Make yerself a cup of tea, its a long few posts for yer all to catch up.
 
My latest project I got few weeks ago. Wasnt planning another project, but it just kinda happened.  Got garage full as is with my VW trike, Harris, n Ninja fighter, but hey ho. Was at the right price and just round corner from me.
 

 
Had been sat outside n well weathered. Everything either rust or brush painted hammerite. Nice. Been sat for a year as had an electrical problem. Him n his mates couldnt sort it so gave up and it just sat in corner of shed in bits and several boxes. Tank got damaged from kicking about on floor. Few dents n a big ass dent underneath n tap snapped off. Why do I buy these things? Well its a 2004 bike and it was only £400, round corner and still had T&T on it and a few nice bits like braided hoses, renthals, high level race pipe, brand new discs F/R, Chain n sprockets, n stack of spares like brake pads another chain, etc, etc.  
 
Original plan was to break it, or just get it running n flog on for small profit as a tatty winter hack for someone. Got it running within an hour n phoned him and left a message on his machine of it revving away quite happily.  He wasnt too chuffed, but hey ho Im good at electrics too.
 
Anyway one thing led to another and decided to keep it n build a drag style bike out of it like this:-
 
http://streetfightercafe.com/images/6-17-2007.jpg
 
A style I havent done before. Always built streetfighters to handle n thought it would be something different. Completely pointless given I live on a remote scottish island with next to no straights, but miles n miles of twisty empty mountain roads with no traffic lights/junctions/cameras, etc. But hey got other bikes sitting there for the twisties, might as well build something different n silly. Show up local chavs imprezas n knee slider brigade up Stornoway who just ride round n round n round town centre all day............... when its sunny of course.
 
Right quick catch up via pics, cos cant be arsed typing every stage of it so far.
 
Stripped it down using a grinder as all bolts rusted solid! :-
 



 
Found some of the exhaust studs were welded onto collars as were snapped. Bodgetastic!:-
 

 
Sorted out loom properly as it was nothing but loose wires n selotape when got it as owner n mate had been attempting to `fix` it:-
 

 
Me mate Yantosh cut out damaged section on underneath of tank, built it back up n put on a new boss for the tap, which I got out of my mates junk pile:-
 

 
While it was there some mods for fuel return were done to allow fuel to be pumped back into tank above fuel level through one of original breather tubes underneath. Reason to be explained later in pics. lol. :-
 


 
Got this fresh GSXR750M motor (last of oil cooled models) offf a mate in exchange for a cut price lid paintjob for his girlfreind:-
 

 
Came with big 36/38mm slingshot carbs too, and matching CDI pack:-
 

 
Straight out of running healthy bike as he upgraded to 12 lump. 102 rwbhp stock n good 110-115 with some jetting n fiddling. Good strong lump n in good nick. So good in fact I sort of got carried away n bought this for £49 delivered:-
 

 
Bargain and in full working order with no play or owt. Correct airflow CFM and A?R ratio, etc to match engine characteristics. All turbo specs required off FastByMe who certainly knows his stuff. On standard motor at low boost to keep it reliable will give bout 150-160 rwbhp n vertical torque curve. Keeping it geared down to 150 flat out in 6th gear too, so will be damn quick acceleration. Yantosh is making my plenum and exhaust headers in exchange for paint too. Keeping costs down. lol.
 
Got a drag spec bandit 12 swingarm coming from Yantosh in exchange for some airbrushing on the SF mag project SV650. Underbraced and some one-off 6-8" extentions to keep front end down.......... hopefully. Might stick on some wheelie bars too. If yer gonna be silly, might as well be properly silly.  
 

Removeable frame section:-
 


 
Flame licks come round to between downtubes too:-
 

 
Had stack of stainless gate bolts sitting doing nowt. Dirt cheap compared to stainless hex heads n available from local farmers shops for pennys. Had some sitting so less to spend out. lol. Turned down some frame fixings for removeable frame section on my lathe...................not. One £15 drill n £15 grinder n bit of wet n dry later.
 

 
Spring washer behind head to hold while tighten rear nut n voila!
 

 
Look cool n cost nowt. Original nuts were so rusted up had to grinder em off. lol.
 
Bodywork gonna be same theme as frame obviously. Blue true flame over bio-mech n skulls, etc. Spraying engine block next and polishing up casings, etc ready to slot into frame. Going to apply some airbrushing to engine block too. Going for organic complete look for bike. Even clock inserts will be airbrushed up to match paintwork.
 
Gonna be a very quick bike in a straight line which is what Im after just for the laugh of it. Gonna be cheap too. Had spent £450 between bike n turbo, but cleaned up original swingarm n 2K blacked it n sold it to a mate for his bandit:-
 

 
Few quid in pocket. He had a new front sprocket n nut I needed sitting spare too. Result.
 

 
Also sprayed up a mates lid black for him for another couple of quid bringing total down to £400 again. Set to drop again tho as just sold B6 engine, carbs, cooler n CDI to another mate. lol. Gonna be a cheap one thats for sure. Few bits to buy yeah (fuel pump, regulator, oil lines) but I`ll find em cheap or biker barter for em. Pikey............me?? lol.
 
I`ll add updates as go, but this is a long termer for me. In no rush whatsoever. Treating it as a hobby n doing odd hour here n there to relax. Want to build something nice on a serious budget just to show it can be done. Just a lot of time n patience.
 
Right off to let me typing fingers cool down............
 
Lemmie know what yer think so far. Workin on a budget of next nowt so being inventive. lol.

Nother wee bitty today. I`ll clearcoat engine n previous engine bits in next few days with comission stuff to give it a gloss finish again.  
 
Airbrushing on tho. Also found out engines had a rebuild n freshen up before I got it. Result!
 
Side of block:-
 

 
Few wee licks ere n there. Runs round to carb rubbers:-
 

 
Some Bio-mech n flames on flat bit of casing above clutch cover:-
 


 
T`other side more of same really. Few wee licks:-
 


 
Wee bitty above starter housing:-
 

 
Not so much on this side, but this side will be getting the generator cover and starter motor artwork done the other day bolted on so will balance out.
 
Still battling tryna get clocks apart. Tiny little rusty damn screws into plastic casing so going slow n steady tryna get em out. One left. lol.
 
Right thats you guys up to date to where I am. No rush project but doin an hour a day or so to chill out after airbrushing for a living all day. lol. Yeah I know airbrushing to relax from airbrushing for a living. lol.
 
Updates to follow as go. So far tho stands me £250 all in. All bike there n bits to come paid for in exchange for airbrushing, etc (long swingarm, plenum, headers). Few bits to buy like fuel pump/reg. Hoses, etc. Should be cheapola 150-160 bhp bike tho. Fearing it for 150 flat out so acceleration should be interesting. lol.

thats some crazy airbrushing
 
great work. I will be keeping an eye on this project

kool project man, love those true flames, wish I had your skill, gonna look the nuts!

Awesome looking build, will watch with great interest.

looks cool man. i will be watching this project. keep up the good work.

yup

She's looking great J. i must bring you a turd to polish this winter. oops... that should have read- my tank and frame to spray to match my shiny swingarm.

Ta rusty. Wee bitty ere n there, but lookin cool so far.
 
Yeah Rob bring yer stuff accross on ferry somepoint. Can 2K black it for ya. Strip bike n bring me parts accross. lol. Come accross for weekend n can take em back sprayed with ya.  Fill yer car with everything needing sprayed black n can do it all together. Take em back accross n reassemble. Easy peasy.

Really impressive  
 
Its gonna look very original with the airbrushing.  

Very good Jon... heard that this bloke ain't bad either... http://www.pitstop-paint.co.uk/   Ahem.
 
One thing that worries me though is all that paint going on before a dry build... turbo, up-pipe and plenum all going to fit okay?  

Front end gonna be slammed low like back so space at front where tubby would normally be will be handy for cooler/intercooler as wheel clearance will be lot less.  
 
Loadsa space for plenum back there tho without HUGE airbox. lol.

Nice work mate  

holy shit jon, your here as well.
zippy.

i reckon hes bored and if theres any more "lols" i`ll call him mitch........

Quote from andyp on 22. Sep 2009 at 22:46:

 
Yeah I get everywhere, the whore that I am. Almost as bad a forum whore as Yan.

Quote from Yantosh on 22. Sep 2009 at 23:04:

 
`Leg Over Ladies`, steady on you`ll get him excited.

Quote from Phil-Kat-311 on 22. Sep 2009 at 21:09:

 
Long time no see bud. What times yer turbo R1 running these days? I predicted ultimately high 8`s years back. Wanna know how close my guess was.

Got a photo today of last nights bitty.
 
Casings well scabby n scored/chipped up under paint or what was left of it:-
 

 
Took sander to worst of scrapes n got carried away n sanded off lettering and rounded all edges, etc. Got rid of 99% of marks tho. Couple of tiny marks that are too deep to sand out, but only tiny. Couple hours last night with wet n dry n bitta polish. Need a proper buff with drill but my polishing mops dead so  will have to wait till get a new one to finish them off properly. Looks ok tho:-
 



 
Think smoothy look works quite well against complexity of airbrushing. Nother buff up with a new polishing mop n shuld look ok.
 
Start sanding another cover back tonight. Not my favourite part of a build.  lol.

I am still workin on this project dont worry. Took a step back from it recently as personal problems overwhelmed any inclination to work on it or generally do owt. :hrm  
 
Back on with it again now tho. :upup  
 
Clutch and other crank casing sanded smooth/polished and back on. Starter too! Looks fab. Not sticking altenator on till in frame tho to maximise clearance.  
 



 
Oil filler plug was `slightly` tight! Dont know my own strength. lol.
 

 
In process of stripping cam cover just now. Not sure whether to attempt to polish it or paint it silver as would be a bastard to do and keep shiny under tank. :hrm  All the fins, etc. I`ll fink of what options n make a choice.
 
Not far off engine in frame stage anyway. :wink:  Under cam cover spotless like rest of engine.  
 

 
Valve clearances fine, cam chain looks very new as do guides. Think I got lucky with this engine big time. :coolg  
 
Once cam cover done engines on its way back into frame.

if I remember correctly, very early GSX600F models had an almost smooth camshaft cover. I could be wrong though.

with a sprocket cover like that, your nicely painted engine and alternator will be covered in chainlube and dirt very quickly

Quote from Captain Chaos on 08. Oct 2009 at 19:08:

 
And correct me if I'm wrong but isn't the cover partly there to stop a snapped chain ripping lumps out of the engine casing? Nice build BTW  

Nother bitty today. Got cam cover done n on. Not perfect but best I can do with basic hand tools n graft. Any imperfections wont be seen once coil leads, hoses, bodywork, turbo pipework, etc, etc on. Dont look too bad tho n summit different for nowt outlay.
 




 
Ground down some more stainless bolts and got removeable frame section bolted up properly:-
 


 
Breather cover to clean up, couple frame touchups from getting engine in, and then onto front end next methinks.

Not a lot to report progress wise as not had much free time with work n guff. Cheers for good comments so far tho folks. Keeping me chipping away at it.
 
Cleaning up wee random bits n bobs in spare time tho n sticking em on. Coils took about 2 hours to clean up!  
 
Some eeejit had colour coded them to match rest of bike in 4" brush and red smoothrite. Duh! Scrubbed up ok eventually tho. Found Taylor leads beneath the smeg too which was cool.
 
Cleaning up odd`s n sods so post a proper update somepoint once got something substantial to show. lol. Works just too busy to get anything substantial done so picking away at wee odds n sods. Folk from states posting lids over to get sprayed n all sorts. Good tho.
 
On side note tho PandKG (Pinstriping and Kustom Graphics) magazine are wanting to run a bi-monthly feature on the build focussing on the artwork obviously. Good advertising for business tho as that mag has a feckin HUGE readership worldwide. Got in touch with em about running a small cheap advert n ended up doing editorial. lol.

Quote from Froudster on 14. Oct 2009 at 16:09:

 
He does.

Have been chipping away at this honest!  
 
Coils, tank rubbers, loadsa misc bits, etc cleaned up n on:-
 

 
Rearsets looking bit better than smoothrite n rust originals:-
 

 
Some matching flames/bio-mech airbrushing on wee bits like shifter arm:-
 

 
Sidestand:-
 

 
Shift rod:-
 

 
Footrest brackets:-
 

 
Polished up footrests n removed those horrible 1/2 ton lead weight things on bottom.
 
Tother side:-
 

 
Cleaned up n painted wee bits like frame brace, relay mount bracket, etc:-
 

 
Stripped seat release mechanism as rusted solid:-
 

 
Where Im up to:-
 

 
In middle of chopping undertray up with grinder n smoothing it off to sleeken up rear end. Hate those original snow-plough extensions, lol:-
 

 
Polishing up exhaust can n bracket at mo too:-
 

 
Decided to use some of old exhaust system. Dont really need can on it with turbo as cops/mot guys up here really layed back on loud pipes. Wanna run it tho as a race can so not too quiet, plus turbo will suck up lot of exhaust noise. At least I can go touring 2-up and down south n stuff without getting too much police hassle. Got a Db kliller insert with the bike so can stuff that in for longer trips to keep the plod happy. lol. Nice high level setup too, but can mount it anywhere really so options are open.
 
Box of bike bits I got with it looking sparce:-
 

 
New brake pads x3, 2x new chains, wheel spindles, n brake parts really. Couple indicators, tax disc holder. Not a lot left really to go on.
 
Got rear wheel and front forks/wheel under desk so they`ll be dragged out before long as running out of small bits. lol.
 
Brand new Suzuki discs on both wheel I noticed too. Bonus.
 
Got new bit of lexan through from Yantosh. Cheers bud. Really need to fix borken clutch cover window on Harris somepoint too so can give it a good clean n thrash.
 

looking good.
 
i love your work, keep it up

Not a lot today, but nother wee bitty.
 
Chopped the rear undertray standard snowplough extension off n smoothed out as much bits of it as possible. Looks pretty good.
 

 
Got it mounted:-
 

 
Looks nice n smooth fitment now:-
 

 
Better side profile too. Much sleeker than crappy stock setup:-
 

 
Dug out wiring loom and gixer CDI box so I`ll get that all back on the loom and connected next few days n see from there really.
 
Gave up on cleaning up exhaust can/pipes as not sure 100% where its going on bike yet as options are well open. Might cut it down 6 inch too so gonna have to wait till more bodywork bit on, etc and see how its looking and turbo pipework routing, etc.
 
Nowt left in bits box except brakes n few random suspension bits. Under table is front end and back wheel so looks like theyre next in line so have something to bolt brakes to. lol.

Suppose obvious answer is leave bandit CDI on there, but what diff is it going to make?
 
Its a gixer 750 motor. Was told its an M model, but screw n locknut adjusters in head so must be an L model?
 
Will built in rev limiter on bandit CDI restrict gixer upper rev limit. Not sure what is on these lumps. Reckon its 12,000rpm on bandit n 13,000rpm on gixer, but not 100% model to model.
 
Wont need to rev arse out of it anyway with turbo on there, but wondering if any pros/cons in swapping/not swapping em over.
 
GSXR Techy guru required.

That would be cool bud!  I`ll get a diagram of pin/colour sequence done off bandit loom and can work it out from between the two.
 
Bandit CDI would be easier, but would prefer 750 CDI on there tbh. Should be easy enough to figure out tho.

Been studying gixer manual and swap over looks easy once identify pins/wire colours. Can anyone check theyre bandit/gixer ones for me? Just need summit like above showing pins on CDI, and which colour wire goes to each from loom. Dont need any other info to work it out as have it already here.
 
All looks straight forwards. Few differences between em obviously, but not hard to figure out. Gixer cdi has no TPS wires, no 2 wires to neutral switch, seperate feed to tacho, no seperate power feed to coils and cdi but combined, etc, etc. Once know what pin goes to what colour wire on gixer can chop n solder the wiring about at the CDI connections.
 
Might need to bridge neutral switch wires at worst to make it run. Should work out ok tho.

Cheers bud.  Mucho appreciated.
 
Gotta go airbrush all day, but I`ll sit tonight n work out my wires.

Weeeellllllll. Did a bit of wiring in between clear coating this afternoon. Got everything chopped about engine connection wise, and clock wiring worked out, etc, etc.
 
Looking fairly neat:-
 

 
Tucked front section of loom into headstock area to cut down on wires and connector blocks visable at front once get that together.
 
Took sidestand switch and neutral switch wires down under sprocket cover n up back of engine to neaten up whats on show. Some blue mini zip ties on starter wires, etc too.
 


 
Still need to solder/tape up a few wires, but got a problem!
 
Altenator wires! They dont match connector wise. No surprise as rest of engione connectors didnt match either. Chopped em off went connect up n wire colours are different. Checked manual and they dont even match wiring diagram colours, or give any explanation about what goes where in genny.
 
Heres gixer genny wires on left (one red, and one pinky/orange), and bandit wires on right (one black, and one black and brown).
 

 
Checked in manual and bandit wire colours are red and black/brown. Hmmm. Looked at bandit lump to get an idea n totally different genny. Black wire went onto bolt originally (yellow circle), and brown/black wire went onto one of the pins (red circle) with the other pin left blank.
 

 
Looking at wiring diagrams for both bikes, both genny outputs are live. One connects into wiring/fuse box, etc, and the other connects into lighting circuit. Presumably lighting one is at higher wattage that other.
 
Well stumped with this un. Cant think of way of figuring it out apart from leaving disconnected till up n running then measuring genny outputs to figure it out. Anyone know theyre gixer/bandit genny`s??

Think the alternator on gixers has 2 outputs still. One of which runs a balanced 12V AC output. i.e. have to have right sized lighting bulbs or end up with dim lights or constantly blowing bulbs. Waiting on techy confirmation tho to figure it out. :hrm  
 
Anyone wanna meter test theyre gixer alternator outputs? lol.
 
Came accross this site on my searches which mght be handy for someone not up to scratch on leccy`s.
 
http://www.btinternet.com/~jhpart/bkwirec.htm
 
Might be handy for someone. Breaks it down into primary school language. lol.

Got yer e-mail Jon.
Dunno why your wiring colours are different but someone was messing with it before wern't they?
The black and brown wire on the bandit is the exiter coil, it needs a switched +ve to excite the alternator. nothing to do with the lights, just a handy point to get sw +ve from.
Gsxr is the same, red to battery and "pinky brown" actually orange, to switched +ve.
Keep up the good work.
R.

Cant be to earth bud. Has to be a positive supply to cdi bud with a limited voltage through 100 ohm resister.
 
Gixer cdi pack has a combined positive feed to cdi through switched live to coils feed pin. Set mine up same.
 
I`ll email you what I put to what later on to make sure Ive not cocked up.

cracking thread/build you got here jon.
i not commenting much just reading and watching with the notification on, lol.

After a fookin lovely day yesterday, today its pishin it doon up ere! River of water running down road. Grrrr. :-
 

 
Got Harris clutch cover back on tho after its slight bandit frame interface. lol. :-
 

 
Dragged both bikes out n stood in the rain giving them a damn good scrub up. After about 5 buckets of soapy water I finally found them underneath the grinding n wire brush bandit smeg. I know theyre technically kwaks but bandits my first Suzi n loving it. lol.  :-
 


 
Can sit in the garage to my hearts content in the evenings fettling n polishing them back up.
 
Anyway not much bandit related to speak of as concentrating on getting other 2 bikes cleaned up n running (harris). Trike just needed a wipe over which was cool.
 
With bikes out of garage got space to drag out bandit front end n look it over:-
 

 
Looks like pile of crap same as rest of bits pre elbow grease. Deceptive tho. Brand new suzuki discs on front and back wheels. Only had bout 100 miles of use by previous owner before bike went off road:-
 

 
Took wheel off n stuck to one side with back wheel. Do them after forks, etc together as will be airbrushing centres/polishing them as a pair anyway.
 
So these are the next bits in line to clean up in evenings:-
 

 
Yoke manky but wire brush n paint can sort that. Forks well rusty up top end where they were hidden weathering behind those shitty original headlight brackets.:-
 

 
Removed n binned them as fooked n just plain ugly. I`ll `buy` (against the blood I know) some new light brackets for forks, or solid mount to 2 tags at bandit frame headstock when get to that stage.
 
Bottom halfs of fork stanchions mint tho n unpitted. I`m thinking along lines of shrouding top halfs of forks where bad in metal tubing between yokes to hide the rusty sections. Best option can think of really.
 
Sorry bout non interesting update, but hey ho every builds got boring bits. lol.

All wiring issues sorted now n soldered up. Back on with the build.

Quote from Jon on 23. Oct 2009 at 13:05:

 
It's definately not a +ve feed bud. If you look at the bandit diagram for the ignition switch, in the on position it shows orange and yellow connects to black and white (earth). they dont show the resistor.  
+ve feed to both coils AND cdi is orange and white.

Not yet. Still not convinced the back brake is bled propperly. Might have to drill out the sheared bleed screw. aagghhh! just been told by a mechanic that you should soak em with penetrating oil and hit em with a hammer before trying to unsrew em. too late now.  

Saw previous owner today. Stood gassing about his current bike n him having few problems getting bits as import model, etc. Told him to log on OSS forum to ask for help locating bits, etc. Whats that he says, so just emailed him the link and the link for my bandit thread. Be interesting to see what he thinks when he goes on, as he`s not seen it since went in back of my hearse in pieces to get it home. lol.
 
Did warn him it had changed slightly.
 
Rob get one of those banjo bolts with nipple built in. Less hassle.  Might have a nice braided rear brake line going spare for ya bud.  Dont think my ones gonna reach to end of Yantosh`s long swingarm.

Sat with my wet n dry n autosol tonight n got one fork leg cleaned up:-
 

 
Not perfect, but pretty good. Had a shitload of scrapes n hammer/tarmac dings like engine casings, etc, but most of em sanded/polished out eventually:-
 

 
T`other one tomorrow night. I`ll slap some 2K black on lower yoke when get a chance too n can bolt em back up in next few days.

Thank god for that......................... yer a big bugger, and Im only ickle.
 
Seriously tho, glad yer liking it. Can pop round for a look whenever bud. Know where I am.
 
Scott`s the previous owner folks n a new forum member.

Dunno if you got my e-mail about cooler J, but when i was up in the big shed looking for a sprocket cover for you (not there, Mud must have it on his 750) i found the bandit cooler, it's a bit bashed though, think someone put something on it in the shed. have a look when you come down. yours if you want it.

Quote from Big_Bad_Bob on 30. Oct 2009 at 11:52:

 
Cheers bud I`ll have a looksee. Bandit cooler small so would need 2 for gixer lump. L`s run pretty hot. Yantosh is digging about at his for a gixer one too. I`ll get Butler to do same. Sure can bodge together summit for it without spending stupid money on fancy cooler. Gonna be shrouded anyway so not seen.

Wow

The calipers look a hell of a lot better  

Nother wee bitty today.  
 
Back caliper hanging on bungee as nowhere to put it yet. Getting well excited about my new swingarm tho. Few feet of alloy to polish n fondle. Muwuhahahahaha............
 

 
Put the piccy up tho to show I did actually airbrush the back of the caliper too cos will be visable through wheel from other side.
 
Back mastercylinder and reservoir cleaned up bolted back on:-
 

 
Needs a new brake light switch, but I`ll get one somepoint when ordering other odds n sods.
 
Mounted the freshly painted horn under the tank as a handy spot out of sight and a nice convenient mounting there from original suzuki breather air valve thingy that I dumped when changed engine. lol.
 

 
Front forks back on. Dropped em through the top yoke as far as could till hit the bars. Only bout an inch or so. Would have liked more, but back end will be slammed down so extra rake n stability in straight line aint a bad thing. Starting to look like more of a bike now:-
 

 
Was happy with the look. till me gorgeous missus came out for a look n thought my gaffer tape on the fork tops looked shite............. so under order to re-do it better. lol.  
 
Theres an exhaust place up town (45 miles away!) that stocks length of pipe. Nowt`s easy up here for parts! Couple of quid should net me some wee bits of tube to airbrush up and slide over fork legs to neaten em up. I`ll get some next time up there for shopping. Unbolt top yoke n slide em on so no biggy and will look better ultimately. Like the black look tho of the fork tops n hides the crappy pitted sections.
 
Looks like Im onto wheels next as next to no wee bits left to clean up. Wheels are gonna take some graft to get looking nice tho. Rough as fook, but no worse than rest was n think its coming along nice. Well I like it anyway. lol.
 
 

Nowhere to get alloy tube bud up ere. Steel tube from exhaust place up town is closest thing n 45 miles each way.  Makes life interesting tryna build stuff up ere.  Tank shouldnt hit horn, but can bend about/remake the bracket if needs be easy enuf. Was just a handy spot out of the way.
 
Fork tubes were annoying me tho so went back out to shed n came accross couple of dried up part tubes of silicone sealant. Been sat in wee shed since moved in couple years back n god know how many years before that. lol.
 

 
Mixed with the old bandit headlight bracket rubbers:-
 

 
Chop rubbers in half, cut off ends of silicone tubes, clean out dried up silicone/plunger, etc, simmer for 1/2 hour and serve:-
 

 
Need about 4mm trimmed off n sanded/painted/airbrushed up.  
 

 
Sturdy enuf for covers tho and only bout 2mm bigger than fork legs internally so nice snug fit and most importantly........................FREE!   lol.
 
Linz has started to call me Orinocho. Could be worse I suppose. Could be Uncle Bulgaria! lol.
 
No sign of my intercooler yet cos of post strikes. Hey ho. £265 spent all in so far tho when it turns up.

Nowt wrong with Wombles.