Project Fazer: The build thread

[ChristoT]

Noggy, you been on Exup's polish lager again? 

I have been banned from riding by my folks (as we are all painfully aware), so fettling is a way of keeping me from going insane! That, and the satisfaction of making something unique. And the challenge of doing it on a budget!

I actually have 90% (if not more) or parts required to make the bike standard, so that's not an issue. As for the mods I plan, most are time consuming (like making a new link pipe to the under seat exhaust system), and I plan to do as much of the work I can myself. Unlike some, I can wait for parts to turn up cheap: I bought an entire rear end for £50, for pete's sake!! The pricey one will be the USD shocks, and even then, I have stock forks I can fit for the time being!

I know they're standard, but I was eyeing up stock R1 exhausts on ebay - the triangular ones. I saw several at £40, with free postage. I might end up getting those as they could look funky, until I can afford (or can find) carbon exhaust - like Akrapovic - that is what I really lust after.

Yes, I'd rather be on the road. But beggars can't be choosers, at least this way I'm working on a Fazer, and I'm going to be learning as I go to boot. Money and parts aren't huge concerns (yet). When the engine is sorted, I could rebuild the bike to running standard, and sell for a quick grand if mammalia really do go vertical. But I doubt I'll end up there. 

[noggythenog]

Noggy, you been on Exup's polish lager again? 

I have been banned from riding by my folks (as we are all painfully aware), so fettling is a way of keeping me from going insane! That, and the satisfaction of making something unique. And the challenge of doing it on a budget!

I actually have 90% (if not more) or parts required to make the bike standard, so that's not an issue. As for the mods I plan, most are time consuming (like making a new link pipe to the under seat exhaust system), and I plan to do as much of the work I can myself. Unlike some, I can wait for parts to turn up cheap: I bought an entire rear end for £50, for pete's sake!! The pricey one will be the USD shocks, and even then, I have stock forks I can fit for the time being!

I know they're standard, but I was eyeing up stock R1 exhausts on ebay - the triangular ones. I saw several at £40, with free postage. I might end up getting those as they could look funky, until I can afford (or can find) carbon exhaust - like Akrapovic - that is what I really lust after.

Yes, I'd rather be on the road. But beggars can't be choosers, at least this way I'm working on a Fazer, and I'm going to be learning as I go to boot. Money and parts aren't huge concerns (yet). When the engine is sorted, I could rebuild the bike to running standard, and sell for a quick grand if mammalia really do go vertical. But I doubt I'll end up there. 

Ok fair enough...but i had to say it




It'd be a far easier to understand project apart from the engine though...i'd say it is the weakest link here...i really hope it is an easy fix...fazer engines are such bullet proof little lumps so to see one with likely issues just worries me....but hey that's me....& you are you...so fingers crossed.

[Dead Eye]

I've done my share of large projects (mechanical and otherwise - some have taken 3-4 years to see through) and the only advice I can give is to break it up in to small parts and prioritise. So first is the frame, suspension, brakes and other important parts for a fully working rolling chassis. Next is a running, stock, engine with no issues, then move on to the exhaust.

At this point, you want everything as close to stock and don't worry about the little details (like decals and body work etc). Lay a solid foundation. The reason for stock is that its a known quantity and should anything go wrong you have a lot of help to work out the issues. If you start messing with things, it gets awfully complicated awfully fast when trying to figure out what's wrong.

I'm up for helping with labour, but you seem to be interested in doing that yourself. Best of luck.

[ChristoT]

It'd be a far easier to understand project apart from the engine though...i'd say it is the weakest link here...i really hope it is an easy fix...fazer engines are such bullet proof little lumps so to see one with likely issues just worries me....but hey that's me....& you are you...so fingers crossed.

Valves may need grinding, and replace piston rings: nothing major. The bores are fine, so I'll start with those. According to its last MOT (last year, admittedly), it had only done 68k miles!! Obviously, I'll have to cross check the dash to see what it currently is, but there's a good chance I'm sitting on a sub 100k miles engine. 

I've done my share of large projects (mechanical and otherwise - some have taken 3-4 years to see through) and the only advice I can give is to break it up in to small parts and prioritise. So first is the frame, suspension, brakes and other important parts for a fully working rolling chassis. Next is a running, stock, engine with no issues, then move on to the exhaust.

At this point, you want everything as close to stock and don't worry about the little details (like decals and body work etc). Lay a solid foundation. The reason for stock is that its a known quantity and should anything go wrong you have a lot of help to work out the issues. If you start messing with things, it gets awfully complicated awfully fast when trying to figure out what's wrong.

I'm up for helping with labour, but you seem to be interested in doing that yourself. Best of luck.

My plan is to work on what I can, when I can. So when I can (hopefully this week), I'll start work on checking and rebuilding the engine. Then in a fortnight, when the ZX has gone, I can look at fitting the new swingarm, and see what needs doing there in terms of spcers and offsets. Hopefully, the engine will be a short fix, and the swingarm won't be too horrific, so by then I can work on the exhaust - one of the more complex jobs for me. As I'm basing myself off the R1 rear end, I already have measurements there. That will also involve rear fairing modification to accomodate the final solution. Based on that, I may have to remove the airbox if I have to get creative with the rear shock. Once the rear end is done, I'll move forwards to the plumbing: bigger radiator, maybe? And possibly an independent oil cooler? The tank and pod filters are simple swaps (to install at least - tuning the carbs is another matter), the front end is an independent work package. Other things are minor detailling mods: rad guard and belly pan are simple bolt-ons. Only when everything else is done shall I start prep for the respray (to black, of course!), and worry about decals etc.

And did NO-ONE listen to the song in the beginning of the thread?!? 

[Deefer666]

Hmmm I have some triangular R1 under seat exhaust on the shelf. I bought them cos they looked funky

[ChristoT]

Hmmm I have some triangular R1 under seat exhaust on the shelf. I bought them cos they looked funky

I'll have to have a recce when I'm next over! 

What news from you, Deefer? Are you planning to move, or were you just looking?

[Deefer666]

It is a lovely workshop, over 3 times what I have at the moment. but alas it is too rural. I know my place is out in the country but at least I am 30 seconds off the A14.

[ChristoT]

It is a lovely workshop, over 3 times what I have at the moment. but alas it is too rural. I know my place is out in the country but at least I am 30 seconds off the A14.

Easy to find too! (Even if I did have to ask the car shop 50m from you where you were exactly... navigation fail...  )

[His Dudeness]

Personally I think you're mad enough to pull this off   if you take your time and do one job at a time.  Sure you had a trailer attached to the back of a Fazer   This is a project right, not a daily runner? So it doesn't really matter how long it takes or how much it costs, it'll be done when it's done. Good luck!

[ChristoT]

Personally I think you're mad enough to pull this off   if you take your time and do one job at a time.  Sure you had a trailer attached to the back of a Fazer   This is a project right, not a daily runner? So it doesn't really matter how long it takes or how much it costs, it'll be done when it's done. Good luck!

Thanks, His Dudeness!

Come to think of it, the towbar will still fit!!!

[snapper]

"the towbar will still fit!!!! paa forget that, its water wings and a snow plough next surely ?

[ChristoT]

Good point, an amphibious Fazer would save on ferry costs!

[ChristoT]

News on the engine!

It's good, but the timing had been badly set, leading to severe detonation which had fucked the valves. All I need is a new cylinder head, which I'm buying off Deefer.

Unfortunately, the engine was sitting on the cam chain. And fucked it. So I'm replacing that too. And I'll check the selector forks while I'm at it.

Considering an R1 tail section too, as Deefer will be selling one soon. Debating whether to fit that, or chop up the original tail fairing.

[red98]

Looks like the start of a good thread.....interested in that bros swinging arm conversion, lots of pictures please christo..........
think it might be time to change your username....can I suggest



                                                            THE DEVILS APPRENTICE.....................



good luck with the build matey...

[ChristoT]

Fuck that, I'd rather be Deefer's apprentice!

Dead Eye can be Devil's Apprentice, he's the one who torches 600s!

[Punkstig]

Considering an R1 tail section too, as Deefer will be selling one soon. Debating whether to fit that, or chop up the original tail fairing.

Is it the one with the underseat twin exhausts?
I know you're looking into doing underseat exhausts, Buuut, if it is that tail unit consider a normal exhaust, I saw an Underseat exhaust R1 converted to 'normal' exhaust and the shape of that exposed rear end was gorgeous.
What I'm saying is don't get heart set on converting before weighing up the cosmetics!

[Exupnut]

Fuck that, I'd rather be Deefer's apprentice!

Dead Eye can be Devil's Apprentice, he's the one who torches 600s!

and your the one who crashes em lol

[Hedgetrimmer]

Looks like the start of a good thread.....interested in that bros swinging arm conversion, lots of pictures please christo..........
think it might be time to change your username....can I suggest



                                                            THE DEVILS APPRENTICE.....................



good luck with the build matey...

Yep, 

Will be watching with interest - good luck, you're obviously set on it, so get stuck in 

[bigbluebear]

Fuck that, I'd rather be Deefer's apprentice!

Dead Eye can be Devil's Apprentice, he's the one who torches 600s!

and your the one who crashes em lol

Can be quite a double act called........Crashed and Burned

[mickvp]

Fuck that, I'd rather be Deefer's apprentice!

Dead Eye can be Devil's Apprentice, he's the one who torches 600s!

and your the one who crashes em lol

Can be quite a double act called........Crashed and Burned

HAHA!

[noggythenog]

 
I used to have this game on my PS1....Crash Bandicoot...i declare Christo.............Christo the Crash Bandicoot!
 
even one pic of him and the Christo Crash Bandicoot Fighter.
& Christo Bandicoot through the years!

[ChristoT]

I've been nicknamed Crash Bandicoot before, actually!

[apage16]

I'm looking forward to seeing how this pans out Christot!


I'd say I could help out, as I'm local to you. But I'm about to move to Germany!


But in any case, I totally get your thinking. If you can't ride, the easy second best is messing with your ride. (close third is watching others ride, perhaps on youtube...  )


Good luck, and looking forward to seeing you back on two wheels. Whether they are standard OR a kickass custom!!

[Dead Eye]

Fuck that, I'd rather be Deefer's apprentice!

Dead Eye can be Devil's Apprentice, he's the one who torches 600s!

and your the one who crashes em lol

*ahem* 600 - singular. Thank you very much.

At least Exup stood up for me haha

The build will be interesting... though my concern is your lack of cash tends to lead you to be a tight fisted bastard and you end up buying things because of their price and not their quality.

Make sure you get a decent engine head and a decent cam chain - this is gonna set you back a bit as it is. The valve stuff is time consuming, but you'll get there in the end... I REALLY need to finish mine before I forget where all the parts are

[ChristoT]

Well, I'm getting the cylinder head off Deefer, and I may get round to grinding the other as a spare. And I don't plan to skimp on the engine internals.

After all: who needs food, eh?