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Author Topic: Finally Winter rebuild can start!  (Read 4185 times)

horse

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Finally Winter rebuild can start!
« on: February 15, 2016, 01:29:07 PM »

Finally I now have all the pieces together to start winter rebuild:

New Bodywork:


New Headers:




And finally collect ex-Hawk BSB engine yesterday:





So now starts all the fun, aim to be back on road in April after flashing ECU and setting up engine.
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davemfox

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Re: Finally Winter rebuild can start!
« Reply #1 on: February 15, 2016, 01:50:31 PM »

Nice one mate :headbang: have a dobbin

Dave
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horse

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Re: Finally Winter rebuild can start!
« Reply #2 on: February 15, 2016, 01:59:16 PM »

Cheers Dave, think we need to try again and arrange a forum meet up this summer!
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Matt83

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Re: Finally Winter rebuild can start!
« Reply #3 on: February 15, 2016, 02:08:12 PM »

Lots of fun ahead rebuilding that! What paint are you going for?
Fancy doing a joint dyno session? Will be similar maps, mine has the same airbox this year. Just need to find a stock ecu for the remap.
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horse

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Re: Finally Winter rebuild can start!
« Reply #4 on: February 15, 2016, 05:28:03 PM »

Think I'm just going to run it naked at the start and see if it grows on me.............
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michael4012

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Re: Finally Winter rebuild can start!
« Reply #5 on: February 15, 2016, 09:07:29 PM »

Nice too its under way mate :icon_thumright: Iv got the same stacks as you got  :-P
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philly46

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Re: Finally Winter rebuild can start!
« Reply #6 on: February 16, 2016, 12:04:22 PM »

Have you got any data on the airboxes?

I'm running OEM but recently acquired the box which takes the throttle bodies.
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HammyUK

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Re: Finally Winter rebuild can start!
« Reply #7 on: February 16, 2016, 02:45:22 PM »

The idea was to get a greater volume of air into the airbox at high speed to increase peak power.
Whilst at 120+mph they do this - the overall pressure (which is what they wanted to increase) didn't change - well not until the filled the frame rails with expanding foam. Kawasaki make the frame open for a couple of reasons - the first is obviously weight, second is ease of manufacture, thirdly the route to the airbox is through the frame - it doesn't matter what you do with the airbox - if you don't make the route from the front to the stacks a sealed system then you will never increase the pressure beyond a certain point. Vivaldi ended up filling the frame rails. MSS, Hawk and PSG-1 didn't and made as much bhp but more importantly more torque. What they did do was change the internal structure of the airbox slightly rather than removing the lid and using the tank as the lid (which they found never sealed properly due to the anti-vibration rubbers, removing them made the alloy tanks crack).
Hawk and PSG-1 made a two piece carbon airbox with a quick release top. This kept the pressure the same and increased airspeed into the throttle bodies. It also used the standard air filter shape so race versions were easily available rather than having to make one off's.
They look good but give Rob a call at RJS and ask him just how much work it REALLY takes to get one working anywhere near properly. Kit ECU, sensors, brackets, etc that unless you happen to have access to a complete Vivaldi bike is basically guesswork nowadays. There aren't any diagrams, parts fische, etc.
They made it up as they went along testing, racing then binned them afterwards and went to Suzuki!!
I did have 3 full bikes in my possession at one point and about £500k of parts and even then all 3 bikes were different despite coming straight from Vivaldi!!
They're a talking point to have - just don't expect BSB spec power on the road - or decent throttle response either for that matter.
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Matt83

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Re: Finally Winter rebuild can start!
« Reply #8 on: February 16, 2016, 02:55:03 PM »

Very interesting read! Added some bhp, cheers! Mine uses the tank to seal. I did look at the way the air has to flow through the intake, it looks like there's improvements to be made by smoothing off the strengthening webs at the front of the intake and then forcing all air into the airbox instead of down the frame
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philly46

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Re: Finally Winter rebuild can start!
« Reply #9 on: February 16, 2016, 04:40:49 PM »

Cheers for that, the reason I asked for any data is that I can include it in my studies (motorcycle engineering). So rather than bolting items on and rolling with "well Jim said it gives 5bhp" we have to test and verify everything or it might as well go in the bin.
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HammyUK

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Re: Finally Winter rebuild can start!
« Reply #10 on: February 16, 2016, 05:17:49 PM »

Very interesting read! Added some bhp, cheers! Mine uses the tank to seal. I did look at the way the air has to flow through the intake, it looks like there's improvements to be made by smoothing off the strengthening webs at the front of the intake and then forcing all air into the airbox instead of down the frame

They all used an alloy front tube/clock mount - the OE snaps too easily.
You can replicas from Oz online or AP Metalcraft will make you one - they made the originals and the three types of tanks they used!

I still have the PSG-1 large capacity tank and carbon airbox here that they trialled at the end and then used on the 06/07 bikes.
« Last Edit: February 16, 2016, 05:21:11 PM by HammyUK »
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philly46

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Re: Finally Winter rebuild can start!
« Reply #11 on: February 16, 2016, 06:42:14 PM »

Thanks for those details, just from a quick search I've found some useful content.

Can you send me some pictures of those parts you mentioned please?
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HammyUK

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Re: Finally Winter rebuild can start!
« Reply #12 on: February 16, 2016, 07:40:36 PM »

Which parts?
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Matt83

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Re: Finally Winter rebuild can start!
« Reply #13 on: February 16, 2016, 09:54:10 PM »

Don't suppose you've got one of those fuel tanks for sale?
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philly46

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Re: Finally Winter rebuild can start!
« Reply #14 on: February 16, 2016, 11:33:47 PM »

Which parts?
The fuel tank and airbox please.
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