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Guzzi 1100 custom build

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    Posted: 16 Jan 2022 at 11:34
thought I would start a thread on the build of my Guzzi 1100...  not sure on the final look yet...  but it will be a comfortable bike, so no clip ons!  this is my first Guzzi build, but i have 9 Ducatis under my belt!

Here it is as it came, and what's left after I took all the parts off I know I wont use...





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Post Options Post Options   Thanks (0) Thanks(0)   Quote Buzzer Quote  Post ReplyReply Direct Link To This Post Posted: 17 Jan 2022 at 10:18
As you can see not much progress at the moment, that's because I am finishing off my last build...  However I did have some time to spare to make some Bell Mouths for the Keihin carbs I will be using on this build.  I made them using the old method of metal spinning in the lathe.  At first I just made them open, but when I thought about it I wanted some gauze on there.  It took a bit of thinking about to come up with a method of attaching it that looed neat.  here is the result, and a link to a video of how I did it!









Edited by Buzzer - 17 Jan 2022 at 10:23
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Post Options Post Options   Thanks (0) Thanks(0)   Quote paulbricey Quote  Post ReplyReply Direct Link To This Post Posted: 17 Jan 2022 at 11:01
They look beautiful & great work (love the bellmouth turning !)..... wish I had the skills & a bigger lathe....wish the engineer monkey on my back wouldn't scream 5 micron air-borne particles Wink
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Buzzer Quote  Post ReplyReply Direct Link To This Post Posted: 17 Jan 2022 at 14:11
Originally posted by paulbricey paulbricey wrote:

They look beautiful & great work (love the bellmouth turning !)..... wish I had the skills & a bigger lathe....wish the engineer monkey on my back wouldn't scream 5 micron air-borne particles Wink

Do you think we have the same MonkeyBig smileLOLLOL  mine keeps saying "fit filters, fit the filters..." TongueTongue
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Brian UK View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Brian UK Quote  Post ReplyReply Direct Link To This Post Posted: 17 Jan 2022 at 16:08
There is no doubt filters are fitted for a very good reason.

Brian.

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Post Options Post Options   Thanks (0) Thanks(0)   Quote Buzzer Quote  Post ReplyReply Direct Link To This Post Posted: 31 Jan 2022 at 09:50
Time to make some silencers(lose word!) I bought these cheap stainless ones off eBay as the hard part in making silencers is rolling the cone… and they are expensive to bye. I cut the end off, removed the inner resonator tune and made some cones for the end. this makes them re-packable for the future. I can also fit the baffle for MOT time.

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Post Options Post Options   Thanks (0) Thanks(0)   Quote Buzzer Quote  Post ReplyReply Direct Link To This Post Posted: 12 Feb 2022 at 13:57

Up on the hoist for the first time… I have temporarily used a build stand that I have used for Ducati’s, but I will have to make a specific one as this one will impede making the exhaust fit on the bike. First job has been to make some inlet manifolds to fit the carbs… I wanted them angled upwards and inwards, and that took some working out to get the compound angle right! it ended up as 68.5 degrees. As the carb diameter is larger than the head inlet, I needed to use a tapered tube… To do this I turned up a tapered mandrel, and after annealing the alloy tube, I pressed it in with the vice, which expanded the tube by the required few mm. I then turned a grove to accept the lip inside the carb mounting blocks.

 

the next bit was actually quite difficult… I needed to make the hole on the flange a nice fit on the tube, but at an angle. I deliberately cut the 10mm plate quite large so I could get it mounted on the milling machine at the exact angle. I then bored the hole with an indexable boring head. If that milling machine looks old, it is! I did some work on it a few months ago and found a date… 1929!

 

Next job was to TIG weld the flanges on, drill the holes, and finally cut to shape.

 

here is a short video of the manifolds being made...

 

https://www.youtube.com/watch?v=-2EfrVdAiKo

 

 

 

 

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Post Options Post Options   Thanks (0) Thanks(0)   Quote R100CS Quote  Post ReplyReply Direct Link To This Post Posted: 12 Feb 2022 at 17:31
1929 those were the days things were made to last, not use once, throw away and buy a new next time.
1st R100CS flattened by a truck
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Buzzer Quote  Post ReplyReply Direct Link To This Post Posted: 14 Feb 2022 at 11:32
Originally posted by R100CS R100CS wrote:

1929 those were the days things were made to last, not use once, throw away and buy a new next time.

yep, I replaced the miller a few years ago with a new one...  but went back to the old one within a month as the new one was so poor...

a little side track as I had a new facing cutter for my milling machine and wanted to try it! I took the top yoke off and removed the section where the ignition switch fits… and milled it flat. I then contoured the edge to blend it in. Those power files are a great piece of kit, something i bought thinking I may not use it much, but I use it all the time! Then into the blaster to clean it up, it can wait a while for polishing….


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Post Options Post Options   Thanks (0) Thanks(0)   Quote Buzzer Quote  Post ReplyReply Direct Link To This Post Posted: 15 Feb 2022 at 18:35
One thing I hated about the bike was the side stand… Just how agricultural is that bracket! I know its a great functional design, but its SO ugly!  so out come the angle grinder and it is no more!  In the loft (or as my wife calls it the spares department!!) i had a side stand off a 1994 Honda CBR 600…  it bolted straight on!  Just need to adjust the angle a little when the ride height has been set.  a job for much later on...

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Post Options Post Options   Thanks (0) Thanks(0)   Quote Ken-Guzzibear Quote  Post ReplyReply Direct Link To This Post Posted: 15 Feb 2022 at 18:38
The Ev /Cali long side stand was designed for Police use ( Some Harleys use exactly the same stand) It means you can operate it with a boot from the saddle and once deployed the bike will not be knocked over by the wind blast of a passing truck. 

The bracket is designed so it allows the bike to lean furthermore there can be an additional gismo that operates a secondary rear calliper to effectively add a park brake, used mainly on the Convert auto box. 




Edited by Ken-Guzzibear - 15 Feb 2022 at 18:41
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Brian UK Quote  Post ReplyReply Direct Link To This Post Posted: 15 Feb 2022 at 21:18
Beauty is in the eye of the beholder, as they say.
Brian.

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Post Options Post Options   Thanks (0) Thanks(0)   Quote Buzzer Quote  Post ReplyReply Direct Link To This Post Posted: 17 Feb 2022 at 10:00
Originally posted by Brian UK Brian UK wrote:

Beauty is in the eye of the beholder, as they say.

That is so True Brian Big smile

yesterdays job was to mock up the exhaust... I had ordered some 2" mandrel bends and straight pipe as I wanted that chunky look, and for the pipe to fit straight into the silencer with no reducer. From a performance aspect, the large headers are probably not I deal... but I wont miss a few BHP! I also wanted that angled swept back look (old School!!) The bends are 135, 45 and 30 degrees. It should all polish nicely as its stainless steel. This bike will have more forward mounted foot rests, hence I could kick up the silencers earlier...

I find making exhaust systems quite therapeutic, although sometimes I could do with a third hand. My wife used to help, but since I burned the back of her hand with the hot end of the filler rod, all help has been withdrawn!LOL



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Post Options Post Options   Thanks (0) Thanks(0)   Quote johnno Quote  Post ReplyReply Direct Link To This Post Posted: 17 Feb 2022 at 12:52
Pipe work  Thumbs Up
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Ken-Guzzibear Quote  Post ReplyReply Direct Link To This Post Posted: 18 Feb 2022 at 12:06
Nicely done on the zorst do you tig it?
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