KR-1S.co.uk Forum

That was my thinking Fred. It's going to be matched to swingarm, so tolerance is going to be tight.

We'll see in due time if there are any issues from the design and I'll correct if required.

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suzuki use same arrangement on VJ22 vj23 (male rail on swingarm)...

Slot fits on rail on swingarm

92 GSXR swingarm - female rail this time...

That makes sense, less parts, less cost, less weight

My KTM Superduke has a similar setup aswell if its any help and they have alot of small calipers

http://i.ebayimg.com/t/KTM-Adventure-95 ... ~60_12.JPG

My fabricator should be getting a new set this week, which means the fuel cell can be made and I can also finish the fabrication work off on the frame.

I think I mentioned this earlier in this thread or somewhere else, but I wanted to utilise the air scoop on the right hand side of the fairing.

To make the best of it, I decided to route the ducting through the frame, which will fan out into the airbox.

I made up an oval insert and started cutting the required size hole in the frame.

The bit I thought you might find especially interesting, was seeing what's inside one of these frames.

The "E-Box" as Kawasaki call it, is a reinforcing spar joined to both sides of the frame, providing extra strength and rigidity.





Obviously cutting this hole in the chassis compromises the structural integrity, so reinforcement needs to be added to put back what I've taken away.

brave man cutting a hole in the frame,love it mate

Looking spot on Ben!

Very suzuki rgv250 vj23 the shape of that hole! Is that where you took your inspiration from?

Regarding the frame, I doubt that it will have weakened it that much. Material nearest to the neutral axis is hardly under any load at all. Look at castellated beams, hardly any material in the centre of the beam. The greatest loads are at the furthest point from the centre hence that's where all the material is.

I think simply welding the oval piece in place will suffice. I prepare to be shot down by other members though haha.

Keep up the good work

Dan

brave man cutting a hole in the frame,love it mate

Too right........

I had to look twice at that though Ben Makes me feel better at having a go at repairing my 'merely' dented Tzr frame.

I wouldn't be brave enough to cut a hole in it though

I took my inspiration from the TZ to be honest Dan, but have seen other examples of later proddy 2-stroke 250's where they have run air feeds through the chassis.

From an engineering perspective, the part I'm having welded back in place will provide the strength it needs.

I want to be pushing the boundries with this build and in doing so, making at times what seem to be drastic or radical changes to the KR and getting out of our comfort zones .

Ben i think i love you a little bit and hate you just the same , i was happy ammassing parts to build one standard kr1 one for best and one to use for sunny work transport but i have now been in the loft with a tape measure and the lap top looking at and marking up one of my frames , git . er i mean love this thread =D>

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can you imagine rocking up to race with a mini aquarium and fish in place in that hole

I'm just going to grumble about the VJ23 a bit...
left and right cylinders - okay KRs have different barrels too - its a Vee they can be identical
but what was Suzuki thinking with...
left and right pistons (the right barrel is twisted out of plane of crank by 5° or so)
left and right reeds (actually the reed is the same but slotted holes to match 2 different bolt patterns)
the crankcase halves look like they were made by different companies with different skrinkage allowances

will that get t tube through ,if you offset the obrounds youle get a straighter run

fred wrote:will that get t tube through ,if you offset the obrounds youle get a straighter run

I'm totally not understanding. What are you asking Fred?

Hi Ben,

I think Fred was saying that the run would be straighter if you had cut the hole through the frame at an angle to avoid the right angle in and out of the frame.

Cheers,
Bernie

just me thinking aloud if the cutout on the outside of the frame was 2" infront of the inside cutout would be in same plane as the air feed ,looking realy realy good ,i rekon a tig welders going to be on your crimbo list this year