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Old 02-08-2016, 04:42 PM   #16
Unbalanced
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Interesting project. I recently finished a 916/1098 hybrid and I'm currently building an ST4 with a 1198 motor.

Look forward to watching your progress.
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Old 02-08-2016, 07:04 PM   #17
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Today's update - sanded, cleaned, and clear coated the tank, pulled the throttle cables to get the 90 degree fittings installed at Motion Pro, and I pulled bearings from a few extra suspension links I have to modify them (the link needs to be machined down by ~6mm on one end so it sits perfectly in the middle when using a 848/1098 swingarm on a xx9 chassis). Going to make a few of them.







Here's a stock link installed, you can see how the adjuster is just slightly off to the right. Will trim 5-6mm off the left side of the pivot which will line things up straight.
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Old 02-08-2016, 07:11 PM   #18
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Originally Posted by Unbalanced View Post
Interesting project. I recently finished a 916/1098 hybrid and I'm currently building an ST4 with a 1198 motor.

Look forward to watching your progress.
Nice! any links to pics?

I'm trying to get this finished ASAP so I can get back to my main build - a 1100 2V motor in a SBK frame. Aiming for 100whp and 300-350 pounds.
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Old 02-09-2016, 09:39 AM   #19
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Originally Posted by viva_brasil View Post
Nice! any links to pics?

I'm trying to get this finished ASAP so I can get back to my main build - a 1100 2V motor in a SBK frame. Aiming for 100whp and 300-350 pounds.
No pics, but it's got about 25 trackdays on it without a single problem. It's a great bike.

The ST4/1198 will be mainly for commuting and weekend blasts to the coast. I'm just getting started on it.

On another note, you might take a look at the 996 suspension rocker, it's a little different than the 999 and 1098 versions. I wrestled with the 1098 swingarm swap, there are some geometry issues associated with the swap, ultimately I just used the 916 arm. My current project will use the 1098 arm though.
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Old 02-09-2016, 10:05 AM   #20
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The 748, 996, 998 look like the same design as the 749, 999:

916


999


The 848, 1098 have the shock closer to the engine case and the adjuster link towards the back of the bike:


I haven't tried fitting the 1098 arm, shock, and adjuster link to a 999 pivot... I just realized the only 999 pivot link I have is a flat link with a modified Ohlins, which definitely won't work with the 1098 OEM length shock. I may pick up an OEM 748/916/998/749/999 link to test.
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Old 02-09-2016, 09:16 PM   #21
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All exhaust parts are in - can't wait to start working on it

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Old 02-10-2016, 08:18 PM   #22
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*Edit - also went by Motion Pro for the throttle cable elbows. Last time I went, the guy that I worked with was super helpful and we pieced together a custom cable for the 2VSBK (single cable into a split that actuates two throttle bodies). Totally different experience this time, this dude (different from person from the previous experience) didn't want to help at all - they'll only do full custom cables or nothing basically. Anyway, I was able to bend the hose / housing myself -which worked really well. I was planning on making my own elbow out of very small steel or aluminum tubing, but wasn't needed in the end.

Had some time today to start fabricating the exhaust stuff. Will try to take these initial parts to get fully welded before continuing to build. I don't have SS wire nor the right gas for SS welding, but can get by for some quick tacks.

Beginning of the vertical cylinder manifold - had to modify this to clear the 848/1098 shock:


And modified the horizontal cylinder manifold - removed the cat and re-routing it for an under-belly muffler:


Mocking up the horizontal cylinder muffler:




And what the mufflers will look like roughly:


My current idea is to have dual side exits with mufflers angled rear-wards slightly. Initially was going to do a tail-mounted muffler for the vertical cylinder, but not much space and may get too hot.

Last edited by viva_brasil; 02-10-2016 at 09:48 PM..
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Old 02-13-2016, 11:36 AM   #23
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Try not to inhale any chrome or galvanized fumes when you are welding on that.
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Old 02-14-2016, 11:46 AM   #24
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Yea I wear a respirator at home with ventilation, and we have a fume extraction system at work. Some years ago I was welding a galvanized rod to a plate and inhaled just a bit by accident, wasn't fun.

I have a local welder doing the full welds on the exhaust since it's a bit trickier... Combining different thickness material, possibly different types of stainless, though pretty sure the OEM stuff is 304. Doing it piece by piece in case the metal contacts a bit here and there, should have the initial batch of welded tubing back by tomorrow.
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Old 02-16-2016, 07:50 PM   #25
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Couple updates - got the initial exhaust parts back, decided to take the bike off the jig for the final stuff. Did lots of thinking about the headlights, finally have an idea that I'm happy with and think will complement the style I'm going for.

Also sanded, buffed, polished, and waxed the tank (after having clear coated the bare metal tank last week). Had issues getting the pump back in because of the shitty OEM seal on that thing. Found an equivalent off-the-shelf seal at Grainger that worked much better and managed to get the pump back in today.

Tank:


Vertical cylinder manifold:


Horizontal cylinder pipe:


Some pics off the jig:


Need a better frame plugging option for the back...


Last edited by viva_brasil; 02-16-2016 at 07:52 PM..
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Old 02-17-2016, 06:07 AM   #26
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Old 02-17-2016, 10:21 AM   #27
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Taking some days off so won't be back to work on her till next week, here's what's left - parts/to-do's:

Parts:
- Clip Ons
- Tank grips
- New front brake lines
- Front lights
- Aluminum and SS stock

To Dos:
- Exhaust
- Rear tail light bracket
- Rear subframe plugs
- Front mount
*Edit / Add:
- Machine the suspension link and press in the new bearing, swap with current link
- Finish fuel lines

Last edited by viva_brasil; 02-17-2016 at 10:23 AM..
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Old 03-02-2016, 10:25 PM   #28
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Quick updates:

- Front End: going with dual PIAA lights, making a mount for the gauges and lights out of carbon fiber. Getting the mold cut out of sheet metal.

- Clip ons, tank grips, and brake lines installed

- Getting the subframe end plugged by welding on some shim stock and will probably powdercoat it afterwards

- Got the suspension link modified and installed - 5mm machined from one end - with new bearing - and 5mm spacer added to other end:
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Old 03-14-2016, 11:57 AM   #29
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Couple updates of the exhaust, doing it piece by piece to get it right...





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Old 03-14-2016, 06:56 PM   #30
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Very pretty things.

What's the assembly that sits above the intake runners?
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