Next Generation 81' GL1100i

[DCSparrowhawk]

Heres a photo of the spacer.

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[Rat]

Coming along nicely ... Wog made a set of headers to get the carbs moved forward out of the way of your knees ...

https://ngwclub.com/forum/viewtopic.php ... 80#p777280

Gord

[nakedinterstate81]

I have the regular carbs on my gl1100 and do not like the seating position with the original seat either. I am 6'3, long legs and flat footing the bike with my knees bent. Sitting upright, my spine takes the force of every pot hole.
I am considering a little more sporty position like in a Ducati Supersport, slightly leaning forward and elevate the seat.
Perhaps using the deck of a long board skate board with custom cut foam, or a piece of marine board.

[DCSparrowhawk]

Coming along nicely ... Wog made a set of headers to get the carbs moved forward out of the way of your knees ...

https://ngwclub.com/forum/viewtopic.php ... 80#p777280

Gord

Thats nutty! I love it though.

I've sourced the intakes from Randall, but worst case ontario I'll have to do the same thing. Obviously not quite as ridiculously, but an extra 2" of forward (While sitting on the bike) would make all the difference.

While spooling through Pinterest, I found a radiator guard which incorporates highway peg foot rests... That might be the solution for highway travel. In-town, it'd be slightly annoying but its manageable.

I'm going to be plopping K&N air filters to the carbs. I am unsure as towards how it will change the way my knees hit. I have a funny feeling it will resolve itself, as the tips of my knees hit the top of the velocity stacks... I think the angle of my knees will hit the tank before it hits the filter...

We'll find out once Canada Posts finds my package with my filters...

[DCSparrowhawk]

I've spent (most of my spending money) and the last few months building a 3D printer capable of printing high-strength demanding materials such as nylons, HDT nylons, carbon fiber infused nylons, polycarbonates, carbon fiber infused polycarbonates, and most importantly PEEK.

I've been designing my rim spacer along with an airbox for the weber 40 IDF carbs.

Weber 40 IDF Airbox
The airbox integrates a new trumpet design right into the box eliminating the need to source smaller trumpets, and shorter jet holders. In the photo is the design previous to the one I'll be using, but it's just small diameter changes and quality of life updates. In the photo as well I'm only using cheap crappy prototype material. The final print will be out of high-density nylon with about 14,000 PSI tensile strength. I originally opted for carbon fiber-infused nylon, but for this particular application, that material is way overkill.

The airbox design is meant to utilize the same air filter as this kit:
https://www.tdotperformance.ca/k-n-56-1 ... embly.html

Between the integration of the trumpets to the box, lack of need to change the holders, and overall cost of production - the price has been dramatically reduced for what I'd consider a better product.

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Rim Spacer/Brake Adapter Prototype
In the photos, these look a bit rough. This was one of the first proper 3d prints I tried, and didn't even consider the dimensional accuracy difference between CNC milling and FDM extrusion. Needless to say, FDM is quite accurate, but nowhere near as accurate as a CNC mill. I had to do a bit of rubber mallet hammering to get everything to fit, and although I'd consider it a successful prototype I'm going to be playing around a bit before I send off to get machined. So far - looks very good.

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[DCSparrowhawk]

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83' Rim On 98 GSXR750 Forks & Brakes

Spacers worked perfectly - a slight change in overall wheel design has resulted in a wonky spaced rim due to axle design. Long story short I need a new shaft made and have to shorten the female nut on the axle to properly center the wheel, as it seems the female nut sets the distance for the whole rim. Makes sense to me.

Calipers are not on the bike as of when this photo was taken, but they're on now and they fit.

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Dunlop 404 Tyres

Really happy with the way these look, picked up the rear tyre as well.


Progressive 412 Rear Shocks

Picked up a "Used" set of 412 progressive rears off of some other make/model. These things look brand spanking new and came in the original box (I think from the 90s?) They're 0.5" lower than suggested for Gl1100, but my maths seem to work out that I went down ~0.5" in the front. Eyeball measurement confirms that its... Pretty close.

Next Steps

I have to rebuild the carbs with rebuild kits from CB Performance and change some jetting.

Figure out throttle linkage and get it on the bike. I think I'm going to do a 2-1 throttle cable with tensioners mounted to the intake tubes, pulling indv. bell cranks on the front of the carbs.

All the electrical is coming out. Everything. Each wire is being replaced, plugged, loomed, and put back in. I have a full M.Unit set-up that I've been bench testing with a mobile PSU and (I think) its good to go.

Will be swapping out stock coils for the neon coil.

Welding up exhaust and exhaust hangers.

New Stator

Hydraulic Clutch conversion

Figure out some sort of front fender.

We'll see how far I get in the next couple weeks.

[Rat]

Nice work ... lookin good

Gord

[5speed]

looking wicked.

[DCSparrowhawk]

First Attempt At An Exhaust

In all honesty, I'm working on acquiring a TIG welder and currently practicing on a loaner TIG as much as possible on 304 stainless in the hopes of making a real pretty exhaust one day for this bike (and others in the future). As it stands, this one has been MIG welded together and ground down to look partially acceptable. If anyone has an idea on how to sand a muffler perfectly flush I'm all ears!

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Repurposed and bent some "Exhaust Hangers" from a few pieces that were previously attached to the head studs to hold up the header's guards. Just hammered on a bench vice to get the desired shape. These have been tacked to the muffler and I'll be using an oversized bolt and nut to secure it to the rear of the passenger peg mounds as shown.

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A Bit Of Pretty Stuff

Ground down the fins on the valve covers - and filled the GL 1100 with JB Weld and sanded it down to make a flush "Knuckle" look. Pictures are throughout the process but you get the idea. I've also removed the fins from the front belt covers.

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Also - Picked up an additional GL1100 as I sold one of my other bikes. I love the engine of the wing, and having a nice OEM original gives me a good benchmark to compare against. Being from the Canadian Rockies I felt guilty riding a roided-out performance scalpel to tour through the mountains - this new wing is perfect for the job - and runs like a dream. Brakes kinda suck so I think once this project is out running and riding the dual 6 pot calipers paired with the huge rotor will really help out.

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[schrutebucks]

Subscribed!
Love that you kept the stock front wheel with the fork swap.

[DCSparrowhawk]

Apologies for the delay - moved into a new shop, and I've been working with a Canadian Top Fuel dragster team, as well as becoming more involved in building experimental class composite airplanes. Lots of valuable information and skills to translate into this build.

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Motogadget M.Unit Install

The installation went pretty well. The most difficult part is sorting out a completely new wiring harness - and all the accessories I'd like to include, to then actually wiring up my own wiring diagram. With the removal of the original carbs and the air box - I now have a large gap underneath the faux tank, and will be 3D printing a box to house the M.Unit, the coil pack, and rectifier. I will also include a large storage cubby hole which I plan to run dual AEM Wideband AFR meters to accurately tune each side of the bike as I intend to navigate the Canadian Rockies with this bike - I'd like to know where I'm at - at all times. That will come in a later post.

Long story short - it starts and runs (No tuning or anything done yet to carbs - just making sure it all works together.)

https://youtu.be/spKn2_0Vwpw

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Throttle Linkage

Going against the grain - I'm going to "ATTEMPT" to fashion a dual bellcrank system with a split throttle cable to run both carbs. I have a hunch that the difference in cable stretch will equate to impossible sync between both carbs - but I'm a moron so let's do it anyways and learn for myself... The pictures were a real rough-cut version of the bellcranks - I now have much prettier and properly machined pieces. Working on a method to support the cable and include a cable tensioner. The idle adjustment is tuned on the rear end of both carbs.

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Electric Fuel Pump

Welded a bracket to the fuel tank (What a challenge that was...) and I'm now able to mount the little electric fuel pump in-line from the petcock, with a Y junction to each carb. I'm presuming I can wedge a fuel filter in between the petcock and the pump - yet to be verified.

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[Rat]

Jeez ...

Gord

[DCSparrowhawk]

Jeez ...

Gord

Jeez Louise?!

[Fred Camper]

Keep in mind the GL has great binders but Mother Honda put in a master cylinder that takes high effort unlike modern bikes. To make the brakes two finger, a different master cylinder diameter often fixes them. Best to start there. On an GL1000, a 15mm is about right, but not sure on your bike.

[DCSparrowhawk]

Keep in mind the GL has great binders but Mother Honda put in a master cylinder that takes high effort unlike modern bikes. To make the brakes two finger, a different master cylinder diameter often fixes them. Best to start there. On an GL1000, a 15mm is about right, but not sure on your bike.

For sure - the original wing I have is quite high effort indeed compared to a modern bike. Using the dual 6 pot front brakes from the GSXR - I went with the VFR800 brake master cylinder to match the clutch - though it's somewhere in my notes I'm pretty sure it ended up to a very close match to the GSXR OEM diameter. We'll see how it plays out - I have a rep from Hel Performance who will be making up some braided front lines so I can see if the brakes are adequate come the first test ride - which isn't too far away at this point.

Great point - we'll see how she goes!