Guzzi 1100 Custom build

[scott_m]

There are many roads to Rome, right?

I have 2 cabinets in my workshop. One glass bead as well and the other dry soda.

I really am looking forward to a vapour blasting cabinet next year though.

 

[buzzer]

spot on, many roads to Rome! I must try soda in mine...i have some delicate carbs I need to do...

Onto building the engine… of note is the tool to compress the clutch, which is actually the centre splines off the gearbox, and a threaded bar into the crankshaft. this makes the plates perfectly aligned and makes fitting the gearbox easy.

next the cylinder heads… it took three attempts on these to get the bead out of one oilway! note the new tin of grinding paste, the old one has run out of the fine end, but it was 50 years old, I can remember my Dad buying it me as a teenager! Good to see the company is still going and using the same tin! Just to be sure I checked the bores for wear… there is none at all! Got to love Nikasil bores!

here is the engine and gearbox all back together… I decided to add some accurate timing marks on the flywheel for each cylinder so I can use a strobe and see what’s happening in reality. used my new digital DTI gauge… not sure I like it… watching that needle go round is far more satisfying!

and finally its all back together and ready to go into the frame

 

[scott_m]

Beautiful workmanship! My compliments Sir.

FWIW: I am probably going to procure my initial vapour blast cabinet from this company. I’ve heard nothing but positive things about them and their guaranteed upgrade program is right up my alley in that initially. I am going to buy the $1,000 table top model strictly for carburetor work. Then I will make the jump to the $4k range for the larger bench top model.

Who knows, if it generates good income for me, I may go up to a commercial size model but $8k-$12k is a lot of money for a piece of equipment.

Baby steps…

Micro Vapor Hone

The Micro Vapor Hone is the smallest bench top vapor hone in the world but is still as effective as our larger machines. Made in the USA

vaporhoningtechnologies.com

 

[GTM®]

I am going to buy the $1,000 table top model strictly for carburetor work. Then I will make the jump to the $4k range for the larger bench top model.

Scott, I've owned the Micro for ~4 years. Worth every penny. We have a local guy with the big tank versions for bigger work (who's made a business of just that), but the Micro handles 75% of everything we need done.

 

[scott_m]

Awesome to hear Todd! Thank You Very Much.

I’ve been impressed with this company and I’m definitely going to pull the trigger on it now.

Thanks so much my brother!

 

[buzzer]

Here is the finished final drive with a new bearing and seals.

 

[scott_m]

Looking great! It's exciting to see and I look forward to seeing the completely finished result.

 

[buzzer]

The engine is now back in the frame, a nice and easy job with the removeable bottom frame rails…

 

[buzzer]

I didn't want to use the frame as a breather as it can rot them out, and rust partials can drop down so I am told... so I decided to make a new breather the vent the crank case and also the heads. Here is is... will it work? Who knows, we will see!!

 

[buzzer]

Two jobs today... first was to make a paddock stand. I hate the universal ones as they are very difficult to get a bike on one on your own..., and often not that secure. this one positively locks onto the wheel spindle, and when its on the lift I can clamp it to the top so its nice and secure.


The second was to make some bushes out of bronze to take the play put of the clutch lever as the hole had worn oval. I drilled it out and made some over size top hat bushes. Finally, here it is on its wheels!

https://jtccc.files.wordpress.com/2022/11/clutch-lever-copy.jpg[/img]

 

[scott_m]

Lovely craftsmanship!

 

[buzzer]

I pondered for a long time on the throttle arrangement for this bike… I wanted to keep the pull to open, pull to close for a couple of reasons… First, its safer… manufactures didn’t go to this arrangement for no reason as bikes evolved. Second, it means you can have much lighter return springs, which in turn males the throttle much lighter, particularly if you are going for a quick action. . A light fast action action throttle feels like you have 20 BHP more!

I couldn’t find a 4 cable throttle anywhere, so I ended up making one from scratch…

 

[buzzer]

I needed to make some brackets out of alloy tube, but of you squash the ends in the vice it looks crap… so I made this little die that profiles the ends round which also make them stronger.

 

[scott_m]

That’s impressive mill skills.

 

[buzzer]

That’s impressive mill skills.

Thanks! its my new mill!

I made a speedo housing earlier in the build, but I was not happy with the result, so I tried again... this one is better...

turning the dome took some doing! I have rubber mounted it as I always feel electronics need it…

 

[buzzer]

I wanted to add some custom detail onto the bike, in particular on the valve covers... So I tried the technique of etching alloy... have to say it worked rather well! Oh, and although those indicators are small, they are amazingly bright!

 

[BrianR]

I love watching this thread and I am amazed at the skills that you and Todd and others show in caring for their bikes. But you need to understand sometimes the state of misery that you let hacks like myself fall into, as we read and view such wonderful skillsets.
Thanks so much and pass the Ativan!

 

[scott_m]

I often think that I will engage in this type of stuff when I retire. As if I will ever have time to do stuff like this... Maybe, but I'm not holding my breath about it!

Without a doubt, my FAVORITE part of this motorcycle is the "Construito, non Acquistato". That is simply PRICELESS and the best thing I have ever seen on a motorcycle, ever. If I had a custom motorcycle building company like Todd and GTM, then that would be my company slogan! It's just awesome.

Kudos on that amazing detail!

 

[buzzer]

Thanks guys!

Onto for me what is the most enjoyable part of a build... the wiring. I have a process for this I stick to. First I draw out the wiring diagram in Microsoft Visio, and colour code the wires. Then I order the wire in, which is quite cheap and any connectors I need. So often the standard of the electrics is what make a bike trouble free in the future. I then build the loom actually on the bike, circuit by circuit, wire by wire, which I hold temporarily in place with some Velcro cable ties. When its all in place I use that braided sheathing and close the ends with heat shrink tubing. it make a neat job. Rather than connect the main battery leads up, I use a fly lead with a 10 amp fuse just in case I make a mistake. I crimp, and if needed solder every joint. I have rubber mounted the coils and put them on an alloy heat sink. I also like to make my own HT leads out of solid copper lead, so I can get them to fit perfectly...

I have also used up the last of the Tygon fuel tube I had in stock... Its 8mm ID and I am unable to source any more without buying a large quantity, which is really annoying.

 

[DeadEye]

Nice work !
how much does that complete unit weight ?