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

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RC45
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Re: RC45's Project-NS500 Replica - Pukka NS500 Rear Wheel!!!

#76 Post by RC45 » Thu Feb 27, 2014 2:54 am

And yet another wrinkle appears .. :smt010 :smt009

The NS500 rear wheel is too wide for the trick HRC NSR250 F3 swing arm - and I am not going to be machining the NS500 wheel, so it is off to find a suitably sized donor swing arm.

1 step forward and 3 steps backwards, yet again LOL :shock: :eek: :grin:

And some extra research has shown this wheel to be from an ex-Team Maclean RS500, not an NS500. Which is still ok - its a perfect condition 4.00 x 18 Comstar. Got a set of Avon Vintage race tires on the way.
Last edited by RC45 on Sun Mar 02, 2014 2:55 pm, edited 1 time in total.
CBR1000RR SP2 HRC WSBK
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RC45
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Re: RC45's Project-NS500 Replica - Pukka RS500 Rear Wheel!!!

#77 Post by RC45 » Sun Mar 02, 2014 2:57 pm

I am not exactly sure what I will do with them, but they seemed like a good purchase to make - this trio of unused HRC Keihin PE34 magnesium bodied carbs.

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CBR1000RR SP2 HRC WSBK
TZ500V/OW53 Track bike
YZR500 OW81 Clone
OW69 Daytona 200 Replica - 784cc Monster
NS400 Track Bike
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TZ250T 2KM
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rd84
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Re: RC45's Project-NS500 Replica - Trio of magnesium HRC PE3

#78 Post by rd84 » Wed Mar 05, 2014 9:36 pm

Hope this is of interest - I spotted this on the Chris Ambler Race Fabrication Facebook page........

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https://www.facebook.com/ChrisAmblerRac ... on?fref=ts

Cheers
Paul

RC45
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Re: RC45's Project-NS500 Replica - Trio of magnesium HRC PE3

#79 Post by RC45 » Thu Mar 06, 2014 4:22 am

Very interesting. A bespoke tank and all.
Last edited by RC45 on Thu Mar 06, 2014 7:33 am, 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

RC45
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Re: RC45's Project-NS500 Replica - Trio of magnesium HRC PE3

#80 Post by RC45 » Sat Mar 08, 2014 12:28 am

I will take small wins where ever I can.

It turns out that the sprocket dimensions of the HRC RS500 is the same as those of 5 bolt Marchesini wheels - and it just so happens that the rear wheel of the OW81 YZR rep is a Marchesini - and I have a couple AFAM sprockets for it... and they fit :)

Image

It is not much, but the huge 18" rear wheel shod with a 170/60/18 sort of looks the part/

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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

RC45
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Re: RC45's Project-NS500 Replica - Marchesini sprocket fits!

#81 Post by RC45 » Sat Mar 08, 2014 3:13 am

Finally - the great Comstar spoke bolt mystery solved.

Here is a picture of the fasteners HRC thought where good enough for GP500 use (and GP125, GP250 & F1)

They are nothing more than bolt, alloy washers and a flange lock nut.

My conclusion then is that for track use I will not even bother with any special bolts to lace up 16", 17" or 18" wheels from now on.

According to the RS500 owners manual, tighten Comstar spoke bolts to 14-18ft-lb.



The bolt on the wheel
Image

A stock NS400 bolt and nut with nuts welded on to ease removal
Image

The HRC RS500 bolt, washers & nut
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

RC45
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Re: RC45's Project-NS500 Replica - Custom engine cases??

#82 Post by RC45 » Mon Mar 10, 2014 10:08 am

In my obsessive pursuit of an NS500 like bike, I am determined to have the correct pipe layout - 2 up and 1 down.

After looking at all sorts of options to achieve this, I think it will be simplest to just have new engine cases made that reverse the cylinder layout.

So now the question is whether to go CNC or sand cast... and the answer will lie in whether anyone else is interested in a set of such cases.

If no-one else sees value in such a set, then a 1 off CNC exercise is the way to go. However, if 1 or 2 other brave souls wanted to have proper layout engines in their NS projects, it might make sense to get 5 sets of cases sand cast.

So - anyone else crazy enough to want a 2 up, 1 down set of NS cases???
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

rd84
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Re: RC45's Project-NS500 Replica - Custom engine cases??

#83 Post by rd84 » Mon Mar 10, 2014 11:06 am

Why don't you contact this specialist NS400/500 company in the UK to see if they are interested in joining you on a 500 crankcase project ? .......

http://www.classicracereplicas.com/company.asp?ID=68

Cheers
Paul

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Re: RC45's Project-NS500 Replica - Custom engine cases??

#84 Post by RC45 » Fri Mar 14, 2014 9:36 am

Have visited with foundry & patter maker - this part of the project is going to be pretty expensive and take a while. Realistic time frame is about 2 years to do this on a reasonable budget.

Pattern maker will work with me during off peak times to create the GP-style custom case patterns and cores. In the mean time the rest of the build progresses.
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

begbie
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Re: RC45's Project-NS500 Replica - Custom engine cases??

#85 Post by begbie » Fri Mar 14, 2014 4:10 pm

Intresting, If going the trouble of making custom cases, why not design in some different cylinders ? guess one problem is the NS stroke of 50.6.
May be have the crank stroked by 3.4mm then use Rz350 barrels for 525cc or the Athena Rz392 cylinders 68mm bore for 588cc, this would make big lazy power
or RGV 250 barrels use a 50.6 stroke and have separate heads, these can be taken out to 150cc each, bit mor of a screamer and powervalve linkages to deal with.

RC45
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Re: RC45's Project-NS500 Replica - Custom engine cases??

#86 Post by RC45 » Sat Aug 16, 2014 7:22 am

Well - in an effort to jump start the NS500 build I have bought a hopefully running NS400 to use as a rolling test bed for suspension, bodywork and engine ideas while the NS500 dream motor slowly comes together.

Bought it sight unseen of eBay on the chance it is a decent bike - if nothing else I get a full set of electrics and some decent spannies out of the deal :) Should be here in 2 weeks.

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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 - Custom engine cases??

#87 Post by oktrg500 » Sat Aug 16, 2014 8:20 am

Nice. Great to see some action again in this thread.

RC45
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Re: RC45's Project-NS500 Replica - Custom engine cases??

#88 Post by RC45 » Mon Aug 18, 2014 6:08 pm

Yep - trust me, every time I walk into the garage the stalled NS500 stares me right in the face, taunting me, teasing me - spitting at me :)

In true motorcycle addict style I decided to "show that bike whose the boss...." - I simply spent more money :lol:

I also fixed all the images that imageshack stopped resizing.
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 - Marchesini sprocket fits!

#89 Post by wolfgangh » Sat Aug 23, 2014 7:46 am

RC45 wrote:Finally - the great Comstar spoke bolt mystery solved.

Here is a picture of the fasteners HRC thought where good enough for GP500 use (and GP125, GP250 & F1)

They are nothing more than bolt, alloy washers and a flange lock nut.

My conclusion then is that for track use I will not even bother with any special bolts to lace up 16", 17" or 18" wheels from now on.

According to the RS500 owners manual, tighten Comstar spoke bolts to 14-18ft-lb.



The bolt on the wheel
Image
This works for the outer bolts for the rims only, how did you replace the inner bolts on the hub? They need to have smaller diamter inside. For the conversion of a 16" ns400r front wheel to 17" you are required to use the original hub with rear wheel spokes and rim. Someone must have made replacement bolts already, I am keen on buying a set

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ns86
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Re: RC45's Project-NS500 Replica - running NS400 inbound

#90 Post by ns86 » Sun Aug 24, 2014 12:23 am

I'll second that. Have my rim conversion parts but I need bolt's as well. Like wolfgangh, I have been searching a long time. Any help appreciated
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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