T3 - Tinks Annual Project Bike ('98 VFR800)

Discussion in '5th Generation 1998-2001' started by tinkerinWstuff, Oct 24, 2011.

  1. NorcalBoy

    NorcalBoy Member

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    I knew you'd like it.




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  2. tinkerinWstuff

    tinkerinWstuff Administrator Staff Member

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    A little progress today.

    6gen tank arrived. Tank is important because the rear of the tank mounts to the subframe. Subframe in relation to the front tank mount holes up at the steering stem and the height is critical so the tank follows the frame with a consistent gap.

    Had to cut 1" off the front of the upper subframe mount location
    [​IMG]

    mocked up in location with the tank bolted up front and pinned at the rear. Blocked up the subframe. Also had the seat on to verify the proper fit against the tank. Too low and there's a gap, too high and it gets scrunched up.
    [​IMG]

    How the front looks after cut. Hopefully tomorrow my rod that fits between the aluminum mount point on the 5th gen frame will be welded to the steel subframe in the proper location.
    [​IMG]
    [​IMG]
     
  3. NorcalBoy

    NorcalBoy Member

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    So far so good. If I might suggest something.....I'd also be thinking about the layout of the undertail and location of the battery. If you plan on using the 6g undertail and integrated battery box, you might run into some clearance issues. You probably already have this figured, but I thought I would throw it out there anyway.



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  4. tinkerinWstuff

    tinkerinWstuff Administrator Staff Member

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    always - please do


    I do have the 6th gen undertail. I had the bike mocked up earlier with the 5th gen tank, subframe, seat, and exhaust. I did not include the undertail in the mockup because it wouldn't fit in easily with the linked brakes and electrical harness dangling.

    I assumed some modifications will be necessary but have no idea what I'm in for. Thought about trying to include it in the mockup but decided I'd stress about getting the mounting points in the correct location and cross that bridge when I get there.

    any insight or concerns you can think of would be greatly appreciated.
     
  5. NorcalBoy

    NorcalBoy Member

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    Here is a pic that might shed some light on what I was thinking about.

    [​IMG]

    The loss of 1" and the length that was removed from the support downtubes is going to make life difficult for the stock undertail. The pin that is protruding from the removed, right, downtube support is what the front of the stock undertail hangs on for support. The seat latch locking mechanism will have to be relocated too. The stock 6g undertail is unforgiving, with respect to fitment. I don't have the magic answer, but I envision some clearance and relocation issues, especially with the battery, when shortening the subframe. Clearance for the tire is going to be interesting. It isn't a deal breaker, but I believe this will be making life somewhat difficult for you further on down the road.

    Edit: There are also two trim panels that attach on both sides of the subframe backbone/undertail/battery box, below the seat, that will no longer fit and will have to be rethought.






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  6. tinkerinWstuff

    tinkerinWstuff Administrator Staff Member

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    Oh goody, just as progress starts to happen, more headaches ahead.

    Thanks for the picture, that will be very helpful. Tough to see on my phone but I look forward to a peek on the laptop screen later today. I've waited to purchase a battery in anticipation of just this type of problem.

    Subframe dropped off at the machinist this morning to be drilled accurately and have the crossmember mount shaft welded in place. Was warned I may not get it back until next week. Then the bike will go to another shop with a tube bender to fabricate the lower mounts.

    After that, to the exhaust shop for modification to the pipe to clear the right rearset.

    Then I'll know what nightmare I've created for myself on the inner fender.

    Finally - powder coating and paint!
     
  7. tinkerinWstuff

    tinkerinWstuff Administrator Staff Member

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    Hopefully tomorrow I can finish the lower mounts

    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
     
  8. tinkerinWstuff

    tinkerinWstuff Administrator Staff Member

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    tried to fabricate the lower mounts by heating and bending over a mandrel. looked like hell.

    bike is loaded in the truck and will be dropped off tomorrow at a shop with the proper tools to fabricate what I want for the lower mounts.

    Did some tweaking on the fairing stay and checked out how the LED mirrors might look.

    [​IMG]
     
  9. Fazer1Sniper

    Fazer1Sniper New Member

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    She's getting closer!
     
  10. tinkerinWstuff

    tinkerinWstuff Administrator Staff Member

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    While bike is at the shop, it's full steam ahead on the body work.

    Working on the right side panel that I've been dreading.

    before:
    [​IMG]

    Panel is welded together. The plastic welding process tweaks the shit out of the panel. Badbilly tipped me off on the 3rd gen project to do a pre-fit of the panels before paint. Using lessons learned on that project, I am trying to do better this time.

    I clamped the panels together and then reheat the shit out of the welded panel. Then leave to cool so it will match the mating panel. Sort of a stress-releaving process:

    [​IMG]
    [​IMG]

    Next will be fiberglass filler and hours of sanding.


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  11. tinkerinWstuff

    tinkerinWstuff Administrator Staff Member

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    planets aligned perfectly. Wife and kid are gone with mild temps and no wind.

    my sanding layer of primer is down:
    [​IMG]
     
  12. 82ndGreasemonkey

    82ndGreasemonkey New Member

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    Lookin GREAT! I can't wait to see this come together. Really, really nice work tink
     
  13. tinkerinWstuff

    tinkerinWstuff Administrator Staff Member

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    Thanks!

    I might have to try and hold the final picture for an official unveiling at R3-2012
     
  14. Fazer1Sniper

    Fazer1Sniper New Member

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    So I gotta ride 39 hours straight, over 2400 miles to see this damn ride?
     
  15. tinkerinWstuff

    tinkerinWstuff Administrator Staff Member

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    not 39hrs straight. Just make it to Denver and we can ride the rest of the way.

    otherwise you'll have to wait for the after party pics to get the final product.
     
  16. Fazer1Sniper

    Fazer1Sniper New Member

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  17. pap11y

    pap11y New Member

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    Good stuff :)
     
  18. stoops

    stoops New Member

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    what? sadface, but i'll still keep following along :pop2:
     
  19. tinkerinWstuff

    tinkerinWstuff Administrator Staff Member

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    no worries, you'll just have to wait a couple extra weeks for the official photo shoot unveiling of the final product.
     
  20. TOE CUTTER

    TOE CUTTER Mullet Man

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    Your not done yet? Less chatting and more sanding!
     
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