Rips R1

[RIPPERTON]

Heres the crankshaft weighting experiment underway.
Added 2.2kg to the crank right out wide. This is an extreme amount but need to know what effect adding too much weight might have. Hopefully increase cornering speed by smoothing out the power

http://i37.photobucket.com/albums/e62/ripperton_2008/DSC00059.jpg

http://i37.photobucket.com/albums/e62/ripperton_2008/DSC00060.jpg

http://i37.photobucket.com/albums/e62/ripperton_2008/DSC00061-1.jpg

http://i37.photobucket.com/albums/e62/ripperton_2008/DSC00062-2.jpg

http://i37.photobucket.com/albums/e62/ripperton_2008/DSC00063-2.jpg

http://i37.photobucket.com/albums/e62/ripperton_2008/DSC00064-1.jpg

[wade193]

Your an ideas man Rip. When are you hoping to test it?

[Wiccad]

I'd be fitting a bigger back brake to counteract the run on when you need to decelerate quickly. The difference between my previous bike KY 750 and my current K1600 at the track is quite noticeable under breaking how the 600 lacks engine breaking. In your case kinetic run on but a very similar effect. That said the added gyroscopic force would to my mind make the bike more inclined to fight tip in but be more stable once turned.

[RIPPERTON]

Your an ideas man Rip. When are you hoping to test it?

This bike has been apart for 3 years sitting in the corner collecting dust. Theres a lot of work and spares to get for this bike before i runs again. Hopefully next year sometime.
I might only get 3 laps out of it before it blows cause what I did to the crank is pretty traumatic. If it does go up Il just convert it to electric and throw the piston engine over the fence

[spotcom]

I, for one, am keen to hear the results. Yer a thinker, Mr Rip!

[muzz]

i get what your trying to do but wouldnt that rob power after the corner?

[Turtle]

Whens the Big test Dan ?

[SLAC]

Whens the Big test Dan ?

When ever it is please tell us all so when it blows up and throws a rod out and spews oil all over the track i for one dont want to be there...

[RIPPERTON]

Its going to be a while cause the rest of the bike is a mess.
Its got a lot of stuff missing, needs new rad. Got to modify the front sprocket so the CBR starter fits and also make it so the CBR Lithium batteries can be used in it.

I also thought the weighting rings would obstruct the crankcase windage ports between cyl 1/2 and 3/4 but it turned out to be ok. Air will still be able to breath around under the pistons.

[SLAC]

Air will still be able to breath around under the pistons.

Even so will there be too much pressure?

[RIPPERTON]

Heh here she is at PI in Nov 05. Told ya she was a mess

http://i37.photobucket.com/albums/e62/ripperton_2008/05-3.jpg

http://i37.photobucket.com/albums/e62/ripperton_2008/05-5.jpg

http://i37.photobucket.com/albums/e62/ripperton_2008/05-6.jpg

[RIPPERTON]

It lives
Fired her up this morning.
Had to bump start it down my steep street and when it fired suddenly realised I had the idle set up to 2000rpm and had no rear brakes and theres a T intersection at the bottom of my street so I pull the clutch and the engine is flaring up as I trying not to wipe anyone out as I make it through the Intersection. Im like cool no noises and its on all 4 cylinders as Im trying to wind the idle down with my right hand and stop the engine flaring by slipping the clutch but better head back cause its got no water and no fuel.
So where do I get a lower radiator hose for a 98 R1 on Christmas day.
Utterly amazed that it still runs. :ayyy: :ayyy:

[Big Lunt]

Gee this is going to be interesting once its finished!!!!

Its always a good feeling when an engine starts after its been sitting around for a while - even more so when its been sitting around in pieces.

Well done keep us posted on the progress

[RIPPERTON]

Heres a vid of the engine revving in the garage.
Doesnt really sound any slower revving up or down.
Had it round the block a few times and it feels very smooth on power. Cant notice any less power than before. Still pretty amazed its running at all with that amount of mods to the crank.


http://www.youtube.com/watch?v=SpUEJBb3CMY

[BART]

Danny, love your work !!!!

You're a regular Doc Brown. When are you going to start working on a flux capacitor :lmao::lmao:

[RIPPERTON]

Thanks Bart
It might not have a Flux Capacitor but if it works the way Ive planned it might just be a time machine, ie Lap Time Machine.
1,30's maybe

[Jake]

Hopefully increase cornering speed by smoothing out the power
Doesn't this fly in the face of what Yamahahaha are doing with the BB? :confused1:

[RIPPERTON]

Doesn't this fly in the face of what Yamahahaha are doing with the BB? :confused1:

?? what ARE they doing with the BB ??

[zenodamper]

Presumably he is meaning spacing the pulses thru the rubber...

[Jake]

Yeps :ayyy:

[stormr]

Can't remember where I read it but Yamaha are supposedly (according to rival race crews who claim to have seen the Yam crankshaft) running an extremely light crank on Rossi's M1 to reduce gyroscopic inertia to improve turn-in / change of direction response.

The description I read was something like "it looks like a bent stick".

[RIPPERTON]

Can't remember where I read it but Yamaha are supposedly (according to rival race crews who claim to have seen the Yam crankshaft) running an extremely light crank on Rossi's M1 to reduce gyroscopic inertia to improve turn-in / change of direction response.

The description I read was something like "it looks like a bent stick".

Yeah why not they got traction control to look after wheelspin

[RIPPERTON]

06R6 ???? or 98R1 ????

http://i37.photobucket.com/albums/e62/ripperton_2008/DSC00097.jpg

Have red tinted screen coming from Zaks fairings

[holdontight]

How about 98 R1PPERTON

[RIPPERTON]

PiMp yO crankshaft experiment :mod_smilie_rockwoot :mod_smilie_rockwoot

http://i37.photobucket.com/albums/e62/ripperton_2008/DSC00064-3.jpg?t=1234751831

http://i37.photobucket.com/albums/e62/ripperton_2008/DSC00065-1.jpg?t=1234751886

http://i37.photobucket.com/albums/e62/ripperton_2008/DSC00066-2.jpg?t=1234751900

[Big Lunt]

Nice work that looks good

[RIPPERTON]

IT WORKS !!!!!!!!!!!!! :mod_smilie_rockwoot :mod_smilie_rockwoot

My Crankshaft mod not only didnt blow up but actually performed quite well and had the predicted effect on corner exits.
You could apply more throttle earlier.
You could apply throttle at full lean angle.
It was smooth and safe feeling. It gave confidence in the bike and tires.
In those long lingering corners that seem to go on for ever and force you to feather the throttle now are done under throttle and accelerating (and leaving long fat rubber trails).
I found I was hooking the bike from apex to exit on full angle and ramping the throttle up much quicker than I used to and much quicker than on the CBR.
The bike seemed to turn very aggressively and maintain more of an angle until later in the turn. Turns seemed to be longer ie more linked together because I didnt have to be upright to be on the gas. Corner speed is now a product of how much centrifugal force the tires can handle from the bike going around a corner not how well they can handle engine power.
This bone stock 98R1 is less than a second slower than my 152kg CBR around Eastern Creek.
When I say bone stock Im talking about engine power up mods. Stock cams, pistons and compression. It has a Dynojet kit in the carbs. It has stock suspension !!!!!! The front caliper rubbers just decided to swell up and jam the pistons and they were dragging the whole time. Also didnt have a screen and couldnt hold it flat down the straight. Clutch was slipping in higher gears in spite of me putting a shim under the diaphram.It has undergone extensive lightening like my CBR but dont know how much it weighes. Could be 155kg.
The extra weight in the crank didnt have any side effects in braking or yawing the bike.
Definitely doing this mod to my CBR. Going to take as much weight of it before welding the rings on. Probly weld at least 4 rings.
Will post some pics later .

[Mr.Ed]

Wow... it sounds like you have had a massive break through there! Congratulations mate! :ayyy: And the bike is looking better than when it left the factory IMO!
I know it may sound stupid, but could it have any ill effect on the long run??:confused1:

[RUSSELL]

im impressed ripper!! be sure to copyright or patent pend or sumthing before someone catches on....., your onto something here!!!

[spotcom]

It was good to bump into you again today Rip, and to hear that this had gone well. You were pretty chuffed at the time, and with good reason!

I'm very interested to hear how it goes when you do it to the CBR. I suspect this will be a better guide, given that you're more familiar with that bike on the track (of recent times, anyhow). Also, lap times will also be a bit of a guide too, won't they?

Good write-up, and great results! :ayyy:

[RIPPERTON]

Thanks guys
heres some shots
on the gas
http://i37.photobucket.com/albums/e62/ripperton_2008/straight.jpg?t=1235201433
traffic, Claudio going wide, Big Lunt
http://i37.photobucket.com/albums/e62/ripperton_2008/t2chase.jpg?t=1235201602
http://i37.photobucket.com/albums/e62/ripperton_2008/t2chase2.jpg?t=1235201564
Tiffany or someone
http://i37.photobucket.com/albums/e62/ripperton_2008/t2-3.jpg?t=1235201641
t2 or something
http://i37.photobucket.com/albums/e62/ripperton_2008/t2.jpg?t=1235201680
t3
http://i37.photobucket.com/albums/e62/ripperton_2008/t3.jpg?t=1235201700
t9 bumper with mate Gary
http://i37.photobucket.com/albums/e62/ripperton_2008/t9.jpg?t=1235201725

[Big Lunt]

Good ride and the bike was coming out hard - I could see when you were hitting the throttle and it just kept its line

Good riding today I think we scared a couple of people around the circuit and the best one was coming out of 12 and down the straight!!!

[usual suspect]

Thanks guys
heres some shots
on the gas
http://i37.photobucket.com/albums/e62/ripperton_2008/straight.jpg?t=1235201433
traffic, Claudio going wide, Big Lunt
http://i37.photobucket.com/albums/e62/ripperton_2008/t2chase.jpg?t=1235201602
http://i37.photobucket.com/albums/e62/ripperton_2008/t2chase2.jpg?t=1235201564
Tiffany or someone
http://i37.photobucket.com/albums/e62/ripperton_2008/t2-3.jpg?t=1235201641
t2 or something
http://i37.photobucket.com/albums/e62/ripperton_2008/t2.jpg?t=1235201680
t3
http://i37.photobucket.com/albums/e62/ripperton_2008/t3.jpg?t=1235201700
t9 bumper with mate Gary
http://i37.photobucket.com/albums/e62/ripperton_2008/t9.jpg?t=1235201725


Big improvement on his shot, do you think he might be listening??

[SIX36]

Much better variety but still blurry and out of focus with no colour....

[RIPPERTON]

Weighed the R1 after EC ride day, 152kg.
Have just drained 3kg of fuel out of it.
149kg :mod_smilie_rockwoot :mod_smilie_rockwoot

[spotcom]

Hey, Rip, do you think that the heat is frying your battery? I was just wondering why there were so many dead cells in it after the last session yesterday...

[RIPPERTON]

Hey, Rip, do you think that the heat is frying your battery? I was just wondering why there were so many dead cells in it after the last session yesterday...

Dont know
I dont think it got hot cause it was under the seat and behind the bottom of the fuel tank.
Any hot air coming off the engine would go out to the sides.
Those cells have a higher discharge rating than the other big BMI cells Im using in the CBR. But theres nothing on the R1 except electronics. No fuel pump, No exup. Ive told the importer about it and hes trying to figure it out.
Im going to run the CBR bat in it now.

[WET4URacing]

so rip when can we have the R1 showdown. mines only a little bit not standard. i promise

[stetto]

im impressed ripper!! be sure to copyright or patent pend or sumthing before someone catches on....., your onto something here!!!

Call em Ripper Rings, you may use that :ayyy:

[RIPPERTON]

so rip when can we have the R1 showdown. mines only a little bit not standard. i promise

Right after you sober the fuck up. :lmao:

[Turtle]

Weighed the R1 after EC ride day, 152kg.
Have just drained 3kg of fuel out of it.
149kg :mod_smilie_rockwoot :mod_smilie_rockwoot

Geez, thats light, what do you use to weigh it ?

[RIPPERTON]

Large packaging scales at a factory I used to work at.
Just roll the bike on.

[RIPPERTON]

2.3Ah lithium battery has shit itself in the last session of the last track day I did at The Creek so it has been temporarily replaced with the 10Ah mega power station out of the CBR. Had to make a new battery tray for this.
2mm thick commercial grade crap painted sex red.
http://i37.photobucket.com/albums/e62/ripperton_2008/DSC00084.jpg?t=1238284315

http://i37.photobucket.com/albums/e62/ripperton_2008/DSC00085-1.jpg?t=1238284477
Houses the UCU and battery
http://i37.photobucket.com/albums/e62/ripperton_2008/DSC00086-1.jpg?t=1238284546

http://i37.photobucket.com/albums/e62/ripperton_2008/DSC00087.jpg?t=1238284595

Have ordered a FJ1300 clutch spring as its the same size as the R1.

[Big Lunt]

whats next???

[RIPPERTON]

whats next???

Oil cooler and alloy fuel tank

[Turtle]

You are definately an "Ideas" man Rip..........good onya mate...

[Big Lunt]

I think you will need to give some guidance on reducing some weight off mine.........I am keeping my side stand and also starter motor for convenience though!!!!!!!!!!!!!!!!!!!!!

[RIPPERTON]

I think you will need to give some guidance on reducing some weight off mine.........I am keeping my side stand and also starter motor for convenience though!!!!!!!!!!!!!!!!!!!!!

forget about it :lmao:
Nah seriously you have to start making stuff out if alloy. Unless your a fabricator its going to cost you millions

[Big Lunt]

forget about it :lmao:
Nah seriously you have to start making stuff out if alloy. Unless your a fabricator its going to cost you millions


Simple then upgrade to a newer bike with more HP and less weight:ayyy:

I will keep the old girl for a while she still has some life left in her

[RIPPERTON]

Simple then upgrade to a newer bike with more HP and less weight:ayyy:

I will keep the old girl for a while she still has some life left in her

Ill be keeping mine, The CBR will go before it does.

[burlo53]

Just wondering,after looking at your welds on the crank,how the fuck did you balance it?I thought vibration would destroy your engine at high revs.Amazing!

[Big Lunt]

Engineering genius from what I have seen

[RIPPERTON]

Just wondering,after looking at your welds on the crank,how the fuck did you balance it?I thought vibration would destroy your engine at high revs.Amazing!

Duncan & Foster at Moorebank did the balance work and it took them 9 goes at it. was 13gr out on one plane and cost $165. But it was balanced before I started welding rings on. Its pretty smooth now.
Next time I will try to place equal welds on each side of the ring to reduce balance costs.

[WET4URacing]

Have ordered a FJ1300 clutch spring as its the same size as the R1.


dont bother. YEC is the only way to go. i went that way 10yrs ago

[RIPPERTON]

Original tank with fittings 5.54kg (18l)
Alloy tank in 1.6mm with fittings 1.7kg 15l
3.8kg saving..... Hmm looks like Ive got something to do this weekend.

[Grunta]

Good Luck with that one should be an interesting and possibly catastrophic result:confused1:

[RIPPERTON]

Good Luck with that one should be an interesting and possibly catastrophic result:confused1:

What a strange thing to say :confused1:

[Turtle]

Original tank with fittings 5.54kg (18l)
Alloy tank in 1.6mm with fittings 1.7kg 15l
3.8kg saving..... Hmm looks like Ive got something to do this weekend.

Whats it weigh now ???

[RIPPERTON]

I going to be down around the 146 - 147kg mark.

If this thing had some power it would be a MotoGP bike

[Turtle]

I going to be down around the 146 - 147kg mark.

If this thing had some power it would be a MotoGP bike

Faaarrrkkkk !!!!!!! Thats an RGV.............

[Mr.Ed]

I going to be down around the 146 - 147kg mark.

If this thing had some power it would be a MotoGP bike

I wonder what kinda weight you'd get from a bike like the new 600RR which is supposed to be 155 dry... that'd be a killer 600.

[Turtle]

I going to be down around the 146 - 147kg mark.

If this thing had some power it would be a MotoGP bike

Whats wrong with the engine ??? No Balls ?

[RIPPERTON]

Whats wrong with the engine ??? No Balls ?

Its just stock
was keeping Claudio on the straights so its not under powered for a 98.
Needs cams pistons and Keihin 41's

[Turtle]

Its just stock
was keeping Claudio on the straights so its not under powered for a 98.
Needs cams pistons and Keihin 41's

Didn't realise it was an Oldie....

[muzz]

if you take off the ten kgs you added to your crank you could get even lighter:lmao:

[WET4URacing]

nice muzz

[RIPPERTON]

simple minds

[WET4URacing]

is that whats on your turn table?

[Big Lunt]

Its just stock
was keeping Claudio on the straights so its not under powered for a 98.
Needs cams pistons and Keihin 41's

I think I only I can claim the stock r1 award!!!

Dan get that dragging front brake sorted first and then get a full exhaust system. I think that will make a difference

Add to the fact you are no horse jockey!!!!

[stetto]

if you take off the ten kgs you added to your crank you could get even lighter:lmao:

:lmao:

[RIPPERTON]

New FJ1300 spring arrives in the mail and it has 7mm free height which is 0.5mm more than the ol spring.
Weighes exactly the same and is same thickness.
install it and the lever feels heavier but have yet to test it.
Could say the old spring was flogged out after 71kkm

[WET4URacing]

YEC is the only way to go. i fitted 1 to a FJ1300

[RIPPERTON]

Filler neck, weld on....2 hours. quarter inch pitch

http://i37.photobucket.com/albums/e62/ripperton_2008/DSC00092-1.jpg?t=1238824388

http://i37.photobucket.com/albums/e62/ripperton_2008/DSC00093-1.jpg?t=1238824434

[RIPPERTON]

Scribing sheet
http://i37.photobucket.com/albums/e62/ripperton_2008/DSC00094-1.jpg?t=1238899586

cutting, my favorite tool the cutoff wheel Muhahaha :storm:
http://i37.photobucket.com/albums/e62/ripperton_2008/DSC00095-1.jpg?t=1238899634

just before final bend
http://i37.photobucket.com/albums/e62/ripperton_2008/DSC00096-1.jpg?t=1238899686

full circle
http://i37.photobucket.com/albums/e62/ripperton_2008/DSC00097-1.jpg?t=1238899718

[WET4URacing]

pizza oven? for the pizza delivery bike?

[Big Lunt]

Rip you defintely are the professor around here!!!

[RIPPERTON]

Well, here it is,... the worlds ugliest R1.....and most probably the worlds lightest.

The new tank is 1.8kg
The old one was 5.6kg
Thats 3.8kg off the bike.
149kg minus 3.8kg is 145.2kg.

http://i37.photobucket.com/albums/e62/ripperton_2008/DSC00061-2.jpg?t=1240040018

http://i37.photobucket.com/albums/e62/ripperton_2008/DSC00062-4.jpg?t=1240040237

http://i37.photobucket.com/albums/e62/ripperton_2008/DSC00063-4.jpg?t=1240040251

[Big Lunt]

Can I ask a stoopid question but you are going to cover that all with something right??

[Turtle]

Have you moved it further back than the original ?

[RIPPERTON]

Can I ask a stoopid question but you are going to cover that all with something right??

Nope
well maybe a small cover on the airbox inlets to cut the noise a bit .


Have you moved it further back than the original ?

not really. it just doesnt go as far forward.

[Cedric]

Are you able to lock in with the outside leg with that new tank?

[stetto]

Are you able to lock in with the outside leg with that new tank?

exactly wat i was thinking, wat u gunna grip? stomp grips on the new tank lol

[RIPPERTON]

Next project is a low pressure external oil cooler. Im forced to make this because back in the early days of lightening the bike I foolishly removed the stock water cooled oil cooler and blanked it off with an alloy plate welded on. It was ok for street use but as soon as it hit the track or anything about 180kmh it would cook the oil.
now I would prefere the stock unit as they work pretty well and they are bullet proof, compact and ive never seen one leak. But since Ive welded a plate over the hole in the crank case I cant go back to the standard unit.
But in the adversity of this I have found a unique way of getting the oil out of the engine under low pressure and high volume which ive never seen done before.
Ive designed a new oil pressure relief valve that will be welded onto "that "plate and a plug will be fitted into the original location of the relief valve inside the sump. The exhaust of the new relief valve will be directed to a small oil radiator via a hose mounted in front of the block and then from the radiator back to the sump.
So the oil cooler will only be recieving hot oil when the oil pressure relief valve is open and dumping excess oil.
Ive got some pressure readings from the stock relief valve and when hot idle oil pressure is 15psi (excuse the imperial shit) and when revved up the pressure climbs to 70psi when the relief valve opens...at 4000rpm.
So this system will be ok for a track bike as the injun is mostly always doing more than 4000 rpm.
Ive already got the radiator, its a power steering oil cooler of a EF Falcon.
Theres a few advantages of this system.
A: low pressure means the radiator and hoses are under low strain so will be more reliable.
B: An external cooler should be more effective as it has cool air going through it not hot water.
C: I can add another rad or fit a bigger one if need be.
Heres a prelim 3D model. The 90 degree fittng is available from Pirtek.
Il also be using the original piston and spring and valve body dimensions for the same spring preload and opening pressure

http://i37.photobucket.com/albums/e62/ripperton_2008/PRESSURERELIEFVALVE.jpg?t=1240912767

[RIPPERTON]

evolution of design
base has bulkier weld area and is shorter overall in length
The cap is longer and bulkier and has a weldon hose fitting
piston has holes for better oil flow.
room for shims to adjust oil pressure. May lower relief pressure to 60psi

http://i37.photobucket.com/albums/e62/ripperton_2008/PRESSURERELIEFVALVE2.jpg?t=1241005985

[RIPPERTON]

Plug is done
have planed to put the oil return straight into the floor of the sump near the oil pickup. This will double as a sump plug, for oil changes just pull the hose.
Anyone want a Titanium sump plug for an R1....$20

http://i37.photobucket.com/albums/e62/ripperton_2008/DSC00067-2.jpg?t=1241180546

[RIPPERTON]

More evolution stuff
this has a large diameter axial exhaust hose fitting which would go out between 2 headers pipes.
http://i37.photobucket.com/albums/e62/ripperton_2008/PRESSURERELIEFVALVE3.jpg?t=1241765598

Here's the actual unit which will be radial outlet and will go out between header pipes 3 & 4
Im fitting a set of Acro Ti headers of an 04Gix1000.
http://i37.photobucket.com/albums/e62/ripperton_2008/DSC00069-2.jpg?t=1241765737
http://i37.photobucket.com/albums/e62/ripperton_2008/DSC00070-2.jpg?t=1241765926
http://i37.photobucket.com/albums/e62/ripperton_2008/DSC00071-2.jpg?t=1241765950
http://i37.photobucket.com/albums/e62/ripperton_2008/DSC00072-1.jpg?t=1241765970

[holdontight]

That look heavy RIP. you may have to drill some holes somewhere to balance it back out :lmao::lmao:

[RIPPERTON]

That look heavy RIP. you may have to drill some holes somewhere to balance it back out :lmao::lmao:

http://i37.photobucket.com/albums/e62/ripperton_2008/CRAZYGUY.jpg?t=1241769093

[RIPPERTON]

teh oil cooler, 700gr
Ducati 999 (dropped at ECreek and parted out)
$150 from Chris in Seven Hills off Ducati Spot Forum (yes I did sign up :dropjaw: )
Top frame plate will be welded to the bottom frame plate of the R1 radiator and bottom lug will be used as the stay, bracketed off the sump now instead of the block. Fitting mounts will be cut down to minimum height and alloy fittings made up with large diameter hose sections that will hopefully lead out in between the 3rd and 4th header pipe.

http://i37.photobucket.com/albums/e62/ripperton_2008/DSC00078-1.jpg?t=1243244959

As you can see Ive already been at it with the cutoff wheel and flapper disc. Took 140 grams of lugs grommets bolts and shit off it.
it is now worthy of the R1

[jasonbw]

it is now worthy of the R1

:D some shit I just don't understand, and that's not a question on your ability, it's just saying I'm engineerilly challenged. Keep those pics coming!!!!

[Naked Twin]

http://i37.photobucket.com/albums/e62/ripperton_2008/CRAZYGUY.jpg?t=1241769093


I thought you saved that picture for me. Some people just can't be trusted.

As Jason says keep the pics coming.

Nick

[CowskinBodybag]

Next project is a low pressure external oil cooler. Im forced to make this because back in the early days of lightening the bike I foolishly removed the stock water cooled oil cooler and blanked it off with an alloy plate welded on.

couldn't just drill and tap a fitting into it?

[RIPPERTON]

couldn't just drill and tap a fitting into it?

You mean to get the oil out ?
I probly could buy a pressure reliefe valve and screw it in.
Didnt think of that but it was more fun making my own.

More pics coming soon. have secured a Ti system for $400 albiet a Gix1000 one but will make it fit.
Have also ditched the alloy tank and replaced it with a plastic 5l kart tank that weighes 420 gr !!!!!!!!!!!!!!!!
getting a 1.6mm alloy cradle laser cut (260gr). so thats another kilo off

[RIPPERTON]

This is a special thanks post for PYMM who allowed me the privilege of paying him $50 to remove his old Stainless LeoVinci exhaust off his 04R1.
That system was lovingly restored and cleaned and sold for $400 to a guy in Melbourne.
That $400 went to buy the Gix 1k Ti system I posted in For sale section.
I just recieved it in the post and mocked it in and it fits perfectly. I will remove the spigots off the old headers and weld them onto the new ti system.

Of course I weighed it ..........the Worlds lightest R1 just lost another 1.17kg.
Ive lost track of what it would weigh now but its under 145kg :mod_smilie_rockwoot.

Thanks PYMM

[WET4URacing]

i beg to differ.

[RIPPERTON]

Home grown A123 batteries....334gr

http://i37.photobucket.com/albums/e62/ripperton_2008/DSC00035.jpg?t=1246677097

Got the shits with the alloy tank trying to stop it leaking, apparently I cant weld for shit or the cut off wheel contaminated the alloy.
All the better cause the 5 liter Kart tank and its 1.6mm laser cut alloy cradle comes to a total of 700gr which is a kilo lighter than the alloy tank and 4.9kg lighter than the steel roady tank.
Also mounted the ECU on the cradle which allowed me to shorten the wiring harness by 500mm and 150gr.

http://i37.photobucket.com/albums/e62/ripperton_2008/DSC00040-2.jpg?t=1246677460

http://i37.photobucket.com/albums/e62/ripperton_2008/DSC00038-1.jpg?t=1246677474

http://i37.photobucket.com/albums/e62/ripperton_2008/DSC00037-1.jpg?t=1246677489

http://i37.photobucket.com/albums/e62/ripperton_2008/DSC00036-1.jpg?t=1246677507

[Big Lunt]

I have to ask this but are you going to start shaving some weight off yourself in the pursuit of the lightest machine/rider combination???

I think that tank is a better idea and possibly a little more comfortable.

Question is are you going to cover anything with it???

[RIPPERTON]

I have to ask this but are you going to start shaving some weight off yourself in the pursuit of the lightest machine/rider combination???
I think that tank is a better idea and possibly a little more comfortable.
Question is are you going to cover anything with it???


No Im not going to lose any weight. Im 43 Ive got a drivers licence and a desk job. Im going down hill from here, no more triathlons for me.

Tanks not only a better idea but a cheaper one. The tank was $50 and the laser cutting was $40.
I used a full bottle of Argon trying to weld the alloy one ...$136 right there.
Yeah Il have to cover it. Have to keep it looking beautiful. Looks like a CBR race galss tank cover or make one from scratch using the old tank as a mold

[WET4URacing]

mmmmm my carbon kevlar tank at 2kgs isnt anywhere compared to that ultra slimline weight saving item u have there ripper. nice addition.
admin may remove if i'm out of order but i doubt it

[RIPPERTON]

mmmmm my carbon kevlar tank at 2kgs isnt anywhere compared to that ultra slimline weight saving item u have there ripper. nice addition.

Thanks Paul.
I hope I dont get the shits with having to refuel it after every single session.

[HA98]

just needs a carbon fibre airbox now...

[RIPPERTON]

just needs a carbon fibre airbox now...

Nah
Keihins with pod filters

[WET4URacing]

ram air wood be too much for u hey ripper. u woodnt want too many modifications

[RIPPERTON]

Kind of yeah
I started this project trying to see what kind of performance you could get by only reducing weight and not increasing horsepower at all.
So the motor still has original power I think (136hp).
The CBR is a different story, thats getting both lightening and power mods.
I used to have a carbon ramair box for the R1 but sold it.

Got the Gixxer Ti headers fitted last night with very little mods.
Shortened the link pipe and took an angle out of it and put a few dents in the 2 left header pipes for the oil filter.
Shortened the water pipe coming out of the cases so it sits closer to the cases.
May have to lower the belly pan.
I have a spare Acro Ti muffler with 60mm diameter for sale soon as I shorten it.

[RIPPERTON]

http://i37.photobucket.com/albums/e62/ripperton_2008/DSC00041.jpg?t=1246864090

http://i37.photobucket.com/albums/e62/ripperton_2008/DSC00042.jpg?t=1246864138

http://i37.photobucket.com/albums/e62/ripperton_2008/DSC00044.jpg?t=1246864156

[muzz]

how did you get on welding that ti?
they tell me its a right karrrrnt

[RIPPERTON]

So I went to weld on the new relief valve and it turned into another alloy welding nightmare.
Ended up cracking the case around the main oil gallery and couldnt get the crack to weld up.
So now looking for another crank case and will redesign a bolt on relief valve that takes the place of the oil cooler.
I could just use the standard oil cooler but want to use the Duc rad.
Had nothing to do this arvo so pulled the CBR motor and have started designing the crank weights before sending the block to get resleeved.

[RIPPERTON]

Finite Element Analysis of crank
http://www.youtube.com/watch?v=FpkWjmP08ko

[saf]

Great job! Very interesting reading.... just don't bin it! Reconstructing laborious custom parts that've been damaged is a pain in the arse, though you seem to enjoy it :)

[RIPPERTON]

Seemed like a simple enough weld job. The material I was welding to was plate not Yamaha casting so should have been easy.
http://i37.photobucket.com/albums/e62/ripperton_2008/DSC00045.jpg?t=1247561291

Instant nightmare. I hate alloy welding
http://i37.photobucket.com/albums/e62/ripperton_2008/DSC00050-1.jpg?t=1247561390

[muzz]

alloys gotta be super clean mate to weld ,and if the cases are anodized thats gotta come off as well
did you weld the first plate on?

[RIPPERTON]

alloys gotta be super clean mate to weld ,and if the cases are anodized thats gotta come off as well
did you weld the first plate on?

Hah no, that was done by a pro welder back in 2003.
But back then the cases had just come out of a caustic tank as the engine was apart.
This time the engine was still in the frame and as it got hot the remnant oil started to flow and contaminate the weld

[muzz]

Hah no, that was done by a pro welder back in 2003.
But back then the cases had just come out of a caustic tank as the engine was apart.
This time the engine was still in the frame and as it got hot the remnant oil started to flow and contaminate the weld

yip that will do it:ayyy:

[Killer848]

Rip wish i had your skills and tools!, the stuff you are doing to this bike is awesome. I love this kind of stuff but can't quite do it myself.
Keep up the good work :ayyy:

[RIPPERTON]

Rip wish i had your skills and tools!, the stuff you are doing to this bike is awesome. I love this kind of stuff but can't quite do it myself.
Keep up the good work :ayyy:

Thnx killer
Im taking a risk with the Alusil as it might be the quality of the aluminium in the casting that causes the bores and pistons to score in spite of the alusil.
But at $440, its probly worth it.
If it fails again I can sleeve back down to 75mm

[lilninja]

Rip your absolutley insane, but I love reading all about your exploits. Just stay away from my bike :lmao:

[RIPPERTON]

Got new crankcases from Clipstone Yamaha in Smelbourne for $270 shipped and have been testing the R1 around the streets today.
Got a new standard oil cooler but have decided to forge ahead with the external pressure relief valve and low pressure oil cooler circuit.
Got some 6061 75mm solid round from a friend and have turned up one side of the screw on valve body.

http://i37.photobucket.com/albums/e62/ripperton_2008/DSC00074-2.jpg?t=1252669765

http://i37.photobucket.com/albums/e62/ripperton_2008/PRESSURERELIEFVALVE4.jpg?t=1252670180

[RIPPERTON]

drilling the 6 main flow holes into the engine side of the cover

http://i37.photobucket.com/albums/e62/ripperton_2008/DSC00075-2.jpg?t=1252721652

engine side

http://i37.photobucket.com/albums/e62/ripperton_2008/DSC00076-1.jpg?t=1252721711

valve side with seat and 8 bypass grooves

http://i37.photobucket.com/albums/e62/ripperton_2008/DSC00077-2.jpg?t=1252721736

[RIPPERTON]

Using old case as a base to stop warping of the sump when welding on hose fitting

http://i37.photobucket.com/albums/e62/ripperton_2008/DSC00078-2.jpg?t=1252748007

valve in place

http://i37.photobucket.com/albums/e62/ripperton_2008/DSC00079-3.jpg?t=1252748075

needs some heat shielding in between the hoses and headers
had it running tonight, will do some pressure testing tmrw

http://i37.photobucket.com/albums/e62/ripperton_2008/DSC00080-2.jpg?t=1252748110

[RIPPERTON]

Yes thats right I shelled the tank. Its 2.3kg but it will do for now till I make a fiber glass mold out of it.
have done plenty of test rides and the oil system is holding up so now looking for a track day :ninja:

http://i37.photobucket.com/albums/e62/ripperton_2008/DSC00083.jpg?t=1253428362

[wade193]

Did you sort out the heat shielding yet?

[RIPPERTON]

Did you sort out the heat shielding yet?

yep got a larger diameter hose, slit it length wise and wraped it around. Going to have to rely on airflow to keep the hoses from toasting meaning keeping idling times to a minimum and shutting down as I roll into the pits.
The oil hose is especially for low pressure engine oil and is good for 105 C.
The engine oil pressure is running slightly higher now after 4g in spite of the longer spring chamber I gave it (lower release pressure) I think cause the whole cooling system is longer than the original relief valve body.
Ive measured inlet and outlet temperatures on the rad and it drops over 10 degrees. :ayyy:

[Big Lunt]

Yes thats right I shelled the tank. Its 2.3kg but it will do for now till I make a fiber glass mold out of it.
have done plenty of test rides and the oil system is holding up so now looking for a track day :ninja:

http://i37.photobucket.com/albums/e62/ripperton_2008/DSC00083.jpg?t=1253428362

We may be heading out on the 10th are you in?

[RIPPERTON]

We may be heading out on the 10th are you in?

twist my arm :ayyy:
actually just noticed the 5th Monday might try to catch that too

[Big Lunt]

twist my arm :ayyy:
actually just noticed the 5th Monday might try to catch that too

Good man - we can put the 2 R1's head to head again.

I have gained some HP and shaved a little weight from her:ayyy:

Will let you know when we book

Probably do the sat 10th - ride day on the monday is not the greatest for me as I like to relax the following day

[WET4URacing]

mmmm mite have to join in on this

[RIPPERTON]

Good man - we can put the 2 R1's head to head again.

I have gained some HP and shaved a little weight from her:ayyy:

Will let you know when we book

Cool I got great results from milling 0.5mm off the head and splitting the head gasket. Took one layer off it so now only 2 layers. From 0.6mm to 0.4mm.
over all squished the chambers 0.7mm.

[Big Lunt]

Cool I got great results from milling 0.5mm off the head and splitting the head gasket. Took one layer off it so now only 2 layers. From 0.6mm to 0.4mm.
over all squished the chambers 0.7mm.

Gee you bumping up the compression to??

Did you fix those damn front dragging calipers - that must really be holding it back? Did you kit them?

Last time I saw them the front wheel was hardly spinning!!!!!

[RIPPERTON]

Yeah calipers are great now real brick wall brakes. Standard discs and ZX10 master

[RIPPERTON]

wrap your ass in fibreglass

sacrificed the ol track tank to make a tank mold and got a pro fibreglass guy to do the glass work. came out like a Zaks.

http://i37.photobucket.com/albums/e62/ripperton_2008/DSC00001-2.jpg?t=1254456926

http://i37.photobucket.com/albums/e62/ripperton_2008/DSC00002-2.jpg?t=1254457070

[RIPPERTON]

Got 2 sessions in at the Creek today and the R1 went mostly well.
recorded a 16 degree C drop across the oil radiator and about 57 degree sump temp. No leaks around the valve area.
The milled head gave a noticeable power up and the bike is definitely lighter as I found I was braking too early into 2. Soon adjusted that.

http://i37.photobucket.com/albums/e62/ripperton_2008/DSC00003-2.jpg?t=1254720883

http://i37.photobucket.com/albums/e62/ripperton_2008/DSC00004-2.jpg?t=1254720908

[Big Lunt]

mmmm mite have to join in on this

Bring your R1 out as well it would be good fun

I am not sure what times you are doing on the R1 but I think that 3 of us are not too far apart.

Shit I may lose in the power stakes here..........

RIP when are we doing a ride day - taking mine out this week to see how it goes then the fine tune will start. Hoping to squeeze another 5 hp out of it. She is running rich on both top end and mid range.....small jet and needle adjustment should help. Will wait after this weeks track day has a small flat spot but that is at just under 4000 RPM (who ever sits at those revs at that track????)

Let me know

[RIPPERTON]

Dont know if I will make it on the 10th. Needs new fork seals. will have to have a think about next ride day. what about PI ?

http://i37.photobucket.com/albums/e62/ripperton_2008/05101.jpg?t=1254738006

http://i37.photobucket.com/albums/e62/ripperton_2008/05102.jpg?t=1254738303

[Big Lunt]

Would love to but need more planning work makes it very hard

[RIPPERTON]

went to Phillip Island , R1 blew up motor in second session
drove home, Falcon (yes the one I bought on EBay) blew up transmission just east of Yass, had to get a mate who lived in Campbelltown to come pick me and the trailer up and leave the Falcon on the side of the Hume.
So now I have 3 busted ass vehicles to fix :(

[WET4URacing]

i have no comment. commentless.

[Cedric]

Is that a comment?

[Big Lunt]

went to Phillip Island , R1 blew up motor in second session
drove home, Falcon (yes the one I bought on EBay) blew up transmission just east of Yass, had to get a mate who lived in Campbelltown to come pick me and the trailer up and leave the Falcon on the side of the Hume.
So now I have 3 busted ass vehicles to fix :(

So let me get this straight you went to phillip island this week and blew up the motor!!! There is a guy selling a R1 98 engine on formula extreme site for $700 just to let you know

[SLAC]

went to Phillip Island , R1 blew up motor in second session
drove home, Falcon (yes the one I bought on EBay) blew up transmission just east of Yass, had to get a mate who lived in Campbelltown to come pick me and the trailer up and leave the Falcon on the side of the Hume.
So now I have 3 busted ass vehicles to fix :(

:lmao::dohsmiley: time to drink :beer:

[RIPPERTON]

Another bent Crank leaving me with the obvious conclusion not to mod anymore cranks but also the invaluable proof that ringed cranks work.
Il just have to wait for Honda to bring out a CBR with ringed crank.

this one also spun a big which let the piston hit the head and probly bend some valves.

http://i37.photobucket.com/albums/e62/ripperton_2008/DSC00005-2.jpg?t=1255086272

[RIPPERTON]

:lmao::dohsmiley: time to drink :beer:

way ahead of ya :ayyy:

[Mr.Ed]

Another bent Crank leaving me with the obvious conclusion not to mod anymore cranks but also the invaluable proof that ringed cranks work.
Il just have to wait for Honda to bring out a CBR with ringed crank.

this one also spun a big which let the piston hit the head and probly bend some valves.

http://i37.photobucket.com/albums/e62/ripperton_2008/DSC00005-2.jpg?t=1255086272

I'm sorry to hear mate... I hope you can get them all working again soon and please don't stop tinkering with your bikes as it makes for a very entertaining (and educational) read!:ayyy:

[muzz]

Another bent Crank leaving me with the obvious conclusion not to mod anymore cranks but also the invaluable proof that ringed cranks work.
Il just have to wait for Honda to bring out a CBR with ringed crank.

this one also spun a big which let the piston hit the head and probly bend some valves.

http://i37.photobucket.com/albums/e62/ripperton_2008/DSC00005-2.jpg?t=1255086272

hmmmm let me get this right
2 bent cranks ...2 blown engines....... imvaluable proof that ringed cranks work?
ohh ok:confused1:

[RIPPERTON]

hmmmm let me get this right
2 bent cranks ...2 blown engines....... imvaluable proof that ringed cranks work?
ohh ok:confused1:

Oh god youre thick Muzz
The concept of outer diameter weighting works
It produces smoother power pulses
Its just they cant be made in a garage.
The welding is too traumatic for it. It would have to be designed, cast and machined from scratch with the rings already on it.
Even though its a giant chunk of steel, a crankshaft is a pretty delicate thing cause of the close tolerances involved.

[wade193]

went to Phillip Island , R1 blew up motor in second session
drove home, Falcon (yes the one I bought on EBay) blew up transmission just east of Yass, had to get a mate who lived in Campbelltown to come pick me and the trailer up and leave the Falcon on the side of the Hume.
So now I have 3 busted ass vehicles to fix :(

Ouch, did you have another bike with you at PI just incase the R1 played up, so you could still play?
Whats the plan for the falcon?

[RIPPERTON]

Ouch, did you have another bike with you at PI just incase the R1 played up, so you could still play?
Whats the plan for the falcon?

I didnt have a B bike but Terry Hay did and Id like to thank him publicly for letting me do a few sessions on it (09 R1) Very nice bike even in STD mode.
Got the shit bombed out of me by his son Grant and friends as they were practicing for next weeks MotoGP support race.

A guy at work has a car float so hope to get it and a truck capable of towing 1.6 tonnes of shit up the freeway. :dohsmiley:

[muzz]

Oh god youre thick Muzz
The concept of outer diameter weighting works
It produces smoother power pulses
Its just they cant be made in a garage.
The welding is too traumatic for it. It would have to be designed, cast and machined from scratch with the rings already on it.
Even though its a giant chunk of steel, a crankshaft is a pretty delicate thing cause of the close tolerances involved.

im thick????
i not the one with two fucked bikes and a fucked falcon coz i keep fuckin with it

[ottospunkmeister]

im thick????
i not the one with two fucked bikes and a fucked falcon coz i keep fuckin with it

That's a lot of fucking around then?

[RIPPERTON]

im thick????
i not the one with two fucked bikes and a fucked falcon coz i keep fuckin with it

Yeah your thick cause you havnt got a clue whats going on in this thread.
keep out :confused:

[Greggy-68]

Well i dont knoiw either of you , however, i too had those thoughts. But at the end of the day, i thought, well, why not

They are his bikes
They are his ideas
He is risking his own time, effort, money, and flesh and blood if it all goes wrong.

So Kudos to you Rip, for trying to make a difference.

[RIPPERTON]

Well i dont knoiw either of you , however, i too had those thoughts. But at the end of the day, i thought, well, why not

They are his bikes
They are his ideas
He is risking his own time, effort, money, and flesh and blood if it all goes wrong.

So Kudos to you Rip, for trying to make a difference.

Thanks Greg :ayyy:

[wade193]

Do what ever you want Rip. I enjoy reading about all the mods. As greggy said, your money.

[muzz]

Yeah your thick cause you havnt got a clue whats going on in this thread.
keep out :confused:
bite me bitch ,:finger:

[RIPPERTON]

bite me bitch ,:finger:

R O T F L M G O :lmao: :lmao:

[Big Lunt]

RATS would not be the same with RIP - our very own professor like back to the future

Wait until he has the flux capacitor going - he will travel back in time and change the course of history so he has no broken bikes

On ya rip for tinkering

[Matt01]

Hey Rip,
What is the wet weight of your R1 before and after?
(I didn't start from page 1 on this thread...tooooo many posts to read...)

Has there been a 'seat of the pants' benefit from the weight loss and the many many mods you've completed? ie I noticed you once stated it was like an extra 10-15hp. Is that in acceleration or top speed? Top speed is great.. but getting outta corners quicker and change of direction smoother is much better.
Have you played around with the suspension to allow better power and weight transfer? What about unsprung mass?

No matter how light/powerful the bike is......transfer is the key......
I spose you know that already..:ayyy:

[Terry Hay]

A friend of mine once said...."A good education is expensive".
It's easier to sit on the fence and say "it can't be done" rather than get off your arse and have a go.
I for one applaud your efforts.
Your willingness to sacrifice time, money and motocycles to forward a concept is both daring and commendable.
But it is your candor and ability to completely honest in the face of this mishap that is truly admirable. Many would have not had the courage to continue to post after this outcome. That's a strength of character that few possess.
Good on you Rip.

[*Oggy*]

Yep..Vanilla bikes bore me to tears..... To make a good omelette, you gotta break a few eggs and try a few recipies...or the only other option is MacDonalds.....

[Kwaka12r]

i lost count of how many hours i spent at my old job reading and re reading the R1 mods and the cbr1000 mods.
then when i drink and try to explain them to my girlfriend.

is there anything planned next for the engine?
Big bang has been done but maybe a long bang firing order? ( 1-3-4 then 2 i think)

[RIPPERTON]

Wait until he has the flux capacitor going - he will travel back in time
On ya rip for tinkering

Thanks Claudio
I would go back to the year 1712 in a small town in Germany call Gera.
To observe and document one of the most pivotal events in the history of man kind and then bring it back to the present.

[Belinda]

I think its awesome that your behaving in a way a true scientist would. Theories are only that until put into practice. I mean, unless someone took a risk and put hazelnuts inside the block of chocolate then I would be missing out on my favourite!

Cost is irrelavant if its your passion, be it a $5 block of chocolate or a $22K bike. People devote their entire life to the Sciences, and a PhD is no guarantee of a $100k+ career.

The difference between you and the majority of bike riders is that we ride for pleasure and you think of your bike as an experiment. Most of your thread goes straight over my head (not much mechanics in Zoology:dohsmiley:), but still good to see you testing many hypotheses and not being defeated.

[RIPPERTON]

Hey Rip,
What is the wet weight of your R1 before and after?
(I didn't start from page 1 on this thread...tooooo many posts to read...)

Has there been a 'seat of the pants' benefit from the weight loss and the many many mods you've completed? ie I noticed you once stated it was like an extra 10-15hp. Is that in acceleration or top speed? Top speed is great.. but getting outta corners quicker and change of direction smoother is much better.
Have you played around with the suspension to allow better power and weight transfer? What about unsprung mass?

No matter how light/powerful the bike is......transfer is the key......
I spose you know that already..:ayyy:

It could be about 145kg now. They are like 185 - 190 kg new.
Weight reduction doesnt really change much in top speed but mostly in braking and corner exit. Also makes the bike turn sharper and hold a tight line easier.
Havnt gone to suspension yet, The shock is standard and its 11 years old and has never been worked on or rebuilt. I have seen an Ohlins for sale but havnt got the cash just yet.

[Matt01]

Hey Rip,
Wouldn't it be of great benefit to at least service the rear shock -seals, oil/gas. This would aid in the smooth turn in/tipping point and help the rear settle and use the available power. Have you been playing with the fuel/air system with all of your mods?

Do you think all of the work you have done could be transfered to another capacity bike?
I've always thought about running some mods on a VFR/RFV. Trying to see if 80horses and better power transfer (acceleration like a 600) could be achieved and still retain reliability.
I remember porting my RG250 a looooong time ago. Had lots of fun trying to move the power band (with exhaust chamber length) and also keep the reliability issue..

[RIPPERTON]

Hey Rip,
Wouldn't it be of great benefit to at least service the rear shock -seals, oil/gas. This would aid in the smooth turn in/tipping point and help the rear settle and use the available power. Have you been playing with the fuel/air system with all of your mods?

Do you think all of the work you have done could be transfered to another capacity bike?
I've always thought about running some mods on a VFR/RFV. Trying to see if 80horses and better power transfer (acceleration like a 600) could be achieved and still retain reliability.
I remember porting my RG250 a looooong time ago. Had lots of fun trying to move the power band (with exhaust chamber length) and also keep the reliability issue..


Id rather spend $400 on an Ohlins and have a 10 times better shock.
liter bikes are really the only bikes that suffer from rear stepping out under power. 600 would definitely not need crank weights

[RIPPERTON]

From here on this thread is about the E-vert of my 98R1 (Electric conversion)
heres the start. reinforcing the frame now that the engine is gone.
The 12.5mm solid round aircraft alloy tierod that goes across the frame takes the place of the cylinder head and maintains the bowed shaped of the frame.
The 6mm plate bars that go down to just under the swingarm pivot take the place of the crank cases and maintan its "L" shape. Without this mod the frame would break in half as soon as any load was put on it.

http://i37.photobucket.com/albums/e62/ripperton_2008/Electric%20R1/DSC00021-2.jpg?t=1267495377

http://i37.photobucket.com/albums/e62/ripperton_2008/Electric%20R1/DSC00022-3.jpg?t=1267495407

[Stu23]

Keep going mate.........is what makes the world go around :)

Cant wait next installment

Stu

[medic!]

Keep going mate.........is what makes the world go around :)

Cant wait next installment

Stu

Same here. I prefer ICE's but enjoy reading about all of your tinkerings whatever they be. I think going around turn 1 at the creek on an electric bike at speed would seem a bit surreal the first time with only the noise of the wind and very little vibration. You'll scare the crap out of anyone you pass as they won't hear you coming lol.

[Big Lunt]

RIP keep us posted on this one step by step

I am going the other way in search of more power - looking at a bolt on super charger kit at the moment - literally is bolt on affair

Can't wait to see the finished product and also to put the two R1's side by side at the track again!!!

[RIPPERTON]

Mock up time
the red stripe on the swing arm is the gap I have to cut to get the Tbelt in. A block is going to be bolted back in across the gap inside the RHS
Synchroflex GenIII AT10 25mm wide 10900N tensile strength.

http://i37.photobucket.com/albums/e62/ripperton_2008/Electric%20R1/DSC00031.jpg?t=1267495450

http://i37.photobucket.com/albums/e62/ripperton_2008/Electric%20R1/DSC00032-1.jpg?t=1264899131

http://i37.photobucket.com/albums/e62/ripperton_2008/Electric%20R1/DSC00032-3.jpg?t=1267495536

http://i37.photobucket.com/albums/e62/ripperton_2008/Electric%20R1/DSC00031-2.jpg?t=1267495560

[RIPPERTON]

Variable KERS on the left bar. When i pull this lever, kinetic energy of the bike moving along gets converted in to electrical energy for the battery Pull it in a bit, you get engine brake and pull it a bit further for rear brake. If you dont touch it you have no engine brake at all (angel gear) On track it doesnt mean much in terms of energy recouperation but regen brakes are known to have better feel than friction brakes.

http://i37.photobucket.com/albums/e62/ripperton_2008/Electric%20R1/DSC00036.jpg?t=1265949417
just behind the steering head is a cable operated throttle potentiometer from a Ford Falcon.
http://i37.photobucket.com/albums/e62/ripperton_2008/Electric%20R1/DSC00037.jpg?t=1265949853
http://i37.photobucket.com/albums/e62/ripperton_2008/Electric%20R1/DSC00038.jpg?t=1265949939
http://i37.photobucket.com/albums/e62/ripperton_2008/Electric%20R1/DSC00040.jpg?t=1265949966

hold the green button down for reverse ! yer only track bike in the Australia with reverse gear :lmao:
red button is for controller precharge.

http://i37.photobucket.com/albums/e62/ripperton_2008/Electric%20R1/DSC00039.jpg?t=1265949988

[WET4URacing]

i always thort u were going backwards rip

[nutsa]

Just read through the entire thread and have to say hats off to you mate, engineering and experimentation defiantly improves the breed! keep up the good work and keep the updates of the elec conversion comming!

[RIPPERTON]

hats off to you mate, engineering and experimentation defiantly improves the breed

Thanks Nutsa :ayyy:
but weve always got people like Wetty draggin us back down again :lmao:

[WET4URacing]

not draggin . just gigglin . we will all be dead long before petol is used up and we will lap you 28 times in 1 ride day session rip. cant see the fun in that. unless u have finally figured u cant build an old petrol guzzlin engine, SUCK-SQUISH-BANG-BLOW

[RIPPERTON]

SUCK-SQUISH-BANG-BLOW

well you got the SUCK part right BWAHAHAHAHA

[nutsa]

RIP check out the impressive projects thread i put up in general section if you get a chance, think you will appreciate what some of the guys have done including building a 1000cc two stroke block machined from scratch!

[wade193]

I'm looking forward to this project being completed. Keep up the good work RIP

[RIPPERTON]

Ive put the R1 project in DIY Electric Car Forums so you can check out the feedback I get from other EV builders

http://www.diyelectriccar.com/forums/showthread.php/ripperton-electric-track-bike-41173.html

[RIPPERTON]

Heres my new dash anyway $194 AUD
does motor temp, speed, lapsed time , lap timer, odo,
No tacho though but I can calc my motor rpm through the speed as I have no gearbox hehe

http://i37.photobucket.com/albums/e62/ripperton_2008/Electric%20R1/DSC00037-2.jpg?t=1267495298

[LAW]

Looks sweet, I just googled it to see if it was worth getting something like that for my tracky and it's meant for an electric golfkart :lmao: who needs to know average/peak speeds, odo...on a golf kart?

[Big Lunt]

Lookin good rip make sure you put a decent motor in it so you can show some of the sceptics

I will be awsome to ride with just wind noise

[RIPPERTON]

Il end up making my own motor
Theres just nothing on the market thats exactly the right size
The one Im getting is only a bit too small but Il use it to learn how to make an electric motor.
Magnesium casings , titanium shaft, Aluminium coil windings. Full ceramic bearings.
hows your supercharger going ?

[RIPPERTON]

Looks sweet, I just googled it to see if it was worth getting something like that for my tracky and it's meant for an electric golfkart :lmao: who needs to know average/peak speeds, odo...on a golf kart?

Ive seen the exact same speedo unit as mine but with a different readout inc rpm graph but cant find it.

http://cgi.ebay.com.au/Acewell-3701-Digital-Speedometer-tachometer-odo-trip_W0QQitemZ330379278500QQcmdZViewItemQQptZAU_Mo torcycle_Parts_Accessories?hash=item4cec23b8a4

[RIPPERTON]

for the lamers that couldnt be bothered going over to DIY
T belt and pully
http://i37.photobucket.com/albums/e62/ripperton_2008/Electric%20R1/DSC00054.jpg?t=1267951931

[holdontight]

Love your work ripper. Keep the photos rolling in.

[RIPPERTON]

lets compare brain size shall we.
Heres the R1's old ECU (420gr) next to the new 3 phase brushless controller & capacitor box from Kelly. (7kg)

http://i37.photobucket.com/albums/e62/ripperton_2008/Electric%20R1/DSC00059.jpg?t=1268118596

The R1's ECU is basically a fancy box of matches starting fires in the right place at the right time. Just the thing for a modern caveman
The Controller at full battery voltage can spit out 136 kW, 120v / 1000Amp at least 85% of which the motor will throw at the rear wheel and 15% goes up in heat.

http://i37.photobucket.com/albums/e62/ripperton_2008/Electric%20R1/DSC00058.jpg?t=1268118739

[Mr.Ed]

for the lamers that couldnt be bothered going over to DIY
T belt and pully
http://i37.photobucket.com/albums/e62/ripperton_2008/Electric%20R1/DSC00054.jpg?t=1267951931

After seeing this in person all I can say is WOW!:drool:

[RIPPERTON]

Controller has a new home

http://i37.photobucket.com/albums/e62/ripperton_2008/Electric%20R1/TRAY3.jpg?t=1268468178

http://i37.photobucket.com/albums/e62/ripperton_2008/Electric%20R1/TRAY6.jpg?t=1268468243

http://i37.photobucket.com/albums/e62/ripperton_2008/Electric%20R1/TRAY9.jpg?t=1268468686

http://i37.photobucket.com/albums/e62/ripperton_2008/Electric%20R1/TRAY2.jpg?t=1268468159

[ZXRider]

Hey Rip,

What will be the eco friendly's proposed weight? Will it be much lighter if any?

[Big Lunt]

Il end up making my own motor
Theres just nothing on the market thats exactly the right size
The one Im getting is only a bit too small but Il use it to learn how to make an electric motor.
Magnesium casings , titanium shaft, Aluminium coil windings. Full ceramic bearings.
hows your supercharger going ?

Supercharging road has not been released yet - its for the zx10r not the R1.

Have not heard the release date yet from the guys in states - they are still doing the long term testing I think.

By the way when do you think the bike will be ready to hit the track - let me know as I will book in with you for sure

[Big Lunt]

Love the RS232 control terminal on it.............

For me it would be a mix of work and play together - my two biggest interests (bikes and commercial AV control systems)

On ya RIP keep it goin it is starting to take shape now........home made electric engine - it will of course be over the top coming from you, I can see it now "MOST POWERFUL ELECTRIC SPORTS BIKE"

[RIPPERTON]

been doing some of the low voltage work.
Using the harnesses supplied by Kelly was half the work already done.
I have a handlebar mounted precharge switch, reverse and boost button.
The boost function supplies full 1000 amps regardless of throttle position ??? not sure how effective this will be on track but wired it up anyway, likewise the reverse function...why ??? because its there.
I have a cheapo 200v voltmeter to let me know if the battery voltage is low enough to engage to controller. Over 136v and the controller goes into fault mode.
http://i37.photobucket.com/albums/e62/ripperton_2008/Electric%20R1/wiring1.jpg?t=1269666310

http://i37.photobucket.com/albums/e62/ripperton_2008/Electric%20R1/wiring2.jpg?t=1269666700

http://i37.photobucket.com/albums/e62/ripperton_2008/Electric%20R1/wiring3.jpg?t=1269667360

The cap box assembly is going in under here on another sheet aly tray.

http://i37.photobucket.com/albums/e62/ripperton_2008/Electric%20R1/wiring4.jpg?t=1269666735

[jasonbw]

Cool, your toe looks as deformed as mine!

[RIPPERTON]

$14.500 for 320 8Ah LifeTech cells.
This will make 2 120v 32Ah batteries capable of 1160 peak amps.
around 52kg each

http://i37.photobucket.com/albums/e62/ripperton_2008/Electric%20R1/DSC00110.jpg?t=1273056725

http://i37.photobucket.com/albums/e62/ripperton_2008/Electric%20R1/DSC00111.jpg?t=1273056907

[oldblade]

I am guessing that $145.00 for the battery's

wow you charged me $150.00 for 6 didn't I get ripped off Just kidding still happy with my battery

[The Outsider]

i read it as $14,500 for 320 batts? :eyecrazy:

[WET4URacing]

thort it was spost to be cheap to run a batt bike?????? i'm off to the BP to fill my dinosour up

[Thunderace]

i read it as $14,500 for 320 batts? :eyecrazy:
Surely not :o:eyecrazy:

[The Outsider]

Surely not :o:eyecrazy:

the picture supports what i suspect.
these things arent cheap to build :eyecrazy:

[holdontight]

How heavy is this thing going to end up?

[Marshy]

He'll need to be creatinve to fit that many batteries in, and not too high either, cos they're heavy. Loving the build thread, and reckon it's an awesome project!! Can't wait to see/hear it run.

[Thunderace]

the picture supports what i suspect.
these things arent cheap to build :eyecrazy:
Just buy some Energizer AA's would be the go, same same

[Naked Twin]

He'll need to be creatinve to fit that many batteries in, and not too high either, cos they're heavy. Loving the build thread, and reckon it's an awesome project!! Can't wait to see/hear it run.

I don't think you will be able to hear it unless Rip is installing a CD player with some engine noise playing.

Wet4u you say going to fill up the dinosaur, in electric engines/ batteries have been around as long as the combustion engine, in fact depending on who you believe and when you want to claim the first combustion engine, that is closest to modern day as a compression based engine was said to be in the late 1830s where as the electric engines were first developed in the early 1830s.

So who is really the dinosaur now?

Nick

[Esra]

Seen videos of the e bikes on YouTube. The windnoise and tire noise means they're not that quiet.

Sound like a jet.

[RIPPERTON]

most Ebikes have a lot of chain noise cause they run such small front sprockets to get a reduction.
chain noise is ugly but mine has a Tbelt.
AC drives on the other hand make a fair bit of noise but still not half as much as a Dinosaur bike.
AC noise is rather noice actually. Space ship whir. You will still hear me coming

[RIPPERTON]

Just sold my external oil pressure relief valve system to a guy in California.
sump, valve plug, external valve, oil hose and clamps for $150.

[RIPPERTON]

got my motors today
they are HAWT about 200mm diameter 15.8kg
$600US each

http://i37.photobucket.com/albums/e62/ripperton_2008/Electric%20R1/DSC00116.jpg?t=1273475691

http://i37.photobucket.com/albums/e62/ripperton_2008/Electric%20R1/DSC00117.jpg?t=1273475718

http://i37.photobucket.com/albums/e62/ripperton_2008/Electric%20R1/DSC00118.jpg?t=1273475732

[RIPPERTON]

Motor is half in
gone with a chain for now as Tbelt didnt fit properly.

http://i37.photobucket.com/albums/e62/ripperton_2008/Electric%20R1/DSC00002.jpg?t=1274995905

http://i37.photobucket.com/albums/e62/ripperton_2008/Electric%20R1/DSC00003.jpg?t=1274995905

http://i37.photobucket.com/albums/e62/ripperton_2008/Electric%20R1/DSC00004.jpg?t=1274995905

sprocket sandwiched between 2 keyed flanges.

http://i37.photobucket.com/albums/e62/ripperton_2008/Electric%20R1/DSC00005.jpg?t=1274995905

[WET4URacing]

so ripper what top speeed do you think this will achieve?
this is gettin closer to the track than i thort it wood ever get

[Big Lunt]

Hey Dan

Looking bloody awsome - cant wait to see this out on the track

Great work and of course great engineering

[tazkenny]

How do you go about aligning the driven sprocket with the rear ?

[RIPPERTON]

How do you go about aligning the driven sprocket with the rear ?

had to take some of the upper motor mount lug of the frame away to get the motor frame to move over to the left.

[Cedric]

When do you think she'll be ready for a shakedown run?

[RIPPERTON]

When do you think she'll be ready for a shakedown run?

hopefully by summer
got so much other stuff to do like put the CBR back together and sell it.
took 4 weeks to get a HRC head gasket.

[bristunt]

Dunno if anyone has mentioned this yet, but here is an example of potential performance

http://www.killacycle.com/

[RIPPERTON]

Well CBR is running and for sale
so back to the R1
got the right side motor mount and Capacitor box in.

http://i37.photobucket.com/albums/e62/ripperton_2008/Electric%20R1/rhmotormount.jpg?t=1276845182

http://i37.photobucket.com/albums/e62/ripperton_2008/Electric%20R1/rhmount.jpg?t=1276845182

http://i37.photobucket.com/albums/e62/ripperton_2008/Electric%20R1/capbox.jpg?t=1276845182

http://i37.photobucket.com/albums/e62/ripperton_2008/Electric%20R1/DSC00040-1.jpg?t=1276845182

[RIPPERTON]

doh double post

[SLAC]

Is wind buffering problems going to arise?
How / what do you turn the throttle or what eva drives it?
Is there engine braking?
What holds the counter shaft sprocket or "driven" sprocket on? Fold washer or just the bolt?
What happens if it catches on fire at the creek? EC would only have fire extinguishers for fuel..

All these questions and more will be answered in the next install:crazysmiley:ment...................?

[Big Lunt]

Gee rip that body work looks a little empty with the engine missing

Looks bloody light thats for sure

[Kwaka12r]

when its complete are you going to show the stats? eg. power before , power now, weight before, weight after etc.

[RIPPERTON]

It weighs 91 kg right now
plus about 53kg for batteries 144kg or something like that.
with a standard cooling system I will only run it at minimum amps so no use in dynoing it till I mod the cooling system and run it at 1000amps 120v.
Yes has engine braking
front sprocket is keyed and bolted on.
If ECRD think they need electrical fire extinguishers they better go get some. They dont want to be seen as anti EV or anti environmental.

[RIPPERTON]

This is the sound of the future bitchiz


http://www.youtube.com/watch?v=s9J-x2IV50A

[pan]

Awesome stuff Rip!
The sound reminds me of when I race my remote control car (battery powered) down the street...
Can't wait to see this go!

[Jamesy]

When is the maiden voyage Rip?

[Big Lunt]

Frikin awsome cant wait to see how it all goes.

Get the cooling system so you can give it some gas.........

I am really keen to see how this thing goes

[Marshy]

Un-fucken-believable!! Very nice!! I can't wait until I can buy one of these....

[RIPPERTON]

I actually took it round the block today on the 72v mountain bike battery and it was amazing.
The feeling was awesome as I turned the throttle for the first time as I was sitting on it in the drive way and it
just motored away quietly down the drive. These 2 kids were watching me go past making a quiet humming noise
thinking wtf is that.
The tall gearing didnt seem to bother the motor, it pulled pretty hard away from stand still
Now I just have to make a serious battery.
Marshy I cant wait till I can manufacture these things, they are so much fun.

[RIPPERTON]

On an extension cord !!!!!
proved to be quite futile except for finding out how powerfull the regen brake is
and learning that we can only set it to 10% or the battery overvolts.
A friend is converting a VW van to electric and we "loaned" the 160v lithium battery for a while.
Although only using 120v of it, loaded into the back of the blue ute and connected to the R1
via 20m of 4 strand cable. The voltage drop across the cable would have been a lot !!
The clacking noise isnt mechanical, its called cogging and is common is
brushless permenant magnet motors. This amount of cogging is quite small for a motor of this size.
Still designing the battery.


http://www.youtube.com/watch?v=hNKTRPJFtHE

[WET4URacing]

and i was only jokin about you havin a lead round the creek. ripper your priceless .

i have finally figured out who you need to lend assistance. Whittney the sparky

[RIPPERTON]

The TBelt goes back on with a 1.8:1 reduction and 1.5kg lighter than the chain

http://i37.photobucket.com/albums/e62/ripperton_2008/Electric%20R1/DSC00002-1.jpg?t=1286089414

http://i37.photobucket.com/albums/e62/ripperton_2008/Electric%20R1/DSC00001.jpg?t=1286089414

The pulley came from the Belt shop but was full and weighed about 2.6kg. Had to machine it down and cnc some spokes in it
then rivet some cnced flanks on the sides...and paint it of course.

http://i37.photobucket.com/albums/e62/ripperton_2008/Electric%20R1/DSC00003-1.jpg?t=1286089414

[Jase]

looking good rip ... hows it going with the battery ...

[RIPPERTON]

Ended up deciding not using the $13g worth of LifeTech cells that I bought.
I have a friend who is making a land speed record bike and they would go well in that. Just hope he buys them
I always thought they were too heavy but heavy is good in land speed.
Ive finally gone to the dark side and decided to go LiPo.
They are quite dangerous but they have an amazing power to weight ratio.
The LifeTechs have a cylindrical steel casing which is why they are so heavy but the LiPo's have no casing at all.
Just a plastic pouch,they weigh 112gr each and Il need about 340 of them.
LiPo cells are basically explosives that double as batteries. If you drive a nail through one it will go off like a rocket.
http://enerland.com/upload/product/PQ-4500XQ.jpg

[jasonbw]

LiPo cells are basically explosives that double as batteries. If you drive a nail through one it will go off like a rocket.


..and you want something like that under your arse on a racetrack? Way to turn a lowside into a very highside

[RIPPERTON]

..and you want something like that under your arse on a racetrack? Way to turn a lowside into a very highside

Youve got the same thing between your legs.
However dangerous LiPo is, it will never be as bad as 18l of unleaded fuel.
Thats the big issue with electric v piston. Energy density.
Heres an idea of how much energy there is in fuel.
A piston engine wastes 90% of the calorific energy that is in fuel but liter for liter
of fuel storage volume still has more than twice the driving range of a lithium battery
Llithium batteries will never have the energy density of liquid fuels.

[RIPPERTON]

One more video
feast your ears from 2m 40s
listen for regen braking at 3m 6s


http://www.youtube.com/watch?v=o5ozc_uUCiQ

[wade193]

Rip, is that with the LiPo's?

[RIPPERTON]

Rip, is that with the LiPo's?

GOD no
I havnt even received the sample LiPo cells yet.
Peak amperage of this battery is 180 amps.
Its a single string of LifeTech 8 Ah cells.
Peak amperage of the Lipo batt will be 2250A
thats over 12 times more grunt than this batt

[RIPPERTON]

The definition of Power to Weight ratio

A123 26650 = 72gr, 120A (1.6 amps per gram)
Lifetech 38120 8Ah = 333gr, 330A (2.96 amps per gram)
Enerland XQ4350 Lipo = 108gr, 320A (0.9 amps per gram)

This little 108gr slab puts out 320 Amps for about 3 seconds till it gets hot.
http://i37.photobucket.com/albums/e62/ripperton_2008/Electric%20R1/DSC00005-1.jpg?t=1287116318

http://i37.photobucket.com/albums/e62/ripperton_2008/Electric%20R1/DSC00004-1.jpg?t=1287116318

[SIX36]

This little 108gr slab puts out 320 Amps for about 3 seconds till it gets hot.


Then what???

[red_hornet_TR]

BOOM! lol:lmao:

[RIPPERTON]

BOOM! lol:lmao:

Sure .....if you let it.

http://www.youtube.com/watch?v=RQjudHKh-bI&feature=related

[red_hornet_TR]

You one game man Rip.
Wouldnt like 50kg of that under my ass round turn 12 as you twist the throttle to supply maximum current!

[RIPPERTON]

the TBelt tensioner was a good excuse to experiment with full Ceramic bearings.
Silicon Nitride being the hardest of the 3 materials they come in and full compliment means theres no
cage and as many balls as can fit in there. This material is geometrically perfect and has almost zero thermal expansion
so runs smooth at high speed and needs no grease but without a seal they are a bit noisy.
Forgot to mention the weight difference, 5 gr against 12gr for a full steel bearing but $50 a pop

http://i37.photobucket.com/albums/e62/ripperton_2008/Electric%20R1/DSC00007.jpg?t=1288255369

http://i37.photobucket.com/albums/e62/ripperton_2008/Electric%20R1/DSC00010.jpg?t=1288255369

http://i37.photobucket.com/albums/e62/ripperton_2008/Electric%20R1/DSC00011.jpg?t=1288255369

http://i37.photobucket.com/albums/e62/ripperton_2008/Electric%20R1/DSC00012.jpg?t=1288255369

http://i37.photobucket.com/albums/e62/ripperton_2008/Electric%20R1/DSC00013.jpg?t=1288255369

[SLAC]

So am i right in say that this "quiet" electric driven bike will be the noisiest electric bike around...

[Busta]

can't wait to see this in the flesh...

so when do your batteries arrive Rip?

awesome engineering btw :ayyy:

[RIPPERTON]

can't wait to see this in the flesh...

so when do your batteries arrive Rip?

awesome engineering btw :ayyy:

Thanks
havnt ordered the lipo cells yet
had to get a new job for that.
would be cool if I could sell the CBF or the Falcon....or the CBR !

[Greggy-68]

So am i right in say that this "quiet" electric driven bike will be the noisiest electric bike around...

interestingly, in the latest edition of Race Engine Technology, they make mention that electric race vehicles in the states, the are making them have straight cut gears so they actually make noise!

[Mr.Ed]

interestingly, in the latest edition of Race Engine Technology, they make mention that electric race vehicles in the states, the are making them have straight cut gears so they actually make noise!

Jesus... I have friend with a car that runs straight cut gears, the noise is soooooooo annoying!!! It's like you're trying to max out in reverse... After 20min you feel like shooting yourself.

[Busta]

Jesus... I have friend with a car that runs straight cut gears, the noise is soooooooo annoying!!! It's like you're trying to max out in reverse... After 20min you feel like shooting yourself.

lol dogboxes and gilmer drives.. two of the most annoying sounds to ever come out of a car.. and this is from a guy that used to build rotaries!! haha

[Schtevo]

Hey Rip - have you seen this one?

Link (http://cgi.ebay.com.au/Electric-Motorcycle-converted-VF750-engineered-and-rego_W0QQitemZ170562628631QQcategoryZ102680QQcmdZV iewItemQQ_trksidZp4012.m8QQ_trkparmsZalgo%3DMW%26i ts%3DC%26itu%3DUCC%26otn%3D15%26po%3DLCA%26ps%3D63 %26clkid%3D4964372572028958740)