a new set of clocks. The engine has been fully rebuilt and is running standard carbs so will be very reliable. It has been started and runs well but will benefit from a rolling road day to get it just right, which Steve has already planned for.

I convinced Steve not to have the holes in the front of the fairing for the lights as that was a little mistake on the Abe rep i did for myself, but the lights are all in position if needed in the future so an easy retro fit if it is decided to do. I took the bike down to Illusion Race Paint a couple of weeks ago to get the fairings prepared and then painted in the same Abe Colours as my own bike. Collected it today and it looks as you would expect a YZR500 replica too look! IMO the Alloy Tank looks amazing and fits the bike really well along with the rear seat unit and front fairings (again should have kept it for myself!)
I am hopeful Steve will like it when he visits tomorrow night to confirm the final details he wants on the bike.

The bike should be ready by the weekend dependant on me getting the rear lights, seat, number plate board and a few other items completed so i will have room at long last. I will put a few pictures up of the completed bike with the fairings on and off so you can see the whole bike once i can find a new method of doing do (Any help with this would be good)

Thanks Ade
<img src="https://www.imageupload.co.uk/images/20 ... 500_02.jpg" border="0">

rd84
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Re: Steves Project

#13 Post by rd84 » Sat Sep 16, 2017 10:36 am

Image

Obviously not Steve's bike but your link to http://www.imageupload.co.uk seems to work ok

Cheers
Paul

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Smoker
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Re: Steves Project

#14 Post by Smoker » Sat Sep 16, 2017 4:22 pm

Married the engine to the frame:

Image

Had a nearly new set of R1 Yokes and forks from a cross plane and a new stem was made to fit the RZV Frame:

Image

Swingarm is a RS250 re-worked to fit the RZV frame:

Image

Shock is WP with remote:

Image

Got the oil tank fitted as Steve did not want to run premix:

Image

Also had a alloy oversized radiator that fitted well:

Image

An Aluminium Tank was sourced:

Image

Fitted a completely refurbished set of standard carbs with billet adaptors to hold the Pod filters:

Image

Hey, Ade! :smt006

Ade SYM
Posts: 487
Joined: Wed Sep 15, 2010 4:48 pm
Location: Lecicestershire

Re: Steves Project

#15 Post by Ade SYM » Sat Sep 16, 2017 6:12 pm

Hi Smoker & Steve

Thanks for posting the pictures and updating the thread.

I will need to find a way of putting the new photos onto the thread going forward.

Many Thanks again

Ade

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