Sprocket cover issues

It turns out I will need to cut a hole in the sprocket cover for the propshaft to fit through.  However, on the GSXR 1000 K1, the clutch push rod is very close to the sprocket adapter.  So close in fact that the mechanism that pushes the push rod will clash.  To resolve this I was told by Danny to get a newer sprocket cover with a different type of clutch system.  I bought a K9 cover on eBay but found out that it didn’t fit.

I cut this to pieces with a view to welding it to the original but later found out that it is made from a magnesium-aluminum alloy that can’t be welded.

I have asked about on the Locost forum and someone has shown me their solution…… a Hewland slave cylinder fixed with some custom brackets.

More research needed.

Riveting the floor

First I deburred all the holes in both chassis and floor and wiped down all the swarf, including blowing out the chassis square sections with air to remove as much as possible.

I applied a small bead of black sealant along all chassis rails that will contact the floor.  Then with the help of an assistant I placed the floor on taking care not to slide it about on the sealant and located 4 rivets, one in each corner.  Then I inserted all the rivets in the holes and took the traditional photo.

Using my dads “lazy tong” riveter I finished riveting in about an hour – this was quite tiring on the arms!

Drilling the floor

Spent the evening double checking the marking out and then drilling the holes for the floor.  I centre punched all the holes to keep the drill on line and then drilled through with a 3mm drill bit.  This was followed with a 5mm bit.

I have drilled a total of 152 holes in the floor – still need to deburr all holes in floor and chassis.  Even with 4 clamps on it the floor moved about slightly.  It is best to sit a few rivets in the holes to keep everything in line when drilling.

Marking up the floor

Today was spent getting a bit more organised.  I bought some pipe insulation from Wickes and bubble wrap from a self-storage warehouse.  I want to protect the powder coat as much as possible.

Marked up the floor ready for drilling.  I used masking tape to mark center lines of the chassis frames and measured out rivets at 50mm centers.

Picking up the kit

Headed up the M1 with my dad in his Discovery with trailer and got to MK at about 11am.   Had half an hour looking at some of the cars there and taking photos for reference before Danny arrived and we loaded up the trailer.

There was just enough room with the trailer and the Disco, good job it was empty!

Arrived home with some slight damage to the side bars….. Nothing that cant be touched up later.  Got the chassis in the garage on a couple of aluminum trestles  until I get time to make a trolley for it to sit on.