RC45's Project-NS500 Replica - RS500 mudguard/screen found

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RC45
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Re: RC45's Project-NS500 Replica-custom - RS500R Owners Manu

#61 Post by RC45 » Sun Aug 11, 2013 2:23 pm

Thanks - Ian had to mentioned the magazine test. Great to get hold of the pages, thanks for sharing.
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Re: RC45's Project-NS500 Replica-custom - RS500R Owners Manu

#62 Post by hopit88 » Tue Aug 20, 2013 5:33 pm

First, I LOVE this project for reasons I'll get to later.

I'm kicking around an '83 Factory 750 Interceptor build that will use some spare 1000R wheels I have. I've seen the 400r guys re-lacing wheels to get a 17x3.5 front but haven't been able to source the hardware. What would you actually call the bolt's? A long shoulder bolt and shoulder nut? I think most places would think I was crazy. I see guys doing this mod and they're getting their bolts from somewhere other than where you got yours but where? Ive been on a Japanese site where a guy shows the bolts but the translation is less than useful. Thoughts?

Step by step on removing the stock hardware would be incredibly helpful.

On the R1 test rotors, they obviously don't just bolt on. Custom carriers? Any way to make another set?

Anodized or powder coated on the rims?

Sorry, I know it's a lot at once.

That NS500 has been a favorite of mine since I first saw them(yes, I'm that old) and used it as a basis, along with the early RVF endurance racers, for my '85 VF1000R build I recently completed. Not an NS replica but a tip of the hat to that great looking bike.

My R.
Image
Image
Image
Going for something like this...
Image

I cannot wait to see your NS get completed and you can see why I'm a fan. The end product is going to be a dream machine of mine.
Last edited by hopit88 on Thu Aug 22, 2013 6:47 pm, edited 1 time in total.

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Re: RC45's Project-NS500 Replica-custom - RS500R Owners Manu

#63 Post by gpaddict » Wed Aug 21, 2013 9:21 am

That's beautiful!

rd84
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Re: RC45's Project-NS500 Replica-custom - RS500R Owners Manu

#64 Post by rd84 » Thu Aug 22, 2013 7:01 am

Nice bike - looks fantastic quality !

Cheers
Paul

RC45
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Re: RC45's Project-NS500 Replica-custom - RS500R Owners Manu

#65 Post by RC45 » Tue Oct 01, 2013 8:54 pm

Well, I have another VF1000 rear wheel that is about to donate its rim to the cause. In an effort to make removing the spokes less of a mission, Randy, the fabricator extraordinaire I have been privileged enough o work with has proposed a novel approach.

Tack weld a nut to each screw head and then unbolt them normally.

Almost too simple when you see it from his perspective :)

As for the rotors, I am in the final stages of test fitting and getting carriers CNCed up. If you are interested I can get a second set done at the same time.

The carriers would attach to the Brembo vintage cast iron rotors using Brembo floating rotor buttons and clips.

You would need to source the donor Brembo rotors and the button kits.

Your VF1000 looks amazing!
hopit88 wrote:First, I LOVE this project for reasons I'll get to later.

I'm kicking around an '83 Factory 750 Interceptor build that will use some spare 1000R wheels I have. I've seen the 400r guys re-lacing wheels to get a 17x3.5 front but haven't been able to source the hardware. What would you actually call the bolt's? A long shoulder bolt and shoulder nut? I think most places would think I was crazy. I see guys doing this mod and they're getting their bolts from somewhere other than where you got yours but where? Ive been on a Japanese site where a guy shows the bolts but the translation is less than useful. Thoughts?

Step by step on removing the stock hardware would be incredibly helpful.

On the R1 test rotors, they obviously don't just bolt on. Custom carriers? Any way to make another set?

Anodized or powder coated on the rims?

Sorry, I know it's a lot at once.

That NS500 has been a favorite of mine since I first saw them(yes, I'm that old) and used it as a basis, along with the early RVF endurance racers, for my '85 VF1000R build I recently completed. Not an NS replica but a tip of the hat to that great looking bike.

My R.
Image
Image
Image
Going for something like this...
Image

I cannot wait to see your NS get completed and you can see why I'm a fan. The end product is going to be a dream machine of mine.
Last edited by RC45 on Tue Oct 01, 2013 9:01 pm, edited 1 time in total.
CBR1000RR SP2 HRC WSBK
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OW69 Daytona 200 Replica - 784cc Monster
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Re: RC45's Project-NS500 Replica - Prototype Rotor Carrier..

#66 Post by RC45 » Fri Oct 11, 2013 2:06 pm

The 'rapid prototyped' brake rotor carrier has arrived. I had http://www.quickparts.com" onclick="window.open(this.href);return false; use my CAD drawings to create a SLS resin part.

3D Model
Image

The 3D model translated into the full size item perfectly. This way there is no need to machine multiple CNC prototype parts. Now that the sizing is done, the same 3D model will be used to create the CNC tool paths for the end products.

Real life resin part
Image
Last edited by RC45 on Mon Aug 18, 2014 5:58 pm, edited 2 times in total.
CBR1000RR SP2 HRC WSBK
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two-stroke-brit
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Re: RC45's Project-NS500 Replica - Prototype Rotor Carrier..

#67 Post by two-stroke-brit » Fri Oct 11, 2013 2:21 pm

i wonder if 3D printing would be a quick cost effective method for prototype work like this.
(not for actual use just test fitting etc)

:-x DOH (just looked at there website)
ill get my coat :sad:
She might not be pretty but always a fun ride !!

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Re: RC45's Project-NS500 Replica - Prototype Rotor Carrier..

#68 Post by RC45 » Fri Oct 11, 2013 2:29 pm

two-stroke-brit wrote:i wonder if 3D printing would be a quick cost effective method for prototype work like this.
(not for actual use just test fitting etc)

:-x DOH (just looked at there website)
ill get my coat :sad:
:)

They do 3D printing on an industrial scale hehe. Although the SLS process used to build this part is actually 'laser beams shooting into a pool of resin' and creates larger and far more durable parts than any hobby/home 3D printer could produce.

You can have the part prototyped in a number of different materials depending on the test requirements.
I needed a part strong enough to mount and carry the iron rotor without breaking. I chose an ABS like resin.
CBR1000RR SP2 HRC WSBK
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Re: RC45's Project-NS500 Replica - Prototype Rotor Carrier..

#69 Post by RC45 » Sat Oct 12, 2013 7:44 am

Well, this is why we prototype and test before committing to manufacture :)

First full fitting of re-laced 3.5"x17" Comstar, RS250 forks and the custom 320mm floating rotors. There are clearance issues
Image

Back to the drawing board - either I compromise and run 2 piston floating NS400ncalipers or I re-design the rotor carries and machine custom triples clamps (based on the RS250 layout) to widen the forks so the calipers can clear the spokes and the rotors can clear the fork legs.
Last edited by RC45 on Mon Aug 18, 2014 5:59 pm, edited 1 time in total.
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Re: RC45's Project-NS500 Replica - Comstar, rotors and calip

#70 Post by two-stroke-brit » Sat Oct 12, 2013 5:22 pm

bummer :smt010
She might not be pretty but always a fun ride !!

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Re: RC45's Project-NS500 Replica - Comstar, rotors and calip

#71 Post by RC45 » Sat Oct 12, 2013 6:13 pm

I have been thinking that since low weight was the goal, perhaps the lighter 2 piston floating calipers combined with the lighter over all weight of the finished bike, aggressive brake pads and braided hoses along with the extra leverage of the 320mm rotors might offer excellent braking potential without adding yet more weight by way of larger triple trees and calipers.

Although if I had the triples trees machined from magnesium....

LOL - it never ends.
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Re: RC45's Project-NS500 Replica - Comstar, rotors and calip

#72 Post by gpaddict » Sat Oct 12, 2013 6:42 pm

Isn't that the dead on truth about true customs, you clear one hurdle, only to find that you've created two more obstacles in it's place to deal with!

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Re: RC45's Project-NS500 Replica - Comstar, rotors and calip

#73 Post by RC45 » Sat Oct 12, 2013 7:10 pm

gpaddict wrote:Isn't that the dead on truth about true customs, you clear one hurdle, only to find that you've created two more obstacles in it's place to deal with!
Yep - in fact this is exactly where Honda stood in mid 80's as they designed the RS250... the switch from 1 caliper to 2 calipers coincided with their switch from Comstars to magnesium wheels.

Image

The uniform spoke thickness of the mag wheel allowed the mounting of 2 4 piston calipers.

In order to replicate an NS500/RS500 I really need to widen the forks - if I have any hope of keeping the Comstars and using the 4 piston HRC F3 calipers I have.
Last edited by RC45 on Mon Aug 18, 2014 5:59 pm, edited 1 time in total.
CBR1000RR SP2 HRC WSBK
TZ500V/OW53 Track bike
YZR500 OW81 Clone
OW69 Daytona 200 Replica - 784cc Monster
NS400 Track Bike
RS250R NF5
TZ250T 2KM
TZ250B 3YL
TZR250 3MA Track Bike
427ci C5 Z07

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Re: RC45's Project-NS500 Replica - Comstar, rotors and calip

#74 Post by ns86 » Wed Feb 12, 2014 2:06 pm

RC45, Would you know of a source where I can get the bolts to do the vf1000r rim conversion. Have the rim's need the bolts! Thanx
1985 RZ500
1986 RG500
1986 RG500 C
1992 RGV500 WW ATR
1992 RGV500 LS
1985 NS500 Spencer p
1989 TZR500 Biaggi p
1984 RZV500 Rainey p
1994 NSR250sp R
1983 NS250 p
1987 RG250 WW p
1983 RG250 p
1988 YSR50 p

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Re: RC45's Project-NS500 Replica - Comstar, rotors and calip

#75 Post by RC45 » Wed Feb 26, 2014 1:46 am

I am 1 wheel closer to a complete rolling chassis.

A great authentic piece of NS500 kit just arrived. Pukka 18" HRC NS500 rear wheel :)

Image
Image
CBR1000RR SP2 HRC WSBK
TZ500V/OW53 Track bike
YZR500 OW81 Clone
OW69 Daytona 200 Replica - 784cc Monster
NS400 Track Bike
RS250R NF5
TZ250T 2KM
TZ250B 3YL
TZR250 3MA Track Bike
427ci C5 Z07

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