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

Sub forum for NS400R owners and enthusiasts

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RC45
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Re: RC45's Project-NS500 Replica-custom Comstars come togeth

#46 Post by RC45 » Mon Apr 01, 2013 11:35 am

A more classic NS500 look.

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Last edited by RC45 on Mon Aug 18, 2014 6:28 pm, edited 2 times in total.
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RC45
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Re: RC45's Project-NS500 Replica-custom Comstars come togeth

#47 Post by RC45 » Sun Apr 14, 2013 11:10 pm

Finalized testing dimensions and fitting of R1 Brembo floating 320mm rotors to 17" front Comstars.

Redo the model exactly to R1 rotor specs. Next stop, the CNC machine to make the carriers.

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Last edited by RC45 on Wed Feb 26, 2014 3:27 am, edited 1 time in total.
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Re: RC45's Project-NS500 Replica-custom 320mm floating rotor

#48 Post by matteoitr » Mon Apr 22, 2013 3:54 pm

This job is totally jawdropping!! If it can be usefull to you, i'll scan some pages of racers n.1

http://www.amazon.co.jp/gp/product/imag ... 92&s=books" onclick="window.open(this.href);return false;

RC45
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Re: RC45's Project-NS500 Replica-custom 320mm floating rotor

#49 Post by RC45 » Mon Apr 22, 2013 8:08 pm

matteoitr wrote:This job is totally jawdropping!! If it can be usefull to you, i'll scan some pages of racers n.1

http://www.amazon.co.jp/gp/product/imag ... 92&s=books" onclick="window.open(this.href);return false;
Thanks, that was one of the pictorial resources that inspired me. My copy of the NS500 Racers is getting well dog-eared with the amount of time I spend reading it.

In fact, it lives in the crapper ready for careful review when nature calls :)
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Re: RC45's Project-NS500 Replica-custom 320mm floating rotor

#50 Post by matteoitr » Tue Apr 23, 2013 2:59 am

Hahah same as me

RC45
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Re: RC45's Project-NS500 Replica-custom 320mm floating rotor

#51 Post by RC45 » Wed Jul 17, 2013 12:57 am

Comstars are off to Kosman for widening. A spare NS400 motor is on the water.

Slowly but surely the NS500 is taking shape.
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Ronnie
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Re: RC45's Project-NS500 Replica-custom 320mm floating rotor

#52 Post by Ronnie » Wed Jul 17, 2013 2:41 am

Have you worked out how you're going to move the rear pipe yet to get the right NS500 look?

RC45
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Re: RC45's Project-NS500 Replica-custom 320mm floating rotor

#53 Post by RC45 » Wed Jul 17, 2013 6:39 pm

Ronnie wrote:Have you worked out how you're going to move the rear pipe yet to get the right NS500 look?
I think so. All it will require is for me to become a master exhaust welder :)
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Re: RC45's Project-NS500 Replica-custom 320mm floating rotor

#54 Post by RC45 » Sat Jul 20, 2013 3:34 am

WIP photos of the prototype disk carrier machined from 6061. Will try pick it up tomorrow and test fit and verify correct. Then have a pair machined out of 7075 alloy and anodized dull Honda gold.

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Last edited by RC45 on Wed Feb 26, 2014 3:28 am, edited 2 times in total.
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Re: RC45's Project-NS500 Replica-custom 320mm floating rotor

#55 Post by RC45 » Sat Jul 20, 2013 10:15 pm

The prototype fits great. A couple little tweaks need to be made to the CAD drawing and off to the CNC system again then to design he caliper hangers.

Stock NS400 compared to new rotor
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The 320mm disc
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Last edited by RC45 on Wed Feb 26, 2014 3:33 am, edited 1 time in total.
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Re: RC45's Project-NS500 Replica-custom 320mm floating rotor

#56 Post by oktrg500 » Sun Jul 21, 2013 12:40 pm

I like your attention to details. Thanks for the update.

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Re: RC45's Project-NS500 Replica-custom 320mm floating rotor

#57 Post by RC45 » Sun Jul 28, 2013 2:23 am

Just managed to secure an awesome piece of media... an RS500 Owners & Parts Manual - can't wait for it to arrive :)

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Re: RC45's Project-NS500 Replica-custom 320mm floating rotor

#58 Post by RC45 » Sat Aug 03, 2013 4:58 pm

The RS500 owners manual has arrived. Makes for an interesting read. Since the RS500 made it to the US and Euro GP circuit the manual is English/Japanese - a much easier read than the TZ250 and RZV500R parts manuals.

According to the book, the RS500R in stock 1983 form was good for 120PS (118hp) minimum @ 11,000rpm
and 8gk or torque @ 10,500rpm. Dry weight was 125kg.

Add the 31l of leaded fuel, 1/2l of transmission oil, appropriate amount of radiator fluid, misc. fork/shock fluids and its probably still around 132kg or 290lbs or so.

The big question is there any way to get close to 100hp from even a 500cc version of the NS400 motor? The Honda quoted power figures are also more than likely output shaft numbers rather than rear wheel numbers.

Oh, and stock gearing is good for 116mph in 1st :)

The crankcase exploded views will help with the idea I have for the 2 extra sets of NS400 cases I managed to scrounge up :)
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RuZty
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Re: RC45's Project-NS500 Replica-custom 320mm floating rotor

#59 Post by RuZty » Sun Aug 04, 2013 10:03 am

There was an article in one of the UK mags in the last 6 months, I think Performance Bikes, that had a write up on a big bore NS400 and IIRC it is available as a kit, don't remember the HP. I don't think I bought it but if I find it I'll scan the article. Love these projects of yours, keep up the good work.

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

#60 Post by RuZty » Sun Aug 11, 2013 9:39 am

OK, got the year and magazine wrong. Practical Sportbikes May 2012. None of this may be news to you and the HP is less than what you are after, but might be worth a look. The builder is here; http://www.classicracereplicas.com/company.asp?ID=68
Links to readable full size pics under each image.

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http://i105.photobucket.com/albums/m206 ... g~original

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http://i105.photobucket.com/albums/m206 ... g~original

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http://i105.photobucket.com/albums/m206 ... g~original

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http://i105.photobucket.com/albums/m206 ... g~original

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http://i105.photobucket.com/albums/m206 ... g~original

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