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Last page update was 12 Jan 2006

Fisher Fury Build Progress - October 2004

1st October

The rest of my electrical bits arrived from Vehicle Wiring Products , so I can now work out how the indicators and hazards are best connected. This is an unexpected challenge but all is now clear, having seen how the hazard switch works.

2nd October

Popped into Halfords for something for the wife and picked up a fuel filter while I was there. Noticed that they also sell crankcase vent filters in amongst the other bits in their 'go faster' section and picked up a Ripspeed one.

4th October

Richard  popped back home with me at lunchtime to have a look over the engine and answer a few questions for me. He's offered to help with the sump baffle fitting and clutch spring upgrade, this months main build activity.

8th October

Ordered a YEC race clutch spring from Orwell Motorcycles , my local Yamaha dealer for £61.95 inc. VAT.

9th October

Spent some time looking at the air box and removing the trumpets from it to allow the air filter to be mounted. Also spent resolved the remaining issues I had with the cooling system plumbing. Decided to leave the thermostat housing in situ, rather than relocate it.

11th October

Sylva  has put some more R1ot  pictures and details up on their web site. This is an very light-weight track car with R1 power. I wish Sylva would spend a bit more time on the bodywork, though it is growing on me and would be very easy to improve, seeing as there is so little of it. This could be made into a stunning looking machine with really good aerodynamics, as very as having stunning performance and handling. A little too extreme for my requirements though. The first magazine review  seems to rate it highly.

12th October

Spent an hour and a half this evening looking at the wiring loom and circuit diagram for the R1 engine. I have now identified and labelled all the connectors and have a much better idea of what is going on. More importantly, I now know I have all the bits I need, to get the engine running. There are a few interesting points to have come out of this work though:

13th October

Picked up my YEC clutch spring. Ordered a sump baffle and tulip from All Bikes (Tel. 01303 248444) for 75 including the VAT.

16th October

My All Bikes sump baffle arrived this morning. Not the tidiest bit of metal work in the world but it does the job and save me having to design and make one. Cleaned it up with a dremel and some wire wool to make sure no bits of metal will come off in the engine.

Started my investigations on how to fit a sandwich plate, on which I intend to mount an oil temperature and pressue sensor for the Digidash unit. Also spent 20 minutes with a tooth pick, straightening the fins on the R1 radiator. Then took off the AIS bits and pieces. The engine looks really bare without this on.

17th October

Had a look at the donor steering column this morning. Used an angle grinder to cut off the unwanted bits and tidied up with a file, as an angle grinder is not the best tool to get a good finish with. I dismantled it completely and checked over the bearings. It is good condition and is amazingly simple in construction really. The bearings run so freely that I'm sure the feedback through the steering is going to be better than my Elise.

I also prepared the diff for shot blasting. I used a hole cutter to cut two 62mm diameter wooden plugs and tie wrapped through the diff to block the output shaft holes. I used a bit of silicon sealant to make this oil tight. I also screwed a bolt into the vent hole.

Spent some time cleaning the engine up and removing some more bits. Put it on the scales and it came in at 65.6Kg.

18th October

Took the tilt sensor apart to see how it works and to see whether I should leave it in the car.

19th October

Ordered a sump gasket, four exhaust manifold gaskets, an oil filter and some radiator top-hat mounts that were missing, from Orwell Motorcycles , my local Yamaha dealership.

23th October

Collected parts as ordered from Orwell Motorcycles . Got to say I'm well impressed with the service from this outfit so far. If they are planning to keep my business, they are going about it the right way.

24th October

Found an odd hour to look at the radiator mounting. Using Richard's design as inspiration, I cut out a radiator shaped hole in some MDF to act as a template for my final version in aluminium. The objective is to force all the air through the radiator by mounting the radiator on a flat plate and providing a shaped 'duct' for the incoming air. The design works quite well and I made up some radiator mounts using 26mm lengths of 25mm x 25mm x 3mm thick, right angle. Some lenghts of 25mm x 25mm x 1mm right angle surround the radiator seal around the edges where it sits in front of the mounting plate. This plate will also carry the 100mm diameter, air box intake ducting mount and my twin horns. It's solid, multi-functional and very light. One unexpected discovery was that my radiator is warped slightly. Fortunately, it doesn't make any difference to my design.

Also looked at the paddle shift mounting bracket. I've spoken to Stuart Taylor  and they want 200 + VAT + 12 carriage for their design. Sounds a lot but it really is well made and could save me hours of work. Despite this, I feel the need to have a go at making my own, so I've dug out some large lumps of aluminium from my box of metal bits, with a design in mind. This is going to clamp to the top of the steering column, which is 42mm in diameter.

I'm starting with a 70 x 50 x 20mm block of aluminium, which will have a hole cut in the middle and will then be cut in half horizontally to clamp round the column, using 8mm holes in the top half into an 8mm thread in the bottom half. The pivot will be two 8mm bolts (in the vertical plane), above and below the centre of the steering column. Something like this rough diagram in fact. If it all goes horribly wrong, then a call to Stuart Taylor  will be in order.

25th October

Made up my paddle shift steering column clamp this morning. Simplified the design slightly to make it quicker to fabricate. It now uses 6mm through bolts. It looks good and is very light and solid. Need to find some 5mm carbon fibre sheet and some suitably sized right angle extrusion to make the mount for the paddle.

26th October

Bought some 100mm diameter aluminium air ducting and a 12mm drill bit from B&Q. The drill bit is to finish off my paddle shift clamp and to allow the clamp bolts to be recessed within it.

27th October

Took my differential to be shot-blasted this lunchtime. It is cheaper to paint it but this makes it lighter :-). I've found a place that does small shot blasting jobs for cash, is cheap and also very close to work. There is a powder coating workshop next door which is also going to be handy later on.

Finished my paddle shift steering wheel clamp but I'm not happy with it. It isn't going to provide the quality feel that I want. Whilst looking at other options, I cut out a rough MDF paddle shift template, to allow me to experiment with a few ideas. One idea I was looking at, was to tap holes directly into the steering column but the material is not thick enough. This line of thought led me to a much better idea though, which I am now making up.

The plan is to drill two shallow 2mm holes in the steering column, in a vertical plane to allow two 6mm bolts (which I've machined to a 60° point), to clamp in these holes and to act as the pivot. This means the clamp and pivot are now integral to the paddle shift. This requires an 10mm thick aluminium ring with a 50mm internal diameter and a 100mm outer diameter. The carbon fibre paddle will be shaped as shown and will be attached to this pivoting ring. This solution is incredible strong, highly adjustable and will have the quality feel I was looking for. Better still is is going to be very light. The rod attachment, connected to the engine gear lever, will be bolted to the paddle shift lever.

The only question I have with this design is, can I mount it close enough to the back of the wheel? It must within easy reach. I will need to acquire a boss and wheel next to check this out.

28th October

Picked up my differential at lunchtime. It looks like new. 20 well spent.

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