Guzzi 1100 Custom build

[buzzer]

Hi Guys, thought I would start a thread on my 1100 custom build... I have not started it in earnest just yet, I am currently finishing off a Ducati build, soon as that's finished I will get it on the bike hoist and make a start.

For now, I have just made a couple of parts, some Bell mouths, and a couple of silencers... as I progress I will keep this thread updated. I am not sure on the finished look as yet, but its probably going to be a cafe racer style, but with higher bars as I cant do clip-ons these days!

here is how it arrived...

here is how it looks now, I have acquired a V7 tank for it

here are the bell mouths I have made, using the metal spinning method

here are the silencers in the fabrication stage

here they are finished

 

[buzzer]

here is a short video of how the bell mouths were made

 

[JasonC]

Wow, pretty rooten tooten nice work!

However, it pains me to see an engine running with no air filter, but I'm sure that's just a personal quirk of mine.

So, why Keihins over Dellortos?

Jason

 

[scottmastrocinque]

Wow!

Nice machine work.

Are you a machinist?

 

[buzzer]

Wow, pretty rooten tooten nice work!

However, it pains me to see an engine running with no air filter, but I'm sure that's just a personal quirk of mine.

So, why Keihins over Dellortos?

Jason

Thanks! I have used Keihin carbs for a while now, and I really like them! I have done three EFI to carb conversions on Ducati's now... the first one I did I used Mikuni carbs, and while it went OK, it was only when I did the next one with the FCR's that I realised just how great they are! The Keihins are also cheap, and new, and come with a good selection of jets... they are a great carb!

I agree on the filters... I do have a fall back in that I have made some shorter bell mouths in the past that take a foam filter... I may decided to go with this... But at the end of the day its not like I will be doing 1000's of miles... we will see!

 

[buzzer]

Wow!

Nice machine work.

Are you a machinist?

I wouldn't say I was a machinist... its just a hobby. I have a Boxford lathe and a 1929 milling machine!

 

[Nordicnorm]

....it's just a hobby! My personal jealousy rears it's ugly head

 

[buzzer]

I have made a few of these silencers for various builds over the years, I like them because they are nicely proportioned... Light, re-packable, and I can fit a baffle at MOT time... plus they are cheap on Ebay at around £20 each!

 

[Louisv97]

Thanks! I have used Keihin carbs for a while now, and I really like them! I have done three EFI to carb conversions on Ducati's now... the first one I did I used Mikuni carbs, and while it went OK, it was only when I did the next one with the FCR's that I realised just how great they are! The Keihins are also cheap, and new, and come with a good selection of jets... they are a great carb!

I agree on the filters... I do have a fall back in that I have made some shorter bell mouths in the past that take a foam filter... I may decided to go with this... But at the end of the day its not like I will be doing 1000's of miles... we will see!

That is a beautiful DS. Im guessing it's a 1000 or 1100 that you converted into carb'd? Also have you had any issues with having the crankcase breather filter so close to the outlet?

 

[buzzer]

That is a beautiful DS. Im guessing it's a 1000 or 1100 that you converted into carb'd? Also have you had any issues with having the crankcase breather filter so close to the outlet?

Yes! well spotted... I had misting out of the breather and moved it to the top of a 6" tube which stopped the problem...

Its a 1000 DS, they are great engines! I have done 4 builds now using a 1000 Multistrada as a base. These have plastic tanks and many are affected by the ethanol in the fuel these days. its killing may of them off, and they can be picked up very cheap

 

[Louisv97]

Yes! well spotted... I had misting out of the breather and moved it to the top of a 6" tube which stopped the problem...

Its a 1000 DS, they are great engines! I have done 4 builds now using a 1000 Multistrada as a base. These have plastic tanks and many are affected by the ethanol in the fuel these days. its killing may of them off, and they can be picked up very cheap

I had the same issue with oil spitting out of the breather on my Monster 900. It made things "interesting".

 

[buzzer]

Up on the hoist for the first time… I have temporarily used a build stand that I have used for Ducati’s, but I will have to make a specific one as this one will impede making the exhaust fit on the bike. First job has been to make some inlet manifolds to fit the carbs… I wanted them angled upwards and inwards, and that took some working out to get the compound angle right! it ended up as 68.5 degrees. As the carb diameter is larger than the head inlet, I needed to use a tapered tube… To do this I turned up a tapered mandrel, and after annealing the alloy tube, I pressed it in with the vice, which expanded the tube by the required few mm. I then turned a grove to accept the lip inside the carb mounting blocks.



the next bit was actually quite difficult… I needed to make the hole on the flange a nice fit on the tube, but at an angle. I deliberately cut the 10mm plate quite large so I could get it mounted on the milling machine at the exact angle. I then bored the hole with an indexable boring head. If that milling machine looks old, it is! I did some work on it a few months ago and found a date… 1929!



Next job was to TIG weld the flanges on, drill the holes, and finally cut to shape.



here is a short video of the manifolds being made...

 

[JasonC]

Holy Toledo, that's some SERIOUS hobby work!

Your TIG welding looks fantastic, just like everything else you've shown in these posts.

Can't wait to see more work from you.

Jason

 

[buzzer]

a little side track as I had a new facing cutter for my milling machine and wanted to try it! I took the top yoke off and removed the section where the ignition switch fits… and milled it flat. I then contoured the edge to blend it in. Those power files are a great piece of kit, something i bought thinking I may not use it much, but I use it all the time! Then into the blaster to clean it up, it can wait a while for polishing….

 

[buzzer]

One thing I hated about the bike was the side stand… Just how agricultural is that bracket! I know its a great functional design, but its SO ugly! so out come the angle grinder and it is no more! In the loft (or as my wife calls it the spares department!!) i had a side stand off a 1994 Honda CBR 600… it bolted straight on! Just need to adjust the angle a little when the ride height has been set. a job for much later on...

 

[buzzer]

yesterdays job was to mock up the exhaust... I had ordered some 2" mandrel bends and straight pipe as I wanted that chunky look, and for the pipe to fit straight into the silencer with no reducer. From a performance aspect, the large headers are probably not I deal... but I wont miss a few BHP! I also wanted that angled swept back look (old School!!) The bends are 135, 45 and 30 degrees. It should all polish nicely as its stainless steel. This bike will have more forward mounted foot rests, hence I could kick up the silencers earlier...

I find making exhaust systems quite therapeutic, although sometimes I could do with a third hand. My wife used to help, but since I burned the back of her hand with the hot end of the filler rod, all help has been withdrawn :sad:

 

[JasonC]

Looks like a fun project!

Jason

 

[scottmastrocinque]

Wow! It’s very convenient that you have a nice workshop area to do work like this.

Did you TIG weld your exhausts pipe together?

 

[buzzer]

Wow! It’s very convenient that you have a nice workshop area to do work like this.

Did you TIG weld your exhausts pipe together?

yes, the workshop id nice to have... I have a machine shop next to it as well

I have an AC/DC Tig so I can do steels and aluminium as well...

 

[buzzer]

Next on the list is the new foot controls… I sat on the bike and decided where I wanted the foot pegs to be. This bike wont have rear-sets, I want to to be comfortable to ride! I then measured how long from the peg the brake and gear lever needed to be and set about designing some controls. It would have been easier to have had them water jet cut, but that’s a 3 hour round trip for me, and usually quite a wait, so I decided to mill them out instead. What has made a BIG difference to me is the acquisition of a band saw… Its great for cutting stuff like this out! I was so lucky to acquire it… my mate was throwing it out!

I made a couple of spigots to mount them on the frame which I will weld on. I have used a couple of Oilite bushes on the holes rather than run the alloy directly on the steel. the first spigot I made I realised I had counter bored it a bit too far and it would have been too weak… a case of measure twice cut once! I then bent them in the vice to get the correct crank angle to clear the exhaust.