Building "The Duck" - Discuss Building "The Duck" on CBRXX, the ultimate on-line community for Honda motorcyclists. Read it in General CBR XX Discussion. (General Discussion of the Honda CBR 1100 XX Super Blackbird that does not fit into the other specific forums.)

HANKSXXX · 12-13-2009, 11:40 AM

Great job...
I'm curious...what is the OD of the air intake of the supercharger?
Or perhaps the ID of the hose going to the air filter?
I'd like to try that setup on my Turbo as it is affected by riding in rain>
Very nice setup.
Hank

TheDuck · 12-14-2009, 2:13 PM

Quote:

Originally Posted by HANKSXXX

Great job...
I'm curious...what is the OD of the air intake of the supercharger?
Or perhaps the ID of the hose going to the air filter?
I'd like to try that setup on my Turbo as it is affected by riding in rain>
Very nice setup.
Hank

OD 63mm so ID should be 60mm. Same dia all through. Thought you might like that shot

TheDuck · 12-18-2009, 11:33 AM

Mk1 front end is no more.
One hour with the spanners has left me with a pile of bits

Now I have space I can start making a few 'nice to have' bits for Mk2
I'm certain that Poundy will be pleased to see that my Mrs rides a blue bike

TheDuck · 12-18-2009, 11:36 AM

Just a note for those that have never changed head bearings it is simple job, only two tools can be viewed as essential.

elvetost · 12-18-2009, 3:57 PM

Hey Duck. Great work as always buddy!
Looking forward to the mk2 version!
Any chance you want to get rid of that "nasty" mk1 then?

Can I have first refusal please please please?

Cheers,
Chris

TheDuck · 12-19-2009, 1:28 AM

Quote:

Originally Posted by elevtost

Any chance you want to get rid of that "nasty" mk1 then?

Can I have first refusal please please please?

ummmm somebody on here has already taken that position!
In reality I will be reusing some parts so I'm not quite certain what will be left!

elvetost · 12-19-2009, 5:22 AM

Quote:

Originally Posted by TheDuck

ummmm somebody on here has already taken that position!
In reality I will be reusing some parts so I'm not quite certain what will be left!

sure man no worries.....

Cheers,
Chris

TheDuck · 12-26-2009, 12:58 PM

Christmas has given me the chance to spend some hours in the workshop getting the MK2 front end sorted.
As always the small non showey things take the time. For Mk 2 I wanted to get the steering lock working correctly ............ not essential and with the Kwak yokes a bit of a pain! Essentially the lock stop pin sits too high (the btm yoke stem is also longer than the BBs) when the ignition barel is bolted to the Kwak top yoke so for it to work you have to fabricate a braket. For Mk2 I also want to lower the handlebar position by 8mm so the bracket has to accommodate this change as well. Mk1 ran pressure switches on the Brembo radial brake and clutch master cylinders and there was no space to drop the bars due to the inner faring panels. I have now sourced a couple of micro switches in Japan that can supply the switching requirements and will fit the Brembo cylinders ..... more of that when I fit them.

So a few pictures of my Christmas work so far
1. Its amazing what hides inside a block of aluminium if you look hard enough!
2. Further modifications to the top yoke and the bracket mounting holes drilled and threaded. The length of the two threaded protruberances dictates the relationship of the steering lock pin to the steering head so has to be quite accurate, final fit is taken up though the mounting plate.
3. The bracket has to fit to the ignition barrel.
4. This has to fit to the top yoke.
5. Final item that has to line up is the HISS system. The bracket has to give enough clearance so that the HISS can interact with the key when it is in the ignition barrel.

As I said a bit of a pain to achieve since there is always 4 dimensions fighting against each other ........... and since the bracket is hidden nobody can see the work that has gone into it!

Tomorrow I hope to finish cleaning up the bracket prior to putting it with the pile of bits to be annodised when I next get my buckets bubbling

Oh yes and I've re-built the forks so they will be ready to drop in when I have done the work on the bottom yoke.

GrahamcUK · 12-26-2009, 1:27 PM

High mate , As I have often said the devil is in the detail , it's looking very good though . I would say it was a lot easi.er to get the steering lock to work on the SP1 front end
So you up for a youtube run in the summer?

TheDuck · 12-26-2009, 1:37 PM

Hi Graham you are right with the SP1 it is certainly much easier (remember me grubbing around checking this aspect out on Project 1200

) but a methodical approach can always solve these 'issues'.
A summer run sounds good

elvetost · 12-26-2009, 4:39 PM

Quote:

Originally Posted by TheDuck

Hi Graham you are right with the SP1 it is certainly much easier (remember me grubbing around checking this aspect out on Project 1200

) but a methodical approach can always solve these 'issues'.
A summer run sounds good

As always buddy, your work is amazing. The devil is indeed in the detail...

Lovely keeping up with your thread. Always something nice and unique to look at!

Quote:

Originally Posted by GrahamcUK

High mate , As I have often said the devil is in the detail , it's looking very good though . I would say it was a lot easi.er to get the steering lock to work on the SP1 front end
So you up for a youtube run in the summer?

What? Am I not invited then?

Merry Christmas chaps, and best wishes for a prosperous 2010!
Cheers,
Chris

TheDuck · 12-27-2009, 1:01 PM

Quote:

Originally Posted by elvetost

What? Am I not invited then?

ummmm I can't see that said anywhere, more later this year when the temperature rises above zero!

................. so to todays task, spinning down some titanium to size ready for a couple of items that have to be made. Anybody who has done this knows what a time consuming (and potentially dangerous

) task this is! All I can say is 'thanks' to the inventor of carbide tips and the builder of the coolant system on my lathe!
Another of those time consuming tasks out of the way, might even start to build something up soon

TheDuck · 12-29-2009, 2:09 PM

One piece completed today, a cover that fits over the headstock.
Pic 1 shows the std BB item in place
Pic 2 shows the new item in place
Pic 3 shows a comparison

The std BB item is thin steel pressed sheet and is fixed to a heastock nut. I have noticed that this plate can become distorted when adjusting headstock bearings and this can become worse when a ZX12R steering stem is used. The effect of this is that the nut bears directly on the oil seal below. Since the ZX12 steering stem has a larger diameter than the BB the internal hole has to be enlarged. As pic 3 shows just removing the nut is not a sensible option since the hole is then much too large!
So I have machined one to fit and to take greater load ............ made it from titanium, material overkill is good

elvetost · 12-29-2009, 3:31 PM

Looks sexy man! Loving the Ti overkill too!

Nice work as always buddy!

Cheers,
Chris

GrahamcUK · 12-29-2009, 4:37 PM

Looking very good mate. I've been doing a fair bit of turning this week myself.
All the fun of turning Ti

TheDuck · 12-30-2009, 2:25 AM

Quote:

Originally Posted by GrahamcUK

All the fun of turning Ti

not a 5 minute job is it, spent half of yesterday turning down a couple of short lengths of 55mm bar to 24mm for the fork to caliper spacers ........... 25mm bar has been going at double the price of 55mm recently so economically it is cheaper to end up with a bin full of very expensive swarf than buying the correct size............... strange old world!
Whilst the machining is a very time consuming task, I was pleasantly surprised that I only got through 1 carbide tip in the day, gallons of coolant might be messy but it certainly makes turning acceptable.

GrahamcUK · 12-30-2009, 3:15 AM

Quote:

Originally Posted by TheDuck

Whilst the machining is a very time consuming task, I was pleasantly surprised that I only got through 1 carbide tip in the day, gallons of coolant might be messy but it certainly makes turning acceptable.

Wish I could say the same , I've been turning 316 stainless and as you know I don't have a coolant pump

two tips in three hours

boring a 38 mm hole, 80 mm long in a 50mm bar.
All great fun though.
Keep up the good work mate.

TheDuck · 01-02-2010, 3:43 AM

More devil in detail work, I needed to anodise the igniton/HISS bracket that is now completed and ready to fit so out with the buckets. Whilst I was at it I anodised the lock stops for Mk2 and a selection of shock spacers for when I get to play about with the suspension geometry again.
As you will see (pic 1)you really don't need much kit to do this. I use these small buckets for small items and larger buckets with larger pieces of roofing lead for larger items such as the rear hanger replacements. Any Interest in..... Apart from the acid and dye I use a 2A supply, keep the dye warm with a tropical fish tank heater and use a fish tank aerator to keep the dye moving for a more consistant colour. I've pictured the items just after drying (1/2 hour hot water boiling is the final stage in the process and the kitchen stove is good for this!) so they need a good polish in order to bring out the colour.
The remaining photos are of the mods that I have made to the Brembo radial master cylinders that I use. With all front end conversions bar to inner fairing panel clearance is limited. MK1 used hydraulic switches with when coupled with double banjos on the brakes used up IMHO too much of the available space. Thanks to the nice people of Japan I have fitted micro switches, thus doing away with the hydraulic switch thereby gaining some more space to lower the bars

elvetost · 01-02-2010, 3:14 PM

Great work as always man!
Loving the diy anodising idea!
How durable is the finished product man? Any usefull links please?
Cheers,
Chris

TheDuck · 01-03-2010, 3:51 AM

Quote:

Originally Posted by chris

How durable is the finished product man?

Very good so far, it all depends on how long you carry out the process for as to how deep a 'finish' is produced. I tested a few 'test pieces' and they needed a hard scratch with a sharp instrument to get through (3 hours in my acid bath) and since the colour is sealed into the finish it is of the same depth.
Have a look here for a more 'professional' appraoach!
Anodizing

elvetost · 01-03-2010, 4:57 AM

Thank for the link man!
Would love to do all the alu bits anodised!!! The frame would need a big bath though!
LOL!
Cheers,
Chris

TheDuck · 01-10-2010, 1:11 PM

About time I put something back together since I've been diverted by the back brake ............... but that is another story for the next installment (probably!)

Time for the front end to go back on as usual in picturebook form!
1. I've had the modified top yoke powdercoated matt black, Mk1 had a polished yoke and on a couple of occasions the sun (yes really in the UK) reflected off it into my eyes. So a different approach for MK2.
2. Fitting the lock stops.
3. When fitting the lock stops is is worth doing a dry fit with the forks in so you can check clearances on radiators, oil coolers (or intercoolers) remembering that the forks compress so check for clearance on full bump. Notice how the mounting brackets on my intercooler have been shaped especially for this purpose.
4. Before fitting the lock stops is is worth checking the bar clearances both tank and fairing infils. I'm re-using MK1 bars since I am happy with them so I only needed to check tank clearance.
5. New ZX12R tapered rollers installed along with seals top and bottom and my nice new Ti cover. 2 lock nuts and tab washer. I have spun one of the nuts down to help give me lower bars and give clearance for the top yoke.
6. Ignition barrel and HISS installed on top yoke using the bracket I fabricated and shown a few posts ago ............. and the steering lock is a perfect fit. I'm really pleased with this since the ignition and HISS are flush with the top of the yoke and look as though it is factory build (pic 8 just about shows this)
7. Get those forks in.
8. Yep they fit well.
9. Need bigger and better brakes? These should do along with the 320mm discs! Need some spacers.
10. First two spacers made from Ti. Two more to go.

Not a bad days work, especially since the Ti machining takes a fair chunk of it.

elvetost · 01-10-2010, 3:27 PM

Looks good man!Not too long for mk2 now init!
Duck you are an exceptional machinist mate!
Keep up the good work buddy, always looking forward for more work coming your way!!!
Cheers,
Chris

Edde · 01-10-2010, 4:35 PM

Nice Job

Are the new forks longer or shorter? Will the ground clearence be the same or lower. Are those MK2 off a ZX-12 ? Now I want to go out and buy a lathe. Like you I'm a little short on space. Thanks sharing your journey.

TheDuck · 01-11-2010, 1:47 AM

Quote:

Originally Posted by Edde

Are those MK2 off a ZX-12 ?

certainly are, the latest 12Rs had radial brakes so I'm happy to use those mouning points.
You can convert earlier forks to a radial set up (just need to change the bottoms) which was what I was planning to do until I picked up this mint pair and sold on the bent set that I already had. These forks have been fully stripped and rebuilt using Ohlins std +10% springs which I found worked with Mk1. There was no wear to the bushings which is always nice to see when you pull forks apart.
The new forks appear to be 3mm shorter than MK1 at full extension so not something to be concerned about. There is more than enough ground clearance (far greater than std if wanted) but again that will be down to final set-up and road testing.

XXDAD · 01-11-2010, 1:54 AM

Nice. A lot of work. Thanks.

TheDuck · 01-17-2010, 2:34 AM

Winter strip downs always show lots of things to 'improve' and one thing that I was determined to improve was the air intake to my supercharger. Free flow of air 'in' is always important and I knew that aspect of my conversion had to be improved. Photo 1 shows that the ducting from the air filter to charger inlet pipework turns through 90 degrees in a very short distance (due to the fairing panel) and that the current ducting has a habit of constricting the airflow. The search was on for a solution and it has been found! The new ducting has the added benefits of being lined (cleaner airflow) and heat resistant up to 315 degrees.
Picture 2 shows that tight 90 degree bends are not a problem
Picture 3 shows that even when bent at over 90 degrees the pipe does not collapse and airflow volume is maintained.
Picture 4 that will do nicely!

dracki · 01-17-2010, 3:35 AM

whats the ducting called,who makes it?

TheDuck · 01-17-2010, 8:03 AM

Quote:

Originally Posted by dracki

whats the ducting called,who makes it?

sourced from
SFS Performance - Silicone Hoses I also use their rad hoses, top quality and a very helpful company.

elvetost · 01-17-2010, 4:35 PM

Quote:

Originally Posted by TheDuck

sourced from
SFS Performance - Silicone Hoses I also use their rad hoses, top quality and a very helpful company.

Nice work duck!

Did they make a cooler kit for you, or you just used bits from their parts bin?
Hey man, I just bought something too, will update in a mo!
Keep up the good work buddy. Evolution is inevitable when it comes to bike builds like yours, and I bet you anything this will be a much better bike when its out in the spring man!

Cheers,
Chris

12-13-2009, 11:40 AM	#61
HANKSXXX Join Date: Dec 10 2006 Location: Augusta NJ Posts: 592	Re: Building "The Duck" Great job... I'm curious...what is the OD of the air intake of the supercharger? Or perhaps the ID of the hose going to the air filter? I'd like to try that setup on my Turbo as it is affected by riding in rain> Very nice setup. Hank

12-18-2009, 3:57 PM	#65
elvetost PAOK FC Join Date: Jul 11 2009 Location: Greece Posts: 1,721	Re: Building "The Duck" Hey Duck. Great work as always buddy! Looking forward to the mk2 version! Any chance you want to get rid of that "nasty" mk1 then? Can I have first refusal please please please? Cheers, Chris

12-26-2009, 1:27 PM	#69
GrahamcUK Vendor Join Date: Jun 03 2008 Location: England Posts: 936	Re: Building "The Duck" High mate , As I have often said the devil is in the detail , it's looking very good though . I would say it was a lot easi.er to get the steering lock to work on the SP1 front end So you up for a youtube run in the summer? __________________ *Visit me at gmaxxraceperformance.com* http://www.gmaxxraceperformance.com/ *"Project 1200" the making of a monster.* http://www.cbrxx.com/general-cbr-xx-...ct-1200-a.html

12-26-2009, 1:37 PM	#70
TheDuck Join Date: Oct 25 2008 Location: UK South West Posts: 1,139	Re: Building "The Duck" Hi Graham you are right with the SP1 it is certainly much easier (remember me grubbing around checking this aspect out on Project 1200 ) but a methodical approach can always solve these 'issues'. A summer run sounds good

12-29-2009, 3:31 PM	#74
elvetost PAOK FC Join Date: Jul 11 2009 Location: Greece Posts: 1,721	Re: Building "The Duck" Looks sexy man! Loving the Ti overkill too! Nice work as always buddy! Cheers, Chris

12-29-2009, 4:37 PM	#75
GrahamcUK Vendor Join Date: Jun 03 2008 Location: England Posts: 936	Re: Building "The Duck" Looking very good mate. I've been doing a fair bit of turning this week myself. All the fun of turning Ti __________________ *Visit me at gmaxxraceperformance.com* http://www.gmaxxraceperformance.com/ *"Project 1200" the making of a monster.* http://www.cbrxx.com/general-cbr-xx-...ct-1200-a.html

01-02-2010, 3:14 PM	#79
elvetost PAOK FC Join Date: Jul 11 2009 Location: Greece Posts: 1,721	Re: Building "The Duck" Great work as always man! Loving the diy anodising idea! How durable is the finished product man? Any usefull links please? Cheers, Chris

01-03-2010, 4:57 AM	#81
elvetost PAOK FC Join Date: Jul 11 2009 Location: Greece Posts: 1,721	Re: Building "The Duck" Thank for the link man! Would love to do all the alu bits anodised!!! The frame would need a big bath though! LOL! Cheers, Chris

01-10-2010, 3:27 PM	#83
elvetost PAOK FC Join Date: Jul 11 2009 Location: Greece Posts: 1,721	Re: Building "The Duck" Looks good man!Not too long for mk2 now init! Duck you are an exceptional machinist mate! Keep up the good work buddy, always looking forward for more work coming your way!!! Cheers, Chris

01-10-2010, 4:35 PM	#84
Edde Join Date: Dec 07 2006 Location: Payson, Arizona Posts: 589	Re: Building "The Duck" Nice Job Are the new forks longer or shorter? Will the ground clearence be the same or lower. Are those MK2 off a ZX-12 ? Now I want to go out and buy a lathe. Like you I'm a little short on space. Thanks sharing your journey.

01-11-2010, 1:54 AM	#86
XXDAD Join Date: Feb 05 2008 Location: North Carolina Posts: 521	Re: Building "The Duck" Nice. A lot of work. Thanks.

01-17-2010, 3:35 AM	#88
dracki Back in Black,AC/DC Join Date: Mar 03 2008 Location: Brisbane,Queensland,Australia Posts: 1,946	Re: Building "The Duck" whats the ducting called,who makes it? __________________ Attitude,Charisma,Mojo & Spunk. Thats what you have on a BLACK Blackbird & there the fastest.the rest of you just dream about that annoying Shewie,Lois & Poundstrecher one post at a time

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