Hot Rod Norton 880 long-term project

[grandpaul]

I found a really nice monoshock that fits the space perfectly, and worked out the geometry for the mounting-

It's JUST going to clear the inside of the oil tank, too. Perfect match!

Baby steps...

 

[CarlS]

Cool! Good find, GP.

 

[grandpaul]

Perfect fit on the mounting plates, just need study the optimal end length for maximum adjustability in the intermediate link, then weld them up.

Chain adjustment axle blocks are ALMOST done. I didn't notice he drilled the axle holes too small!

 

[CarlS]

Great job!

 

[DaveM]

Very nice Paul now I will be waiting for the ride report on these :y115:

 

[stevethelondoner]

I was wondering where this project went....nice one

Ride Safe

 

[grandpaul]

Well, all my play money is gone, and now it's getting to where I'm going to need to start selling the occasional bike just to stay afloat. So, this one will progress slowly, but methodically.

I have a good stock 750 crank, but there will be no billet flywheel. I can start putting the engine together as soon as I get the cam (might not be easy due to cost).

I can pretty much assemble the rolling chassis now, but only with the cast Kawasaki front wheel, I can't afford to lace up a pair of custom Excel rims right now.

Going forward and swapping out front wheel is easy, going back and swapping out the crank is VERY HARD!!! tough decision time.

 

[CarlS]

I certainly can relate to to play money being gone. I think I would start with the crank and flywheel.

 

[grandpaul]

Actually, there are lots of little things I can do over the winter; here's a short list that'll keep me bus for a whie:

-clean & prep all the engine parts I already have
-touchup paint the frame & swingarm where I've welded
-re-paint the cylinders
-re-lace the OEM rear hub onto a clean 18" aluminum rim that I have
-complete the mods & fit up the yokes to get proper range of motion
-modify & fit up the standard bar risers
-mount all the foot & hand controls
-fabricate some custom instrument mounts (maybe integrate them with the handlebar mounts?)
-fabricate a battery mounting setup that hides well
-strip down a good wiring harness, modify it for my use, then re-wrap it to look nice
-carefully dress up (Dremel cut) the OEM right crankcase half to match the custom built left half
-carefully recess the backside of the OEM oil tank to clear the monoshock (only need 1/4" or so)
-fabricate a custom headlight mount setup (has to mount to the large diameter USD forks)
-pull the ARD mini-magneto from the Combat & replace with a Sparx setup < that one will cost a few $$

I can do most of the above without spending much money at all, maybe just a bit of materials that i don't already have to work with on the fabrication stuff.

PLENTY to stay busy till the funds get flowing again.

 

[CarlS]

That is enough to keep you occupied and out of trouble - and with little cost other than time.

 

[grandpaul]

Sorry I left this project "in the dark" for so long; TONS of updates:

The monoshock swingarm was finished back in December (15th). Same center of axle to center of shock top mount spacing as standard, with the axle & adjustable link at mid position.

The powdercoating held up quite well to the heat from welding (lowest amperage setting to maintain good penetration and strong bead). Some touchup paint will hide the scars and there you have it.

Here's the rear brake anchor point, not as clean but I'll dress it up.

Now to design a new axle, stub axle and spacers, then have the machinist do 'em up.

 

[grandpaul]

From Jan. 20th-

Had to shake off the cobwebs, it's been a while...

Just got in the Kehin FCR flat slide carbs from Kenny, all set up and pre-jetted, should be plug-and-play-

 

[grandpaul]

From Jan 20th-

Also received the Spykr electric starter setup with VR880 primary drive gearing-

...and the Smith bros. pushrods. Ultralight &amp; extra strong-

 

[grandpaul]

From Feb. 24th-

Well, it's getting longer and longer between updates (lack of play money will do that).

Good news X 2!

Item 1: Since I helped Kenny sell off some of his remaining VR880, Norton & Triumph stuff, and since I've spend a significant amount on everything else I've already bought from him, he cut me a pretty great deal on the Blue bodywork. So, it's paid for and should arrive in a few days. That's the last major expense on the project, everything else is nickle and dime, a hundred here, a couple hundred there.

Item 2: Found a very good deal on a BRAND NEW Megacycle 560-00 cam, significantly below list price (thanx, RoadScholar!). It's on the way and should be on the shelf in a couple of days. I'll need to have the cam followers radiused to co-exist with the lobes on the "warm" cam, but that's not a big deal.

Next step will be to tear down the spare 850 engine and yank all the needed parts out, then send the crank, rods & cam followers to the machinist.

Pix soon...

 

[grandpaul]

From March 4th-

Just received the cam.

Stock cam (upper), Megacycle 560 (lower). You can't see the differences in cam lobe profile with a casual glance, but you can see heartier oiling grooves-

Looks like about .025" difference in overall lobe height, I need to download the actual specs just for grins-

 

[grandpaul]

Boy, did I screw up.

I only sent in the bottom yoke (for polishing) which has been modified and adapted to use the standard Norton head bearings. Now, I need to
send the top one in to get it polished to match; it's in perfect original shape, but just will not do, now that this one looks so nice-

My polishers do absolute mirror-finish work. They are not cheap, but the finish cannot be beat; have to send in 2 or 3 bikes' worth of parts all at one time to make it cost effective.

 

[grandpaul]

From March 31st-

As usual, Buchanan's did a fantasic job lacing up the drop-center 19" front rim to the Dreer VR880 dual disc front hub-

I had a like-new 100/90 Metzler, so I popped it on there. Pair of Brembo full floating discs on the way from Kenny already. So, I should have the rolling chassis ready in a couple of weeks.

I intend to install a hollow mock-up engine in it so I can mount the carbs, pipes, starter & carbon fibre primary to work out any fitment bugs. Then I'll install the bodywork, controls & lighting to show it at the Pediatric Brain Tumor Foundation fundraiser bike show in April...

 

[grandpaul]

From April 2nd-

I'm going to do a mock-up of the bike for prototyping the mounting of all the various components, then go ahead and take it to the PBTF fundraiser bike show next weekend before disassembling it again. For now, the engine is empty inside. Fitted up the forks and clip-on controls-

Slip-fit the front wheel, custom bearings on order, Kenny is sending the Brembo rotors & spacers-

Carbon fibre primary (very rare, 1 of 3)-

 

[grandpaul]

Top end in place-

Kehin FCR flat slide carbs in place (nice and cozy in there)-

AT LAST! Sprint Special Blue bodywork in place (from the original 951 prototype) I'm going to need to fabricate steering stops so the forks don't bump the tank-

 

[grandpaul]

From April 4th-

Just before I took off for a weekend retreat with a couple of friends on the ZRX, I popped on the rear wheel from my Interstate and snapped this shot-

I need to work out the rear wheel spacing, and maybe an alternate disc brake mount for a newer stype caliper (not sure yet). Anyway, I love the serpentine pipes-