FZR Hybrid Project

The teardown

 

 

The custom frame design (see design process here)

 

 

Wheel Fitment:

 

It fits!

 

Now for the frame and swing arm -  paint thanks to Tim Boyd!

 

Now for the rearsets - thanks to our latest sponsor: MotoBits!

This bike is the first FZR to have these custom sets mounted on it - They will be production made from this point on (contract MotoBits for more info, please tell them Pappawheelies sent you)

A little stem modification thanks to Unkl Al of Unkl Al's Custom Emporium

We asked Unkl Al's Custom Emporium weld some material onto a FZR stem in order to lathe it down to the correct dimensions to press it into an R6 triple clamp - without the extra material, the stem would be an incorrect fit with too much play (sloppy!)

Front forks are on...but not done yet

still need to make the collar for the R6 conversion -

Collars are made and on - the front end conversion is complete:

Bodywork was a bit of a challenge - we ended up fabricating a lower 

And because we can - the bodywork balanced to get an idea of how it's going to look:

The bodywork in another stage - still not finished...the lower needs to be modified in order to tip it all downwards more and adjust the lines

Creation of the lower:  This lower was custom fabricated by Louie out of an R6 and TZ lowers

Fitting the pieces:

Fabrication:

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Sanding and detail work:

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Fitted bodywork:

Did you think we forgot about the engine?! 

The intake ports got cleaned up, not finished but it's a start!

 

The new carbs: Keihin FCR 33

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motor on the bench -

we were going to paint it all black but since this is just the stock motor (the superbike motor is still in progress...) just ignore the mis-matched colors and the attempt to scrape off the old black paint...

Shaving weight - ever ounce counts!

 

And it's in!

Now for the custom wiring harness

this is being built from scratch in order to minimize the amount of weight - yes, every ounce counts!  The battery box is temporary as well since the custom-built sub frame won't be ready in time for the first race. 

Suspension links to raise the back of the bike up

These were custom made for us by Daniel 

More harness work - cleaning it up a little

First stumbling block - a FZR400 exhaust won't fit!!

Found a 600 header - we're exhausted (haha)!!

Chris Denzler - notorious Wing Racer, member of the Iceholes racing team and all around fantastic guy - answered our distress call and found a header for us - we owe him a round or 3 at the next get together!!

Front fairing bracket - modified to fit the TZ bodywork

view with the tach and the temp gauge:

made a collar in order for the chain to clear the rear tire

(having friends with machine shops sure comes in handy!  Thanks Brent!)  

bodywork is primered! 

We'll be racing it in primered bodywork this weekend in Spokane

 

2006 saw racing in primer - we never did get around to final paint work on the bike.  But with the motor dialed in and the bike in top running form, 2007 was the year to complete the cosmetics and apply the decals.  Behold:

 

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coming soon: