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KCR
02-27-2014, 10:37 PM
Long time forum lurker..finally signed up. This is my first bike resto/build if you will. Here's how it looked the day I picked it up. 87' model with 12k original miles on the clock. The previous owner had attempted to start a bobber out of the bike as well. Unfortunantly they had the frame chopped an the backboned switched up. This didnt allow the carb to be fitted. So ...chop time it was. Cut the back bone out an rebuilt the tubular back boned to allow fitment of the carb an a battery box (which I later fab'd). The swing arm was also altered an welded solid to make it a rigid frame. The pivot point was welded an capped with a thick 1/4" plate to further strenghten it. Done pretty well actually.
http://i16.photobucket.com/albums/b27/Blue86rx7/IMAG0013.jpg
http://i16.photobucket.com/albums/b27/Blue86rx7/IMAG0020.jpg

KCR
02-27-2014, 10:43 PM
http://i16.photobucket.com/albums/b27/Blue86rx7/IMAG0010.jpg

another shot of the bastard child. It had been dropped off at a buddies from another to have the wiring harness simplified. He lost interest and I scored her for 4 bones. Now to get it back to a working frame

http://i16.photobucket.com/albums/b27/Blue86rx7/IMAG0040.jpg

KCR
02-27-2014, 10:46 PM
After removing the old back boned I began bending some 1" o/d steel tubing. Cut an fitted the rear section into the existing frame tubes. After that began working down the backbone an finished it with some custom spring "perchs" for the springer seat. Also adding a few flat bars for the seat hinge mount an the lower fuel tank mounts.http://i16.photobucket.com/albums/b27/Blue86rx7/IMAG0041.jpg

New frame setup, with motor fitment included.http://i16.photobucket.com/albums/b27/Blue86rx7/IMAG0052.jpg

Spring perchs I made from some 1/4" flat bar. Then welded a "thru bolt" to attach the springs. Springs were scalped off a riding lawn mower seat. Freebie :D as was most all the materials used in this build. Attached the seat hinge as well.http://i16.photobucket.com/albums/b27/Blue86rx7/IMAG0091.jpg

KCR
02-27-2014, 10:51 PM
Next came a quick battery box setop. This would include holes placed in the bottom with rubber gromets (sp?) to keep the wiring from getting cut. Knocked out a quick lid an got it mounted.
http://i16.photobucket.com/albums/b27/Blue86rx7/IMAG0121.jpg

Another shot of it mounted on the frame..

http://i16.photobucket.com/albums/b27/Blue86rx7/IMAG0122.jpg

trying to make the ugly look good. Seat springs evently were replace with shorter ones.

KCR
02-27-2014, 10:53 PM
Next came a tag mount/ brake light set as well as a ignition mount. Both were made from a sheet of aluminum an used the brake to get the bends on the tag holder an polished both up. The starter bolts were perfect for the ignition holder. Ran new bolts to make sure I still had a decent amount of threads in the starter mount holes.

http://i16.photobucket.com/albums/b27/Blue86rx7/IMAG0144.jpg
http://i16.photobucket.com/albums/b27/Blue86rx7/IMAG0146.jpg

Ignition mount
http://i16.photobucket.com/albums/b27/Blue86rx7/IMAG0148.jpg

KCR
02-27-2014, 11:01 PM
Here's a quick shot of tag setup. Used the metal "alarm" wire loom thats commonely used at commercial rollup doors near the floor. Worked well on the brake light wiring as loom. Ran the wiring through the swing arm an out just before the pivot point an under the frame.
http://i16.photobucket.com/albums/b27/Blue86rx7/IMAG0173.jpg

I later went and modified the mount more after painting the frame

http://i16.photobucket.com/albums/b27/Blue86rx7/Bobber/IMAG1558.jpg

KCR
02-27-2014, 11:06 PM
Next I had went through the wiring an cleaned it up an tucked it nicely under the tank as the previous owner had started doing. Cut off anything thats not needed an leave the basics. All of which is hidden nicely under the tank. Welded some new tank mount studs an placed new rubber bushing on the mounts as well. Also fabbed a start button under tank since I deleted all handle bar wiring. The tank had extensive dings an dents from the bars hitting them. I went an welded in a new steer stop an then patched up the dents an got it into primer.

http://i16.photobucket.com/albums/b27/Blue86rx7/IMAG0180.jpg
http://i16.photobucket.com/albums/b27/Blue86rx7/IMAG0305.jpg

Some Redcoat in the tank..and into paint stage next.

http://i16.photobucket.com/albums/b27/Blue86rx7/IMAG0704.jpg

KCR
02-27-2014, 11:11 PM
Intake build. Started off with some metal intercooler pipe from a 300zx..chop cut weld.
http://i16.photobucket.com/albums/b27/Blue86rx7/IMAG0190.jpg

Used a carb cleaner filter and sandwiched between to metal plates. Simple and works.
http://i16.photobucket.com/albums/b27/Blue86rx7/IMAG0192.jpg
http://i16.photobucket.com/albums/b27/Blue86rx7/IMAG0193.jpg
http://i16.photobucket.com/albums/b27/Blue86rx7/IMAG0202.jpg
http://i16.photobucket.com/albums/b27/Blue86rx7/IMAG0203.jpg

KCR
02-27-2014, 11:22 PM
Lil exhaust work. Gave it a nice teardrop cut on the tip. http://i16.photobucket.com/albums/b27/Blue86rx7/IMAG0186.jpg

I'm all about build threads as its neat to see ones creations an learn. So lots of pics I say! Heres the stocker pegs I replaced with a good ole set of steel BMX pegs. Just cut them from the swivel arms an welded a 5/8" bolt to the peg swivel..bolted peg on. done. ... bmx pegs.. $5

http://i16.photobucket.com/albums/b27/Blue86rx7/IMAG0228.jpg

Next I did the drop mod to the front shocks. Pretty straight forward. Lowered the stance 2" in front.
http://i16.photobucket.com/albums/b27/Blue86rx7/Bobber/319191_2379541880710_1015542477_32488925_711834759 _n.jpg

After that I shaved the legs and deleted fender mounts with hand tools and many grades of sand paper..finished with scotch bright pad's.
http://i16.photobucket.com/albums/b27/Blue86rx7/IMAG1543.jpg
Finished results
http://i16.photobucket.com/albums/b27/Blue86rx7/IMAG1547.jpg

KCR
02-27-2014, 11:26 PM
Welded up some harley peg mounts on the forward controls.
http://i16.photobucket.com/albums/b27/Blue86rx7/IMAG1551.jpg
The originals were gnarl and pressed on garbage. Also did some customization to the foot levers.

http://i16.photobucket.com/albums/b27/Blue86rx7/IMAG1550.jpg

http://i16.photobucket.com/albums/b27/Blue86rx7/IMAG1542.jpg

KCR
02-27-2014, 11:33 PM
Last bits on frame before paint. New kickstand mount..and ditch factory one and fab left side plate inplace for foot peg mount.

http://i16.photobucket.com/albums/b27/Blue86rx7/IMAG0691.jpg

FIrst duplicate plate from right side..
http://i16.photobucket.com/albums/b27/Blue86rx7/IMAG0695.jpg
Install
http://i16.photobucket.com/albums/b27/Blue86rx7/IMAG0697.jpg
Notch peg mount plate for motor fitment
http://i16.photobucket.com/albums/b27/Blue86rx7/IMAG0701.jpg
http://i16.photobucket.com/albums/b27/Blue86rx7/IMAG0699.jpg

Before tear down for paint an powder coat..
http://i16.photobucket.com/albums/b27/Blue86rx7/bike3.jpg
http://i16.photobucket.com/albums/b27/Blue86rx7/311976_2375417577605_1736820588_n.jpg

KCR
02-27-2014, 11:42 PM
Prime time http://i16.photobucket.com/albums/b27/Blue86rx7/IMAG0686.jpg

All welds buttered and smooth before hand.
http://i16.photobucket.com/albums/b27/Blue86rx7/IMAG0687.jpg

And finally paint. Basic two stage black cleared over. Later cut and buffed
http://i16.photobucket.com/albums/b27/Blue86rx7/Bobber/466372_3201113579489_1015542477_32824521_209054647 1_o.jpg
http://i16.photobucket.com/albums/b27/Blue86rx7/Bobber/479392_3201264223255_1015542477_32824569_961508626 _o.jpg
http://i16.photobucket.com/albums/b27/Blue86rx7/Bobber/466166_3201089458886_1015542477_32824516_102632078 7_o.jpg
Wet sand and buff time. Shits like a mirror. http://i16.photobucket.com/albums/b27/Blue86rx7/FB_IMG_13378946436015403.jpg
http://i16.photobucket.com/albums/b27/Blue86rx7/CopyofCopyofIMAG0856.jpg

After buffhttp://i16.photobucket.com/albums/b27/Blue86rx7/IMAG0860.jpg

KCR
02-27-2014, 11:45 PM
These pic's are from over the last two years up to current..as I'm bring everyone up to speed.

KCR
02-28-2014, 12:00 AM
Next I tore the motor down some. Basic seals replacements..side cases..head gasket and head plugs.
http://i16.photobucket.com/albums/b27/Blue86rx7/IMAG0581.jpg

ready for chemical stripping, and media blasting in prep for paint and refinishing.
http://i16.photobucket.com/albums/b27/Blue86rx7/IMAG0620-1.jpg

http://i16.photobucket.com/albums/b27/Blue86rx7/IMAG0622.jpg

stripped and cleaned
http://i16.photobucket.com/albums/b27/Blue86rx7/Bobber/431565_2974154305649_1015542477_32727835_902847103 _n.jpg

Head
http://i16.photobucket.com/albums/b27/Blue86rx7/IMAG0597.jpg

KCR
02-28-2014, 12:10 AM
High temp paint spray bomb job..
http://i16.photobucket.com/albums/b27/Blue86rx7/IMAG1005.jpg

Sanded "fins" back to natural metal and ported head a bit while it was off
http://i16.photobucket.com/albums/b27/Blue86rx7/IMAG1075.jpg
Also removed clear from aluminum side cases and scotch brighted to a satin look
http://i16.photobucket.com/albums/b27/Blue86rx7/IMAG1018.jpg
scotch brighted valve adjustment covers and later painted valve cover same color
http://i16.photobucket.com/albums/b27/Blue86rx7/IMAG1011.jpg

KCR
02-28-2014, 12:15 AM
Went through and installed all new seals and gaskets to make this a tight motor. Then onto mounting in fresh frame
http://i16.photobucket.com/albums/b27/Blue86rx7/IMAG1096.jpg

Modified top motor mount brackets and satin blacked them. New hardware
http://i16.photobucket.com/albums/b27/Blue86rx7/IMAG1118.jpg

KCR
02-28-2014, 12:22 AM
Now them nasty wheel. Dismounted tires..and de-spoked for powder coat
http://i16.photobucket.com/albums/b27/Blue86rx7/557792_3224179756129_1015542477_32838283_111610258 3_n.jpg

http://i16.photobucket.com/albums/b27/Blue86rx7/IMAG0757.jpg

Back from the powder coater. Got the triple tree's done as well.

http://i16.photobucket.com/albums/b27/Blue86rx7/IMAG0110.jpg
http://i16.photobucket.com/albums/b27/Blue86rx7/884404_4834598815599_358618688_o.jpg
http://i16.photobucket.com/albums/b27/Blue86rx7/884350_4831810105883_1604238498_o.jpg
http://i16.photobucket.com/albums/b27/Blue86rx7/IMAG0112.jpg

all new spokes and nipples.. loose laced and ready to be trued. Did a quick truing job to save on shop time
http://i16.photobucket.com/albums/b27/Blue86rx7/1902912_10201980946818010_252786797_n.jpg
http://i16.photobucket.com/albums/b27/Blue86rx7/IMAG0126.jpg

Satin black powder coat on forward controls
http://i16.photobucket.com/albums/b27/Blue86rx7/1620810_10202065611934585_660144904_n.jpg

KCR
02-28-2014, 12:46 AM
Next made up some home built frisco's. " stuff
http://i16.photobucket.com/albums/b27/Blue86rx7/420200_4839819386110_847929756_n1.jpg

New risers
http://i16.photobucket.com/albums/b27/Blue86rx7/1888678_10202065535092664_1694091105_n.jpg

KCR
02-28-2014, 12:54 AM
Throttle and clutch cable kits arrived...time to get things under control on this bastard. Venhill makes a great product and I deff recommend it for the bang off ebay.
http://i16.photobucket.com/albums/b27/Blue86rx7/1897740_10202012415484707_938081750_n.jpg

modified an old ebay style throttle to work with my stocker throttle elbow. Also grinded the nastyness down and smoothed the housing up some. Will eventully be gloss black on satin bars.http://i16.photobucket.com/albums/b27/Blue86rx7/1797455_10202060303521878_980698768_n.jpg

Clutch setup. Used factory perch and shaved mirror mount off. Scotch brighted as well. will paint perch gloss black to match other controls...brushed aluminum levers to match.
http://i16.photobucket.com/albums/b27/Blue86rx7/1620836_10202025608894534_1550891335_n.jpg
http://i16.photobucket.com/albums/b27/Blue86rx7/1922515_10202065611814582_661086903_n.jpg
Digging this Venhill clutch cable kit.. was smooth fab work an install. No sloppy long cables. Also made a clutch cable mount on motor top to safe gaurd from rubbing on valve cover.
http://i16.photobucket.com/albums/b27/Blue86rx7/1939411_10202025609094539_905770515_n.jpg
http://i16.photobucket.com/albums/b27/Blue86rx7/1618678_10202025608774531_1485372969_n.jpg

KCR
02-28-2014, 1:02 AM
More goods arrived as of today. Clutch master cylinder... and some misc hardware for clutch perch. Had to modify this mc to except 1" bars. Was 7/8'. Read about grinding and finish with a socket cover with sand paper to dial in diameter. Worked like a champ on my air gun at low rpm.
http://i16.photobucket.com/albums/b27/Blue86rx7/1891055_10202064811114565_1599370409_n.jpg

Installed
http://i16.photobucket.com/albums/b27/Blue86rx7/1902794_10202064811394572_603005201_n.jpg
http://i16.photobucket.com/albums/b27/Blue86rx7/1604822_10202064811514575_2016718791_n.jpg

Also did scotch bright treament to the rear drive hub and brake drum.
http://i16.photobucket.com/albums/b27/Blue86rx7/1922501_10202052803374379_1883731740_n.jpg
http://i16.photobucket.com/albums/b27/Blue86rx7/1779702_10202052803854391_749369440_n.jpg

KCR
02-28-2014, 1:14 AM
Getting there
http://i16.photobucket.com/albums/b27/Blue86rx7/Bobber/1798784_10202065612094589_1756045797_n.jpg

johnnybarndrunks
02-28-2014, 3:33 AM
Lookin' real good! I really dig the gloss black to scotch bare metal look..

Demin
02-28-2014, 8:59 AM
Very cool!!!This is one of my favorite bikes to do.Did you check the camchain tensioner???If not go over to www.suzukisavage.com and check on it.There is a guy over there that sells modified ones.I have'em in mine.If the tensioner comes apart,it's usually catastrophic.

KCR
03-03-2014, 7:37 PM
Thanks dudes! Yeah I checked out the tension mech and she's all good. Made some progress on the throttle cable an got it cut and soldered up. Used a steel pipe cap for a makeshift smolder pot and melted down some silver solder. Worked great.

http://i16.photobucket.com/albums/b27/Blue86rx7/Bobber/1962617_10202088407704465_90509279_n.jpg

knuckled420
03-03-2014, 7:57 PM
not a fan of the bike but am a fan of your work! well done sir! well done...

dfinnegan
03-03-2014, 8:16 PM
Nice build man! Looking good. How did you figure out your wiring harness?

KCR
03-03-2014, 9:15 PM
http://i16.photobucket.com/albums/b27/Blue86rx7/Bobber/IMAG0019.jpg
Thanks guys. The previous owner had chopped out the "unnecessary" stuff and more less needed it all properly soldered and wired up. I basically laid the harness on the floor an drew up a schematic and traced everything down and shortened up for a gas tank wire tuck. Needless to say I became pretty damn good at soldering an heat shrinking the wiring after pretty much redoing it all. Labeled everything with masking tape. Pain staking work but the pay off was a clean frame an no rat nest of wires.

Jetblack
03-04-2014, 12:08 AM
Very nice fab skills and work thanks for sharing, no way in the world would I trust such between my ass and a tire, but hey not may ass.

volcomskater77
03-06-2014, 9:07 PM
@jetblack agreed. I see that going down the street and I see death after a pothole/speedbump. im no engineer but your frame geometry is FUCKED. aside from that, I think you did a very good job on the paint/details

KCR
03-06-2014, 10:08 PM
To the average eye from the photo's it looks sketchy, but it is in fact done solid. Swing arm welded in place and then backed with the 1/4" steel plate that both caps it and supports it swing arm even more along the back side. having done structural welding for years I would've ditched the frame if it looked weak.

volcomskater77
03-07-2014, 7:43 AM
Then in that case you would know better than me. I just wouldn't rock it.

KCR
03-09-2014, 11:24 PM
Speedo delete started today.
http://i16.photobucket.com/albums/b27/Blue86rx7/Bobber/1948076_10202123097451687_2027645661_n.jpg
http://i16.photobucket.com/albums/b27/Blue86rx7/Bobber/1521420_10202123097651692_190337912_n.jpg
http://i16.photobucket.com/albums/b27/Blue86rx7/Bobber/1958468_10202123097851697_584516271_n.jpg
http://i16.photobucket.com/albums/b27/Blue86rx7/Bobber/1902781_10202123098051702_401678513_n.jpg

a plate will soon cover the opening. Pinch weld removed and re-welded.

KCR
08-18-2014, 4:42 PM
http://i16.photobucket.com/albums/b27/Blue86rx7/1606502_10203119896611043_937387279121386841_o.jpg (http://s16.photobucket.com/user/Blue86rx7/media/1606502_10203119896611043_937387279121386841_o.jpg .html)
Finally getting back to this project. Took and got the wheel finish. Did a gold metal flake on the spoke nipples..
http://i16.photobucket.com/albums/b27/Blue86rx7/10608335_10203107927751829_2858294803194741912_o.j pg (http://s16.photobucket.com/user/Blue86rx7/media/10608335_10203107927751829_2858294803194741912_o.j pg.html)

OleDirtyDoc
08-19-2014, 12:18 PM
Cool savage dude.

KCR
08-19-2014, 2:06 PM
http://i16.photobucket.com/albums/b27/Blue86rx7/10509608_10203131454419981_4644223707517993877_n.j pg (http://s16.photobucket.com/user/Blue86rx7/media/10509608_10203131454419981_4644223707517993877_n.j pg.html)

dropped the bars I made off at powder coaters yesterday evening... installed this morning along with the controls. lil grinding an fitment to fit everything with the powder coating now on the bars.

bobberShane69
08-24-2014, 11:37 AM
That thing is sweet, I wish I had the time and money to put that kind of work into my bike.

KCR
08-25-2014, 9:35 PM
Got my headlight in. Popped out the blue dot "hi beam indicator" to install a 20 amp 3 way toggle for lo/hi operation. Drilled it out a bit bigger.. was a tight fit. Bent tabs on switch to clear reflector housing. Ran ground wire under to mounting block leaving only a single power wire going into lamp housing. Also fished tail/ tag light wire through frame for a cleaner look. Pre-dill frame before paint. Everything soldered up an good to go.
http://i16.photobucket.com/albums/b27/Blue86rx7/20140825_191821.jpg (http://s16.photobucket.com/user/Blue86rx7/media/20140825_191821.jpg.html)
http://i16.photobucket.com/albums/b27/Blue86rx7/20140825_191829.jpg (http://s16.photobucket.com/user/Blue86rx7/media/20140825_191829.jpg.html)
http://i16.photobucket.com/albums/b27/Blue86rx7/20140825_192150.jpg (http://s16.photobucket.com/user/Blue86rx7/media/20140825_192150.jpg.html)
http://i16.photobucket.com/albums/b27/Blue86rx7/10603259_10203172514766464_5167672471966265142_n.j pg (http://s16.photobucket.com/user/Blue86rx7/media/10603259_10203172514766464_5167672471966265142_n.j pg.html)
http://i16.photobucket.com/albums/b27/Blue86rx7/20140825_223225.jpg (http://s16.photobucket.com/user/Blue86rx7/media/20140825_223225.jpg.html)

KCR
08-25-2014, 9:37 PM
That thing is sweet, I wish I had the time and money to put that kind of work into my bike. Thanks man. Its been few years and beer funds put into it.