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2012 AK sled build


Mostly getting it ready to ride. Once the bodywork is done I'm going to take it down to the bare chassis to clean/inspect it and I want to weigh a few things. Then reassembly taking weight off where I can for minimal cost. My rough to do list...

-I need to install the aluminum bolts
-Shave some of the castings off the block and install some aluminum hardware
-DH mountain bike handlebars
-Aluminum banjo bolts for the brake
-Titanium front engine mount bolts
-Make a couple CF brackets (turbo & oem gauge brackets, and my shield at the back of the seat) to match the bodywork strictly for aesthetics.
-Fix some steering geometry issues
-Probably pull the turbo apart to inspect it
-Maybe alittle rewiring.

I really want to have it done for the start of the season. Once it's ready to ride I'll probably build rear skid arms to drop some weight (easy 5 lbs) and Id really like to get the CR 37" front end or build my own 36" since I already bought all the rod ends and tube adapters.
 
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Started coating the clutch side now that the braces are done and it's all trimmed. Need to add a second coat and then I'll sand it same as the other side.

 
I've been working on the panels quite a bit. Coated both of them again so now I need to sand them and do the final coat. Here's the clutch side in the sun.


I've only worked with fiberglass in the past which blends all the seams when you sand it down. The Kevlar doesn't do that so the seams will be visible even though the panels will be perfectly smooth. Lessen learned. I decided to leave the seams and keep the carbon look rather than mix pigment and have solid black panels.

Got my new bars yesterday. 318 grams at a full 31" wide. Once they are cut to 29" they should be under 300 grams.


The clamp is area is 31.8 mm so I had to order some 1-1/4" aluminum clamps. I'll have to build a flattop post but I was going to build a new post anyway.
 
Those look alot like mountain bike bars. I just but an old set on my my son's 120. The bars are light & strong as hell!
 
That's amazing!

I can't wait to see the finished product.

Now, will you have to cut openings into it to get air into the engine?
 
I will cut openings. Once I finish the sled and decide where I want the vents I'll cut everything out and do the final coat of resin.
 
Drew gets a big I told ya so from 2013...

I inquired about smaller exhaust holes with yamaha and they said premature flex joint failure was common due to lack of ventilation and excessive heat. Just passing on what I have heard.
Click to expand...

I had lots of heat and one cracked flex pipe so far. Need to inspect the other two closer. I'll be opening up the holes.
 
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