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Terry Shepherd Trellis Frame Sportbike BuildSuzuki TL1000 Engine based custom V-twin sportbikeHistory:A few years back a fellow named Art built a bike based on a TLR motor using a Terry Shepherd designed
and built frame frome the UK. When finished he had a wet-weight somwhere around
360lbs with street lights, compared to 500 for a stock TLR. He also built up the engine and was
putting out somewhere above 140hp.
(I also ended up with my old airbox base and filter coming back as part of the frame kit) Build:Within the first couple of days after picking up the parts at the end of 2007 I had done a rough assembly to start making a list of the to-dos, and there were a lot:
Coming Along:
After some hunting I picked up a set of lightly used Hayabusa Ohlins Road & Track forks with the superbike valving upgrade. Meanwhile I have been working to get the garage outfitted so that I can move my work out there. Once the it was sealed up I begain work on getting an STM slipper clutch adapted to the TLR motor I will be putting into this bike. More details on its own page for this conversion. 2008-07-13 Looking like a motorcycle: After the excitement of the last few weeks I had a few hours to work on the bike again. Mainly this was installation of the spare engine to start getting some measurements for bracketry (rear-sets, radiator, battery, etc) and other critical dimensions (chain length, exhaust clearance, sub-frame fabrication).
2009-01-16 All the major components on: The last few months have seen the construction of the sub-frame, rearsets, and various other small brackets. The fairing (a used CF/Kevlar Sebimoto unit) was obtained, and I have started working on fitting it to the bike. I also picked up a new rear spring (titanium, all of 490g), some lithium cells to build a starting battery, and some Woodcraft pegs and levers for the rear-sets. I still need to come up with some exhaust hangers and a battery box to hold the new starting battery (2lb vs about 8 for the standard lead acid). I also had a chance to weigh it with everything piled on (chain, electrics, fuel-pump) and ended up at 325lb. This would indicate a wet weight of around 365-370lb with a full tank of gas and a few lbs allocated for lights. 2009-02-19 Subframe roughed out: My initial pass at the subframe is done. I still need to do some joint reinforcement with some carbon-fiber thread and resin, but the basic shape and angles are all in place and tacked with aluminum brazing rod. The seat-fairing section sits on a small aluminum frame not-pictured that allows for fine-tuning of the seat inclination angle. 2009-02-22 Starting battery: I finally got around to soldering up the lithium cells to build my starting battery. As is it weighs in at 2lb 0oz, compared to about 8lbs or so for the stock battery. It should have comperable capacity. I have some terminals on order, and will then wrap it up to keep it clean and insulated. I have enough spare cells to build another one with 2/3 the capacity and weight, if it proves sufficient. 2009-02-25 Airtubes formed: I spent a lot of my free time in the last few weeks preping to make the air-tubes. Since the frame is custom and the fairing is from a TLR, there are no commercially available airtubes that will work well with the fairing and get the air to the airbox. The airbox I received with the frame seemed designed to take the air in from just behind the steering stem with a small spout that pointed down to the back of the front tire. I did not like this as it seemed a good way to get crud off the wheel, hot air from the radiator when stopped, and did not take advantage of the air-tube scoops on the fairing. I decided to make carbon-fiber tubes to lead from the fairing inlets to the sides of the airbox. This gave me the excuse to purchase a vacuum pump and build a vacuum bagging system for this and future composite parts. Details of the composite construction on its own page.
2009-05-04 - Test Assembly: Since the last update I have managed to get quite a bit done:
So here are a few teaser pics to fill some space: Final Assembly:I spent the last couple months taking care of all the little niggling aspects that were bugging me: Modifying the fairing for headlights; repainting the frame, swingarm, tank; clearing the fairing, rims, and air system (makes the carbon really "pop", and protects from UV); re-fabricating brackets I wasn't happy with, and setting up all the wiring and lighting. This weekend I started up the final assembly, torquing all fasteners and being quite liberal with the lock-tite. Once I have verified the tank is sealed at the pump, I will mount it up and see if it actually runs. First Ride:
First Track Day:
Specs:345lbs without fuel. 370lbs with 4 gallons. Frame:
Suspension/Steering/Controls:
Brakes:
Drive:
Electronics:
Bodywork:
Setup:
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