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While I was working on the frame, Luke started on the sheetmetal
He used my old beat up FXRP fairing as a buck for the aluminum
getting smoother!
The shell is complete and mostly metal finished!
A quick mockup at ride height to see what we're working with (you can also see the beginnings of the tail section)
I don't have really any pics of the tail section being constructed but here it is with the edges tipped and the underside about 80% metal finished.
The final product set in place! (also a sneek peek of the wheels I had made)
And now the whole reason for doing all of the frame work. I have the turbo mounts tacked in place and the turbo in it's final resting place.
Starting on the primary tubes for the turbo manifold
I made them with 2 dual slip-fit connections to allow for thermal expansion as well as being able to take the turbo setup off of the motor a lot faster. using my stock engine as a mock-up motor.
using a stainless flex bellow along with the 2 slip fit connections will greatly reduce any chance of cracking or stress points, especially with the turbo solid mounted to the frame.
and the last pieces of that puzzle tacked up ready to be final welded.
close up of the turbo up-pipe and wastgate tube final welded
Had to make some solid motor mounts, this is the rear. Simple but stout.
Now for the intercooler. We decided to recess the intercooler into the tank and make a functional duct from the front fairing to force feed air through the intecooler.
intercooler partly tacked up
rear intercooler endtank before being metal finished.
here you can see the path of the duct that needs to be made, as well as the bottom gap that needs to be closed off, and the front end tank that hasn't been made yet.
These are the wheels I had had made (they were powdercoated after this), I wanted to mimic the BBS Turbo-fan style wheels that were used on a lot of 1980's race cars.
And we'll skip ahead a little bit. So a lot has happened in the pic. Intercooler and its plumbing has been finished out, swingarm is mounted along with the new powdercoated wheels. The Hayabusa front end is also installed, as well as the shocks and shock mounts. At this point the sheetmetal was still being finalized and the mockup motor is still in the bike waiting to be swapped out for the S&S 124"
I decided to make it hard on myself and do a titanium downpipe and wastegate merge.
You win a trophy for your welding skills, what I'm looking at are textbook titanium welds with light straw coloration in the heat affected zones... PERFECT and extremely difficult to do with that many welds that close together, without burning the properties out of the material.
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