Author Topic: Gonna build a Flying Mile GSX1100  (Read 1381 times)

Offline megawatt

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Gonna build a Flying Mile GSX1100
« Reply #15 on: January 17, 2013, 08:07:11 PM »
You wouldn't believe it Al , I ain't saying coz I will need to sell what I don't use, to finance the engine.

Offline Alan

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Gonna build a Flying Mile GSX1100
« Reply #16 on: January 17, 2013, 08:36:57 PM »
Quote from: megawatt;414464
You wouldn't believe it Al , I ain't saying coz I will need to sell what I don't use, to finance the engine.

:lol: Nice one, take it you got a good deal then.  Look forward to seeing it.

Offline megawatt

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Gonna build a Flying Mile GSX1100
« Reply #17 on: January 17, 2013, 09:46:49 PM »
Can you delete some messages Alan, your box is full. Ooer!

Offline Alan

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Gonna build a Flying Mile GSX1100
« Reply #18 on: January 17, 2013, 09:55:15 PM »
Done

Offline TeamLonsdale

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Gonna build a Flying Mile GSX1100
« Reply #19 on: January 18, 2013, 06:44:00 PM »
Looks good, but need a good strong motor now, are you thinking turbo ???

Offline Alan

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Gonna build a Flying Mile GSX1100
« Reply #20 on: January 18, 2013, 07:00:46 PM »
Quote from: TeamLonsdale;414576
Looks good, but need a good strong motor now, are you thinking turbo ???

No he is thinking cheap, so don't leave your EFEs parked up, as you may come back to find it minus its lump :lol:

Offline megawatt

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Gonna build a Flying Mile GSX1100
« Reply #21 on: January 18, 2013, 08:17:14 PM »
I ain't got much to spend on this unless you guys wanna sponsor me ? No, oh well. Not interested in turbos or NOS mate. I want a reliable stock motor. If I happen to get offered bigbore pistons, block and a flowed head with big cams???? Oh hang on just got off the phone with PJ and Ian Foxon off OSS. Been offered loadsa engine bits TO BORROW. Also been offered a long swingarm and a Propipe. Just need to do some driving. Got a Pendine  meeting in Welwyn next Saturday, so I'll be picking a few bits up !!!

Offline megawatt

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Gonna build a Flying Mile GSX1100
« Reply #22 on: January 28, 2013, 06:28:05 PM »
Made some progress this weekend. Got talking to some of the guys featured in the BBC2 documentary Speed Dreams and some guys on the Oldskoolsuzuki Facebook group, said I was gonna build a flying mile bike for Pendine sands and got some great offers from people I've never met. Drove up to Waltham Cross on Saturday to meet an OSS stalwart called Ian Foxon. Had a brew and drove to his workshop , where we unloaded some goodies from me to him. Main one being a very old, very small, lathe that needed some brackets making and the drive motor mounting to make it work. Once we'd unloaded the Passat and stopped admiring the Katana and EFE in his workshop, we drove to his lockup in Barnet. There, he presented me with a virtually complete GSX1100 engine. It turns out it wasn't just any GSX 1100 engine. It came with a standard EFE cylinder head( bigger valves and ports than the earlier engines). We then went to his mums garage, where he gave me a rusty Harris exhaust system, a Bandit 1200 swingarm and an undamaged ET headlamp unit.

Well today I managed to unload the parts and got to work stripping the engine for cleaning and checking. The good surprises just kept coming!!!

Made some progress this weekend. Got talking to some of the guys featured in the BBC2 documentary Speed Dreams and some guys on the Oldskoolsuzuki Facebook group, said I was gonna build a flying mile bike for Pendine sands and got some great offers from people I've never met. Drove up to Waltham Cross on Saturday to meet an OSS stalwart called Ian Foxton. Had a brew and drove to his workshop , where we unloaded some goodies from me to him. Main one being a very old, very small, lathe that needed some brackets making and the drive motor mounting to make it work. Once we'd unloaded the Passat and stopped admiring the Katana and EFE in his workshop, we drove to his lockup in Barnet. There, he presented me with a virtually complete GSX1100 engine. It turns out it wasn't just any GSX 1100 engine. It came with a standard EFE cylinder head( bigger valves and ports than the earlier engines). We then went to his mums garage, where he gave me a rusty Harris exhaust system, a Bandit 1200 swingarm and an undamaged ET headlamp unit.

Well today I managed to unload the parts and got to work stripping the engine for cleaning and checking. The good surprises just kept coming!!!

http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1267.jpg
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1259.jpg
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1260.jpg
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1261.jpg
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1262.jpg
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1259-1.jpg
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1260-1.jpg
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1261-1.jpg
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1262-1.jpg
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1265.jpg
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1266.jpg
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1268.jpg
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1269.jpg
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1271.jpg
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1272.jpg

Have removed the head and block and will be splitting the cases very soon to clean out all the oilways and give the crankshaft and gearbox a good check over before rebuilding it.

Offline megawatt

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Gonna build a Flying Mile GSX1100
« Reply #23 on: January 28, 2013, 07:14:21 PM »
Made some progress this weekend. Got talking to some of the guys featured in the BBC2 documentary Speed Dreams and some guys on the Oldskoolsuzuki Facebook group, said I was gonna build a flying mile bike for Pendine sands and got some great offers from people I've never met. Drove up to Waltham Cross on Saturday to meet an OSS stalwart called Ian Foxon. Had a brew and drove to his workshop , where we unloaded some goodies from me to him. Main one being a very old, very small, lathe that needed some brackets making and the drive motor mounting to make it work. Once we'd unloaded the Passat and stopped admiring the Katana and EFE in his workshop, we drove to his lockup in Barnet. There, he presented me with a virtually complete GSX1100 engine. It turns out it wasn't just any GSX 1100 engine. It came with a standard EFE cylinder head( bigger valves and ports than the earlier engines). We then went to his mums garage, where he gave me a rusty Harris exhaust system, a Bandit 1200 swingarm and an undamaged ET headlamp unit.

Well today I managed to unload the parts and got to work stripping the engine for cleaning and checking. The good surprises just kept coming!!!







GSX1100ET headlamp and lockup clutch with crankcase extension!!!







Standard GSX1100 clutch baskets are known for turning into tambourines and eventually exploding when used in tuned drag race engines. This is compounded by Suzuki fitting helical drive gears to the clutch and crankshaft. The solution is to replace the gears with straight cut gears and the clutch backplate with a billet steel one. All riveted together and the rivet heads welded to the backplate. This mod would normally cost at least ?300 to ?400 !!!




Another drag race mod is to replace the standard GSX oil pump gears with GS750 items. These run faster, providing more oil for cooling!

« Last Edit: January 29, 2013, 07:36:24 PM by RFdemon »

Offline fatbob

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Gonna build a Flying Mile GSX1100
« Reply #24 on: January 28, 2013, 07:17:18 PM »
jammie git :lol:
It\'s a trucking life for me.

Offline welshbandit

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Gonna build a Flying Mile GSX1100
« Reply #25 on: January 28, 2013, 07:59:31 PM »
Someone`s been a lucky boy. Bet all your christmas`s have come at once. If it`s sponsorship you want why not ask the boys to chip in what they can. Not saying it`s going to be a lot (cause thanks to the goverment tossers were all skint) but it all helps.
SheepShaggers L.T.D.

Offline megawatt

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Gonna build a Flying Mile GSX1100
« Reply #26 on: January 28, 2013, 08:02:45 PM »
It might come to that when I work out what I need to complete the project. The engine didn't come with clutch springs or rocker cover bolts, so if anyone has any GSX bits lying around ???

Offline busa ash

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Gonna build a Flying Mile GSX1100
« Reply #27 on: January 29, 2013, 09:05:31 AM »
looking good , full speed ahead :wink:

Offline megawatt

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Gonna build a Flying Mile GSX1100
« Reply #28 on: January 29, 2013, 04:41:54 PM »
Found a bit of time to split the engine today and have a look inside. Started by removing head and block, alternator and ignition covers. Then remove anything inside the engine that stopped the top and bottom halves being seperated. At the back of the clutch are a couple of retaining plates that need removing and another one that needs the oil ways blasting through with degreaser and compressed air.





Then it was time to remove all the M6 and M8 bolts from first the top half


.
Then the bottom half.



The engine is normally split with the top half upside down on the bench, retaining the crankshaft and gearbox in place.

Next job was remove the fabricated sump and undo the main bearing bolts hidden inside. Note; the sump fabricator has put his initials in there, a good sign.




sump filter was nice and clean. Also housing modified for racing.


Removed the last two M8 main bearing bolts and tried to seperate the two halves. No joy!!! Did anyone spot the deliberate mistake?

Look at the right hand side of the gearbox? Yep, left an M6 allen bolt in there!!!! Removed it, flipped engine over, couple of taps with a mallet and voila!


 
   Found one slightly galling problem when I split the casings. A small piece of loose aluminium in the top half.





   It's the cam chain guide holder, but I can fix or replace it. Other than that, all looks pretty good.

   Later I started cleaning gasket goop off the sealing faces and cleaning up the M6 threads.

    More tomorrow or Thursday !!! Phew!!!

Offline welshbandit

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Gonna build a Flying Mile GSX1100
« Reply #29 on: January 29, 2013, 06:31:34 PM »
Great thread Mega, following this with interest, top man on the camera too.
SheepShaggers L.T.D.