Guzzi 1100 custom build

[stopintime]

You have earned the right to adjust the factory's mistakes - no worries

Factory Fan Boys without mileage or tools don't impress me much. I understand them, but that's it.

[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://www.youtube.com/watch?v=NoiBIyf7MYY

[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.

[buzzer]

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…

https://www.youtube.com/watch?v=vVhAJ0GDwlE

[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!

https://www.youtube.com/watch?v=TJBqAuzCvzI

[Howie]

just keeps getting better

[ducpainter]

just keeps getting better

Even better would be some color besides orange.

[buzzer]

Even better would be some color besides orange.

its not going to happen  already have the paint for the next Ducati build!

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.

[ducpainter]

its not going to happen  already have the paint for the next Ducati build!

<snip>

That's unfortunate.

[buzzer]

Here is the finished wiring… and the final diagram of which I am always happy to share a full size version. I like to use the braided sheathing rather than the hard PVC stuff of old. I see that many cars and bikes now use it. Its a bit fiddly but if you touch the end on the soldering iron after you cut it, it stops it fraying. Another nice advantage is if you need to pull one or two wires out, you can do by just parting the strands.

[buzzer]

the footrests/and levers are now finished… I pondered how to do the brake light switch and then came upon this neat hydraulic one which bolts onto the union…

[buzzer]

here it is finished...  just waiting on a small part to get it running, which is very frustrating!

[Blackout]

She's beautiful and your work is amazing. What part do you still need?

[buzzer]

She's beautiful and your work is amazing. What part do you still need?

some carb needles and a couple of "O" rings...  Royal Mail strike is not helping...