FZRSupport: the FZROnline Archive

With the way gas prices have been lately scooters are on the move. However they all look the same...BORING! So I've had this old 1984 Honda NH80 lying around my basement in a rubbermaid bin and I finally decided to bust it out. I chucked the frame and front end years ago but kept the motor just in case I needed a project. Since I can't work on the motorcycle swaps till winter, this is it. My goal on this build is $400. So far I'm well within budget but powdercoating isn't going to be cheap. The codename comes from a scooter and chopper mix in case anyone was confused.

The first step was to find a design I liked, which I did after stumbling upon the MadAss scooter from germany. I was looking for a headlight and this popped up.


Now I liked the fact that the gas tank was integrated in the main frame tube and the under tail exhaust. I mean, that is some hot shit. Now, since my 80cc is a 2 stroke I need a place to store the oil as well. So my design turns the seat support into the oil reserve.

Then it was off to find a fork. After talking to Yam I decided to go with a CR80 dirt bike front end. I mean, come on, it's gotta be unique if I'm building it. So I picked up an entire front end for $157.24 shipped. I even won the frame so I had the guy cut the steer tube off so I didn't have to make a new one and could just weld it to the front of my frame.




Now onto the powerplant. As I said, it's an 80cc scooter from 1984. What is going to be rocking about this setup is the rear wheel is a 10" while the front wheel is a 17". Oh yes!

Check out that manly 1" exhaust port. Screaming I tell ya!


All the other bits I've kept for this day.


Now, I could have gone with round tube like the MadAss scooter, but I wanted to make like a little easier since I don't have a tube notcher and settled on 2x4 rectangle tube.


I needed to make some handlebars because I didn't want to buy any. Remember, the goal is $400. I must use whatever methods I have to keep me under that. So I had some 7/8" stock lying around and after some cuts, welds, and sanding it turned into this.






From here it got real boring. It came down to cleaning everything so this baby looks pretty new when I try and sell it once it's done for about a grand. My logic is that the new MadAss sells for $2K with a 49cc motor. Granted mine is a bit older but with how clean it will be and the bigger motor I'm hoping for $1K.


Oh that's right....check out that sweet single sided swinger! MMMMM, TASTEY!



Then I got backed up in the paint booth so I just had taped off parts lying around. Damn that guy in the paint booth taking his sweet time...


And a few of the painted parts.




Welp that's it for progress thus far. Ideas and comments are always welcome. Free parts are good too.
I will keep a tally of costs to see if I stay under budget. I'm not counting consumables that I already have lying around like welding wire, paint, sand paper, etc. Only things that I had to go and buy specifically for this build.
Frame Material = $15
Front end = $157.24
Rectifier = $30
Low Fuel Sender = $11.99
POR-15 Tank Liner = $21.45
Exhaust Metal = $11.39
Oil line nipple = $3.00
EBC Brake Shoes = $12.55
Gold Fren Brake Pads = $14.35
Grips = $6.87
Air Valve Cap = $3.58
Shipping = $4

Total = $288.42

Man Hours Invested (MHI) = ~17

This going to be a tight one. I know for a fact I still need new front and rear brake pads, grips, a front tire (can't really ride the knobbies on the road real well), tank liner, header and muffler(will be homemade but need materials) and a headlight. I'm really hoping I get a deal on the powdercoating. It's going to be close folks! Stay tuned!

FINALLY. I love it. I may have some old grips I can send you that are in fair condition IF you want them. They're kind of funny looking though, YELLOW and BLACK and GRAY (ProGrip 791 i believe). I'll take a photo and show you later this week. I had a spill last year and bent my ProTaper handlebars but the grips were not destroyed.

Of course, if you're going to paint the body red and black ... those grips might look a bit retarded.


LOL2

I'm really glad to see it all coming together. A pretty awesome project that promises to be a great experiment in chassis geometry etc. Of course I have never owned a chopper OR a scooter, which makes it all the more interesting to watch.

YAM93 wrote:FINALLY. I love it. I may have some old grips I can send you that are in fair condition IF you want them. They're kind of funny looking though, YELLOW and BLACK and GRAY (ProGrip 791 i believe). I'll take a photo and show you later this week. I had a spill last year and bent my ProTaper handlebars but the grips were not destroyed.

Of course, if you're going to paint the body red and black ... those grips might look a bit retarded.


LOL2

I'm really glad to see it all coming together. A pretty awesome project that promises to be a great experiment in chassis geometry etc. Of course I have never owned a chopper OR a scooter, which makes it all the more interesting to watch.

Beggars can't be choosers when it comes to budget. I will let you know though. Yeah the frame set up will be interesting. Still trying to figure out how to make a gas cap. DAMN, I need a new seat too. This is getting trickier.

ummm, donations to this build will not be turned down! My goal is to use this money to fund a trip to Scotland. Yam has already donated and I appreciated it a lot. Who else wants to throw some parts or money my way? Anyone?!?!

Not exactly sure what I may have, but put up a list of what you're looking for...

darrin

Just a little more. I couldn't go to bed without getting closer to have the front end done. I really wanted a rolling chassis but I would have settled for the front end bolted up and done. Alas, I got neither. Still here are some more parts painted.
The rim all nicey nice.



The front brake lever. I figured red was appropriate.


The old light switch all perdy now. Off to the left you can see the front brake res cap done up in red as well.


The triples are gloss black.




The rotor was done in stainless.


Black handlebars should contrast nicely against the red levers and stainless control housings


And to show you the tire size difference. On top of each other and side by side.

OK, so I don't lose my list since I seem to be great at misplacing pieces of paper I'm going to type it here. And if anyone can help remove an item from my list, well that is just a bonus.

Seat = ? Any ideas on making one? I may try and cut down the old one cause it's huge and ugly as it stands now.
Grips = ? Possibly Yams. You think the yellow can be sharpied? Maybe painted? Heh.
front('91 Honda CR80)/rear ('84 Honda NH80) pads Front=(no info) Rear=$12.99
Battery = ? I wonder if ANYONE :::cough::: zero9243 :::cough::: would want to donate one of those?
Front tire = $11.99
Por-15 Tank liner = $11.99
Headlight = $40-$50 from what I can tell. Simple 5 3/4" round DOT approved.
Ignition = $10.99
taillight = ? Possibly robbing the one off the FZR?
Exhaust System = $~10 It can't be much for 2 feet of 16g 1" tube

I believe that covers everything that I can think of right now. I hope that is all I need. I may still make it.

Dude that Madass looks like the first version of your FZR Streetfighter (R6 HeadLights??). Anyway you always impress with the projects so I only have a "Good Job so far and please keep it up" to give you. If I think of someting else i"ll chime in.

This is better than monster garage!!! I look forward to the finished project.....I know there is 1k somewhere around here let me go check under my sofa cushions

OK I got a little more done for the scopper!

Made it pretty damn far on the exhaust. I'm down another $11.39 I think it was for metal and all I bought was the 1" tube. The rest I had laying around the basement. It's not cleaned up yet and I did get a dent from clamping but I'll fix it. It was 2 am and I needed to stop and sleep. I'm ecstatic that I just made an entire exhaust/muffler by hand.












I believe Zero will be donating some packing for it. Hopefully it'll sound alright.

I reassembled the front brake MC. It looks pretty.



I also got the steering tube set where I want it. I will be double and triple checking over the next few days to make sure I have it square before I weld it in place. Still have to figure out a gas cap. Oh and if anyone wants to donate some form of speedometer that'd be great!
Are you noticing the nickel on nickel welds??? I sure am!

You have outdone yourself again my friend. Truly awesome work. I'll be interested to know how that pipe performs. If it goes well, I may need your help down the line for my 79 50cc Flying Dutchman.

whaaaaat?!?!? I'm sorry did you just MAKE AN EXHAUST!?! congratulations dude that looks beautiful. Lets talk about the packing we want to get and I'll order it up. I can't wait to hear her.

What is the outside of the exhaust can made out of ? Thick sheet aluminum ? How did you bend it ?

Do you want to fab me a part out of that stuff if I send you a drawing ? Bottom of my fairing won't close, need a middle closure piece I can put couple fairing screws thru. Kind of a funny shape and I don't have any plastic I can use here. The aluminum bar I got isn't wide enough, I could make something rough with 3 plies (overlaps with rivets) but really want something the perfect shape I can paint black and be done with. I don't even care if you have to rivet the 2 plies of aluminum together, just needs to be the right shape.

Giggity. Lookin' really good TK. What a cool project. I assume you'll paint that exhaust & can matte black.

How fast are you trying to turn this project around ? I could just send you $10 you can order some black Galindo superbike grips from Dennis Kirk. Probably the best profile and grip available and not expensive. If you can make that part for me and get it to me before mid-August I'll send you another $40 to put towards Scotland.

Link to the grips: http://denniskirk.com/jsp/product_catal ... Id=&mmyId=

oh, lets tell everyone the last time the engine was running

zero where your avatar is BOY-EEEEEEEEEEEEEEEE ?

I get a feeling the motor hasn't run since the late 80's. You know that swingarm, is that some shaft-drive assembly? I meant to ask earlier, wierd looking with no chain (to me anyway)