[ASTOBBS]

This is an abridged version of my rs125 aprilia project.

Bought bike for £300



In that state, got down to some cleaning, this is the float bowl, I've no idea what that stuff is




Much cleaning later, and I got my wheels powdercoated




Did minor porting to the cylinder and had it replated


Spent some time matching up the cases and eventually got the bottom end built, totally re-conditioned


Decided I needed to shed some weight, so set about ditching all steel parts (except bolts, sprockets, chain and brake discs etc.)
in aluminium, the rear subframe went from


to




The engine cradle went something like this









The clocks frame I 'welded' up using durafix rods, here is the steel

and here it is in the end


At some point I finished the engine and got it bolted in



Had fairings painted


Stuck the decals on


Made an exhaust hanger (used to hang from pillion pegs)


It looks kinda like this now, this pic was taken a while ago with steel rear subframe, and the black seat fairings have now been swapped for silver, plus all the above.





This didn't happend is the exact order above and has taken 18 months, I'm still not finished either.
Full thread can be found here
Old shape total rebuild - Tj Tuning Motorcycle Forum

[flatbeat]

nice work m8y love them bikes

[Leeky]

Very, very good.

Did you machine all the metal yourself, or did you get it done to your own designs? Or did you use kits?

[ASTOBBS]

Did all the cutting of metal myself - think machining is too stronger word, the only tools in the aresenal where, drills, hacksaws and files - and a blowlamp for annealing things. The welding on the rear frame was done by a local guy with TIG.
Every piece has been made from scratch from bought box section/pipe/angle and some salvaged sheet metal.

No kits exist, and to my knowledge I am the only person with an Alu rear subframe, certainly yet to find anyone else with one, have seen one other clock frame, and one other engine cradle - but not on the same bike.

The weight saved;

-890g from engine cradle
-600g on clock frame
-120g Alu handlebars over steel
-2800g on rear sub.

Not a great deal in car terms (or bike terms) but every little helps.

[Leeky]

Well you've done an outstanding job, and you clearly have the patience with it all.