What a nice pair!

Oooh, I can't wait to see if I can make these fit and work something around them.
Even if they don't want to go on, I am sure I can do some 'persuading'.
The pipe lengths are different, and I want to keep them like that; it's something that I've always wanted to experiment with - exhausts and engine pulses.

Titanium headers courtesy of Swagarama.
Cheers!

Burning the midnight oil.

I must admit it's hard work not having my own garage.

Thanks to Genge of course for letting me use his - it's quite cosy for Gordon to share it with all the furniture!

Once the sun goes down though, it gets a bit dark and chilly in there. At this stage it feels sometimes like I take one step forward and two steps back, I'm in uncharted territory (for me) fabricating various components but it's great fun (I think)......

Special Friends are so important...

Gordon would be nowhere without his 'special friends'.

In fact he might still be in the salvage yard.

Gordon would just like to say an extra thank you to all his friends who are supporting him, and he keeps a board in his garage as an reminder of who they are.

However, there are still things that he needs to get him to the track - please visit his wish list and see if you can help. Gordon's Wish List

Air Box 'n' oil tank

Now the motor is in the chassis I can get on with fabricating the air box, firstly out of cardboard to create a template then in alloy. Now I've actualy started I have realised I can double up the space as an oil tank as well.


I've also hollowed out the standard fuel tank to resite the fuel tank and increase the size of the airbox too. Not an easy job and it caused me a few head aches along the way.

A supermono competitor writes...

Hello Mike, Thought you might be interested to see a picture of me, aged 4, enjoying my 1st ever sit on a proper race bike, yours at BSB, Snetterton.

Now, at the ripe old age of 16, it looks like I'm going to have to compete against rider of said bike, on a Supermono called Gordon!
Love what you're doing with your project, I'm still pinching myself about the fact that I'm competing against the legend that is Spike Edwards!!
I'm really looking forward to meeting you when the season kicks off (If my bike's finished by then and we've still got money left for tyres!!)
Cheers m8,
Az
http://www.azmanracing.com/

Gordon is really firing everyone's imagination, and becoming a celebrity in his own right - now that I've read this email - I'm begining to feel very, very old!

Gordon's dreaming!

Just an update on Gordons engine spec: the standard output is approximately 45-48bhp, but after uncles Martin and Roy at Slipstream did their magic it should be between 82-84bhp.

I think I will be able to feel the difference for sure!

It now has a Raptor crank so will spin up quicker and been bored and stroked to take the capacity from 659 to 770. All the starter gears and starter motor are gone, the water pump has been replaced by a electric one too. The clutch basket has been replaced with a 6 spring type to take the extra power. Lighter larger valves, lumpy cam and a pair of 39mm Keihin carbs all help 'pep up' the motor. A larger radiator, re-programmable race ignition and two into two light weight race pipes should stop Gordon being a 'moron'.

Chop to change.

I'm going to chop out the bottom out of the tank so that it will still work as a cover for the newly fabricated fuel tank and airbox.

I am modelling one of Gordon's fancy new fleece tops. Soon to be available in his website shop.

Motors in!

After a bit of a struggle on my own the motor is finally in the chassis. My mate Jody turned up with a bike stand I could use until my own one arrives.

Now I can press on with making the air box, oil and fuel tanks.

Using cardboard as a template I can shape and form the basic outline of the components, then recreate them in alloy....Peter are you busy?

Gordons looking hot!

Picked Gordon up from Slipstream today and he does look 'hot to trot'. Martin and Roy have done a great job turning him around so quickly at such a busy time for them, but the trip down to collect him took me over 15 hours due to the weather!

Here Martin looks like the proud father.

Oh my goodness!

Oh my goodness!
Originally uploaded by no1bloke.

Just picked up some new threads for Gordon from his new mate Ian E. in Leeds - This is apparently a 'danny pedrosa' seat unit. I just don't know how I am going to loose the 32kg necessary to fit on it!

The fairing looks fantastic and the quality of the glass is top shelf, I do hope it fits......

Check out www.iane.co.uk

Subframe doubles up!

The new sub frame is not only to hold the seat unit in place but houses the battery box and will be the area where the CDI unit, fuse box and any other electrical bits and bobs will live.

I've drawn up a wiring diagram with some help from Dave Bennett, all I need now to to figure out where the various compoments are going and get on with it!

Frost.co.uk supplied the wire, conectors, tape and all the heatshrink covering for the harness, cheers boys!

Something old and something new.

Something old and something new.
Originally uploaded by no1bloke.

Utilising the old rear master cylinder and brake lever but with beautifully sculpted 'Peter Day' foot rests and plate. Still some refining work to be done, but its coming together.

Surprise parcel

Surprise parcel
Originally uploaded by no1bloke.

Gordon is just so lucky. Got a fantastic suprise package from Swagarama.biz! Cheers. So sexy!! Off to the garage to mess about with him.

Out of interest the new bars are less than half the weight of the original - Standard 850g new bars 400g, dosn't sound much but it all adds up.

Standard stuff is fine...

Once I got rid of all the stuff at the front, I got to wondering about a fancy tacho.

And then I remembered that this project has absolutely NO budget, and thought, well, what's wrong with the original?

Nothing, it's just all the other stuff that I needed to get rid of - so I set to work, and look, I now have a perfectly fine tacho and temperature gauge.

Just need to work out how to mount them now...

Another mincepie please...

Now that I have got rid of lots of weight from the bike, I can eat more pies. To be honest, to be as competitive as possible, even I will have to drop 5kg! Here is a list of a few things I have removed so far:

Headlamp assembly 1.9kg
Oil tank 2.1kg
Airbox 1.7kg
Wiring harness .95kg
Switches .6kg
Side stand 1kg
Rear mud guard 1.5kg
Starter motor and gears 2.2kg
Fairing mounting / instruments 2.8kg

Subframe 5.5kg

Total removed = 20.25kg

Lean, mean, thrilling machine

Now that the modifications to the swinging arm have been made, the shock fits in the chassis perfectly.

New subframe, fairing mounting bracket and new rear sets, Gordon is really starting to look the part - no longer an old knacker, but a lighter, meaner race machine.

I have brought some weighing scales, and started to weigh the various redundant components. Just the subframe alone is a 4.5kg saving, starter motor 3.5kg, headlamp 2.5kg... that's over 10kg already! I'll do a complete list later.

Gordon's new bits!

Here are some pictures of the work Peter Day performed last week.


Steve Jordan had given Gordon a new GSXR1000 shocker but it was going to interfere with the swinging arm as it moved through it's travel, thus it was either buy a new shock or modify the swinging arm.











Peter Day machined away the cast section of the arm then fabricated a section to cover the hole, then welded the plate into place, perfect!

What a bobby dazzler...

Home now, and over the next few days I will show you just how fabulous Gordon looks with his new bits and pieces.

Peter Day generously took two days out of his busy schedule to fabricate some fabulous components; this pile of swarf came from just the swinging arm!

Gordon gets gripped.

Down in Cambridge working with Peter Day. Here Peter is in action fettling Gordon's bits. We did a full day yesterday 9.30am - 9.30pm, I just don't know where the time went.

Mind you they do say time flies when you're having fun!

Lots more to do today then home.

New Year - New Thumb...

I am pleased to report that Mr. Toby Branfoot at Leeds has done an excellent job repairing my thumb that I damaged at Assen in 2005; and I am almost up and running again. It is now fused with enough bend to grasp a handlebar - the most important thing is that the joint is now 'pain free' - and I just can't wait to get on Gordon and try it out. Off to Peter's tomorrow to start fabricating. Can't wait!

Naked

As you can see Gordon's all 'Naked' - but at least he's on his wheels at last!

Now comes the time consuming process of building a race bike; there are several major hurdles to overcome - but with lots of luck, and some serious work, I'll be on him for some Spanish testing in February!

Gordon and I are borrowing Simon's van (again) and nipping off to Uncle Peter Day's in Cambridge next week; where hopefully he will let me help (or hinder) him to make so new body bits. Sub frame, footrests, oil tank and try and modify the swinging arm to allow the fitment of Gordon's new rear shock absorber.

Santa Claus

Well, you wouldn't believe it, but Santa has called today with some presents for Gordon.
Steve and Sarah Jordan from Jordan M/Cs have sent what looks like a set of forks to me!
Oh, and uncle Phil from 'Dunlop' thought some new shiny boots would look just the job.
Then the Auto Restorers 'Frost' gave me a parcel for Gordon, full of 'goodies' to start his season off just right.
"It must be nice to have special friends like these" I told Gordon!

In the frame...

Just before I started Gordon's re-build I compared his frame to another 'special' frame I have.

This one is really 'top shelf' stuff; it's another project that I've had on the back burner for a while.

It would suit a KTM or BMW motor having the chain on the right side.

The main differences are the weight and the steering head angle. The head stock and swinging arm pivot points are machined from billet alloy not cast, not to mention that Gordon is about 3 kg heavier and £20k cheaper!

That'll be the Day - Peter Day to be precise.

The swinging arm pivot spacer was very badly corroded to the point that I had to replace it, however, the budget said "NO".
But after a phone call to Peter Day he offered to machine Gordon a new one.
What a star, he turned it round in a matter of days.
Now I can start the re-build and with lots of luck get him back on his wheels before Christmas.....

Shaving and saving!

Before I sprayed the frame and swinging arm in lacquer I sawed off as many unwanted lugs, clips and assorted bits as possible. Mainly to tidy up the frame making cleaning easier, looking at the mess on the floor of the garage I collected as many of the bits as possible and adding a bit for filing/swarf it added up to approximately 200g in weight! Yes I know I probably lost more weight in sweat doing the job but all these little bits of weight add up.
I'm looking forward to weighing Gordon and see what he will end up at.

Wheely good start with an excellent paint finish.

I'm really pleased on how the wheels have turned out - they're great; and the frame and swing arm are lacquered now - top job this weekend!

The products I bought from www.frost.co.uk have done the job brilliantly.

However, I am still looking for a motor to borrow so I can start the rebuild whilst Gordon is having Christmas at his Uncle Martins.

Gordon's going to get a 'make over'

I've been looking for a paint product to use on Gordon's frame and swinging arm, I wanted to try and keep the natural finish that got after I had them shot blasted at Guysons the other week.
A clear laquer that would protect them but not add too much weight, plus I wanted the wheels satin black (easy to keep clean...Hee Hee).
I found a company called Frost, they specalise in vehicle restoration and associated products.
After a phone call and some sound advice I have found just the right paint for the job!

I want to get the wheels, frame and swinging arm done this weekend ready for the re-build next week (with luck).
Got the wheels warming up on the front room radiator as I type - optimum temperature and all that - the Missus ain't too happy though...

Solid!

I knew Gordon had done 23,000 miles and expected a certain amount of seized bolts, worn out bearings etc.

I naively thought "they won't be that much to replace" - Wrong! The bearing at the bottom of the shock was £36 plus vat, swinging arm spacer £54 plus vat..... and so on.
It's begining to look like I'll be busy on a lathe turning down new spacers etc.
Next job is painting the wheels and going to get the engine and forks back from Gordon's "special friends" where they have been tuned and fettled.

Just got a letter from Slipstream..

Hi Mike,
Just wanted to let you know Gordon is doing well and is coping without his other bodyparts, he was a little upset when you left, as all kids do when they first go to school. Well since you've been away Gordon and Martin have bonded and a great friendship has blossomed, I think we will all miss him when he's gone. He's always messing around and he makes us laugh all the time, he's really happy now he's found a new family and we're all taking good care of him. The operation will take place soon and he will of course be tranquilised before we give him a heart transplant. Here's Martin and Gordon yesterday, Martin won't put him down for 5 minutes, trying to get any work done around here is a nightmare! Well better go I can hear everyone freaking, must mean Gordon's done another number two over the work-bench, muggings here has to go and clean it up….

Mark - Slipstream Tuning

More wining and designing...

Getting desperate now to get weight off Gordon without spending any more money.

I've bought some files and drill bits so I'm going to see just what I can do - within reason and budget.

The wine helps me think less clearly - it's got to help!

Had a quick saw and file with the frame over the weekend and then weighed what I managed to take off - removing just some lugs and lumps I managed to save 600g! The rear caliper mounting plate is quite heavy so I'll be interested to see how much I can save here. The rear disc is also heavy so that's going to receive the 'big drill' method too!

The motor should be ready mid December with luck then I can start the build for real. Long term friend Peter Day has offered to spend some time with me making various components (sub frame, battery box, oil tank etc) at his workshop as soon as Gordon's back up and on his wheels.

More bits and pieces...

Most of the components have now been bead blasted, courtesy of Tim at Guyson; once Marc had explained stuff, they let me have the use of their demonstration room and all it's facilities.

So as soon as I get the rear suspension linkage seals and bearings I can start the rebuild.

The next thing I need to work out is the wiring loom, I just CAN'T wait.....Not!

Sneaked in from the garage...

After a couple of hours this afternoon at the Guyson factory in Skipton, Gordon is now even allowed in the house.
The frame and swinging arm were a bit scabby to say the least, and there was no way of tarting him up without him looking scruffy - so it was 'down to the metal' to start with.

I was hoping that if the finish was smooth enough I would be able leave him unpainted; however, the blasting did it's job, taking all the paint and debris away but has left the surface a little rough - thinking about it - I'm going to paint him again.

Not sure what colour yet, any ideas? Anyone got any tartan paint?

There, there Gordon...

Come on Gordon, you know that it's for the best.

Martin and Roy at Slipstream are very nice, and they will really look after you.

I'll stay at home and get on with your other body bits...

Click on the photo to see how scared Gordon really is.

More sweat and tears

Now the engine is out of the chassis I was able to pull out the forks and shock ready to be refurbished / serviced / replaced (whichever is applicable) and drop the engine at Slipstream.
I also carried out some careful measurements of the chassis, comparing them to a TZ250 chassis I measured earlier in the year. I was quite surprised to find dimensionally how similar they are the main difference being the length of the swinging arm, but most of the other measurements are very close.
What has surprised me is the contrast in build, for example: the front engine mounting bracket and spacers weigh almost 2kg! yet the front wheel spindle is hollow and very light.
Now without suspension and engine Gordon is looking very sad laid on his side, but it will not be long before he is completely stripped ready for rebuilding.

Engine out.

After a weekend of struggling at last I have managed to get Gordon's engine out of the chassis.
Easy...NOT, I'm still suffering with my left thumb injury so lifting and fiddling is quite hard work. I have to admit I had to resort to a bit of 'butchery' here and there with bolts shearing and rounding off, culminating in me sawing through the header pipes to remove them to get to the front engine mounting bolts, nasty!
On the up side; weight is falling of him. I'm going to borrow some fishing scales to accurately weigh all the components that come off, I will list them and their weight and for all us 'sados' see what the total comes to.
More to come......

Product support being sought.

I've enjoyed riding hard to secure my place in teams that have helped me win championships over the years - where I just had to turn up and race - but I am also enjoying this project with Gordon, taking me back some 20 years, where absolutely everything is under my control.

Just starting to strip him down to drop the motor out and start on the race prep, it's a bit scary to realise I have no race infrastructure at all!

I've emailed a few companies tonight to see if they can help me with some basic work shop supplies - I'll keep you posted if I get a response.

If anyone has any ideas about who might be able to help, please contact me.

Weight loss begins...

Well Gordon tipped the scales at 166.5kg with no fuel in the tank; boy have I got a weight loss programme for him!

Started pulling all the 'not required' bits off and the starter motor alone is 3kg with its gears etc.

With 23,000 miles under his belt and 10 years of wear and tear most things are 'reluctant' to come off easily. The exhaust stud snapped off with several more components rounding off as I undid them.

What have I let myself in for?

Let the work commence!

Well I have finally cleared some space in the garage to start work on Gordon. First thing is to weigh him to see how much work I have to do!
At the moment I have only one set of scales so an accurate weight is hard to work out, but at 85kg (front) & 82.5kg (rear) it doesn't look too good.
However, the weight distribution is almost 50/50 is standard form so I will have to work on moving some weight over the front end.
First, get him down to his bare bones and clean what components I'm going to keep, then next week I'm off down to Martin at Slipstream to drop the engine off so they can work their magic!

European project

On holiday in Texas and wandering round an off road dealer spotted this XR650 Honda, the engine unit looks small and compact ... Hmmm could you squeeze it in a Minimono?
I fancy having a go and at these prices its hard to say no! Brand new complete machines £2600.
One of the guys in the shop races one and reckons 70 BHP is no problem, and they do 1000 mile races off road too.
I wonder how much weight I can get through hand lugage?

Not a bad run about.

While out looking for xr650 motors I spotted this in the traffic. Apparently Mr. Dell himself was driving it. Mind you I am in Texas...