Featured Grab Yourself Some Popcorn. This Might Take A While.

You can get black nitrided forks, but they cost a kidney to buy a set.

 

So after what seems like an age in discussion between myself and the engineering company I've been dealing with, we finally decided to go with Plan B, my original proof-of-concept self designed bracket (as opposed to Plan A of fabricating a one off CAD machined tail tidy, it being the most elegant yet the most expensive option). This was a difficult part to conceive as it meant calculating the relative position in space of the rear exhaust bracket, as it would have been positioned both fore and aft and vertically, to exactly mimic the original termignoni bracket, but crucially allowing me to fit the Evotech tail tidy. To this end, we elected to go with a carbon infused 3d printed part, that I could trial fit, before commiting to fabricating the final part in 316 3mm thick stainless steel. Test fitted the POC bracket tonight and pleasantly surprised that my design works surprisingly well albeit requiring a small 5mm adjustment. Here is a sneak peak of the test bracket in place. Some modifications to beef up the stand off spacers to cross brace them and that aforementioned tweak and I should be good to go to finalise fitting and completion of the D200 exhaust system.Very happy with what started off as a sketch six months ago on a napkin, has been validated. More pics will follow once the final bracket is ready.

 

A little free time today, spent applying some heat reflective foil to the back of the Termignoni heat shields. Fiddly and time consuming job, but happy with the results.





Termignoni logo is actually airbrushed on.. No decals here.

 

Yes correct, it's not a sticker, but airbushed work by my local painter. He's done a lot of paintwork for me over the years and was responsible for the bodywork on the last project and a few of the parts on this one, including a very special piece that is currently in the works for this bike.

 

So the last of the MotoCorse parts have finally arrived (a big thank you to Steve @Conquest Racing Ltd). The first being the side stand and also the titanium bolt. I have a couple of other parts to fit but aside from that, the bike just needs an oil top up and test firing (once the exhaust bracket is complete and I can fit the remainder of the system then I'll be nearly home and dry.







Here's the MotoCorse titanium side stand bolt





And now fitted to the bike. The new side stand is a little longer than stock (which is much better) as for some reason on later bikes, with the OEM one fitted, the bike used to lean over a loooong way on it's original stand which never filled me with confidence!







Almost there now.

 

Understatement of the year! Yes can't wait to see what it sounds like.

 

Remains to be seen. I will know once I've ridden it. What I do know is that with the stock system on it in Italy at WDW2024, it burnt my right inner thigh to the point where I had to get off it for twenty mins, though I was wearing only kevlar jeans at the time, not leathers and it was 34ºC. Hopefully, from past experience, the titanium system will run a little cooler, though the pipework is much higher up and closer to your legs, so we will see!

 

So I finally collected the new exhaust bracket and spacers today. Now in 316 stainless steel and 3mm thick so very sturdy indeed. Almost identical to the original 3D printed version save for a 5mm forward adjustment of the lower two hole centres. This means I can now fit the rest of the exhaust system (barring the main right hand carbon heat shield, due to a missing spring - see my wanted post elsewhere on this forum) which cannot be fitted with the heat shield in place. Parts and waiting on replacements is, I swear, the Nemesis of this build!

Here's the 3D printed bracket, you saw previously, alongside the final stainless steel bracket, some of the corner radii were changed to increase strength further.





A pretty simple process to actually fit it to the bike. The spacer height took some working out, as I had to take into account the thickness of the Evotech tail tidy, between where the spacers meet it's surface and the contact point of the tail tidy onto the subframe underneath, as well as the relation of the whole assembly to the original Termignoni bracket, as well as rotating the supplied exhaust clamp through 90 degrees, as a part of the design, to keep the rear pipework in the same relative position.



With the tail tidy now securely bolted into position, I could finally bolt in the GPS/DDA unit for good. Pro Bolt M8 x 20mm stainless steel bolts



Unlike the Akrapovic system, the Termignoni offering requires a LOT of adjustment and a degree of "persuasion" to get the alignment correct. This was the result of an hour or so's work, after many many trial fittings, but happy with the result. Also fitted the left and rear carbon heat shields. Though you won't see much of the latter, as the number plate will obscure most of it. The green tape on the tail tidy, is merely to hold the number plate light in position temporarily, which the number plate bracket ordinarily does.



And with the number plate and it's bracket fitted. (Registration obscured using some poetic licence).



Here's a view from the left, perhaps a better angle from which to see there's plenty of clearance from the number plate, so no danger of the exhaust gases or the hot pipework melting it (I hope).

 

Last of the anodised parts to go on the bike (well last but one actually). This time it was this CNC Racing rear wheel cone. The only reason I am replacing the OEM red anodised one, is the anodising they used is not as good and has a very opaque shade to it, almost washed out. The new one contrasts much better against the carbon wheel. I also replaced the original wheel nut with a titaniuim one from Addiction Motorsport. For now the nut is only partially tightened as both it and the sprocket side nut will need to be torqued to spec at some later date and the new locking rings fitted, before I ride the bike again. I will post up some pictures of the cone in situ in the next day or so, as I ran out of time today.



Starting to look a lot more purposeful now.

 

Some more progress after work today. Here's the replacement rear wheel cone fitted, that I mentioned yesterday. Rear axle nuts have yet to be torqued to spec and the lock rings can then be fitted.



RHS Termignoni heat shield finally in place (having managed to obtain a replacement spring and sleeve, which were omitted from the full system kit). I appreciate the Termignoni system is not to everyone's taste and since I am not a lover of the Akrapovic underseat offering with its "legs akimbo" silencers and because I have already experienced the under belly Akrapovic system on my last V4, I wanted to try something different. This is not the easiest of systems to fit but not exactly difficult either, compared to some of the other work I've done to this bike.



Hopefully the lengthy process of fitting this heat reflective foil, will pay off and not only protect the carbon but also my legs from being par-boiled.





With the last heat shield now fitted, this is 99.9% of the mechanical work now complete. All that's left is to tension the chain, torque a few parts to spec, run the bike and top up the coolant and oil accordingly, then I can start putting it's clothes back on.

 

It's not the most elegant part, but I think once the bodywork is back on, it will detract it from the eye somewhat.

 

So bike had it's first engine start today, after the stripdown and started first time on the button. Initial impression, aside from how good it sounded, was that it's fookin' loud! Unfortunately, my excitement was cut short, as whilst there appeared to be no oil or coolant leaks, it does appear to have a small fuel leak from where the hose from the tank attaches to the fuel rail. I have checked the clips but strongly suspect it is the hose that needs replacing (as the service manual suggests if the tank has been removed). Parts are already on order and it is a quick fix, so once done I will post up a video of the "second bite at the cherry" It's put me back a week but I would rather be sure it's right rather than fuel leaking onto a hot engine (which will never end well).