The "Whoa..Orange" Build - Suzuki SV650 Forum: SV650, SV1000, Gladius Forums

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Old 08-20-2014, 10:41 AM   #1
jk0311
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The "Whoa..Orange" Build

This has been a long time coming. Lost of false starts and life interfering with my grand plans for my SV rebuild. Now it seems I finally have the resources and solidified idea to begin this build. Follow along and comment if you like. I posted here so ya'll could post vs the non posting build section. Constructive criticism, advice, sarcastic banter is welcome.

My SV looked like this when I got it...




It had an R6 subframe and tail, trailtech headlight, 2nd Gen engine converted to carbs, GSX-R 1K forks, and what looks to be a ZX-10 shock (?) among other mods. The PO did some things a bit different than I would have so that prompted my build plans. The dropped intake valve helped my decision process as well.

Planned mods...(subject to change)
Engine rebuild, cam swap, bumped compression
Yoshimura full system headers, R77 can
Refreshed carbs with Ivan's Jet Kit
LSL crossbar handlebars
Triumph Daytona 675 Subframe/tail
Ducati Monster headlight
House of Kolor Gamma gold w/ Tangerine candy on the tins

Progress thus far: The tank, tail, and fender have been stripped, cleaned and sealed in epoxy primer, awaiting block sanding and paint.





Im going to start fabricating the brackets for the subframe this week. Modification of the lower subframe tubes will be necessary and it gives me an opportunity to try out my new Miller welder!



Frame needs to be stripped bare and repainted. Need to clean up wiring harness as well...





More to come
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Old 08-20-2014, 11:26 AM   #2
DRAGON61
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Re: The "Whoa..Orange" Build

Quite nice when you started but looking forward to the transformation!!
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Old 08-20-2014, 02:00 PM   #3
jk0311
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Re: The "Whoa..Orange" Build

More progress...

Trimmed the lower subframe legs and mocked up subframe and seat. Now to figure the brackets. Any thoughts? The lower legs will be welded to new lengths once seat angle and height has been decided. I am considering just making some new mounts from 1/2 Alum and welding them on the frame after removing the old mounts.






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Old 08-20-2014, 04:58 PM   #4
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Re: The "Whoa..Orange" Build

Good start, quite spiffy. Really like the Triumph tail sections in general, I can't wait to see what it looks like.
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Old 08-21-2014, 08:25 AM   #5
jk0311
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Re: The "Whoa..Orange" Build

Thanks. Im hoping to get all the metal work done in the next week or so. Anyone have any idea what shock that is? I think its from a ZX10 and it is really close to the swing arm which concerns me. When i say close I mean just a few mm close.
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Old 08-21-2014, 10:04 AM   #6
Liquidxen0n
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Re: The "Whoa..Orange" Build

05-06 kaw 636 shock
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Old 08-21-2014, 10:49 AM   #7
jk0311
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Re: The "Whoa..Orange" Build

Quote:
Originally Posted by Liquidxen0n View Post
05-06 kaw 636 shock
I dont believe so...

https://www.svrider.com/forum/showthr...t=80387&page=7

Just found this thread and it would seem (if the sources are correct) that I have a 04-05 ZX10 shock. Why I didnt find that thread earlier is beyond me. Thanks for the input though. If I had not stumbled upon that thread I would have gone right along with ya
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Old 08-21-2014, 11:31 AM   #8
morgantm
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Re: The "Whoa..Orange" Build

Quote:
Originally Posted by jk0311 View Post
I dont believe so...

https://www.svrider.com/forum/showthr...t=80387&page=7

Just found this thread and it would seem (if the sources are correct) that I have a 04-05 ZX10 shock. Why I didnt find that thread earlier is beyond me. Thanks for the input though. If I had not stumbled upon that thread I would have gone right along with ya
You are correct. The 05-06 636 is similar in color and the angled reservoir but it is still a little different

636

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Old 08-21-2014, 12:09 PM   #9
jk0311
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Re: The "Whoa..Orange" Build

Any fitment differences that would be significant? Im not worried about batt tray clearance just fitment in the swingarm, spring rate, ect.
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Old 08-22-2014, 07:11 PM   #10
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Update

Mocked up brackets for the subframe mounting points today. Basically just took a piece of 1/4" MDF and cut/ sanded until I got a shape that flowed with the lines of the frame and then I drew what I had made in my CAD/CAM software. Ran a test cut on the CNC to make sure my CAD design matched my hand made model and now were ready for the 6061 AL versions. Should cut those Monday and get em burned in by Friday. Sorry for no pics, was a bit busy and forgot the camera.

Any of you guys weld onto the SV frame before? Im wondering how the cast AL will do... Happy Friday!
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