The long walk towards the finish line.
I have to admit that when the body parts were molded, I felt like the bike was almost finished. But boy, was I wrong!
First of all, the rear swing didn't look good with the new, curvy body. It looked ancient. I tried to design a cover (as seen on the photo beside), but any design made the swing and the rest of the bike look extremely heavy. And i wanted to make the rear look light! The only solution was to scrap the original swing and make a new one. Naturally, this would change the behavior of the bike, as the original design is very complex and well thought through.
But i had to make this sacrifice. Today, I would definitively make a computer model of the swing and test it in a Finite Element Analysis program, but back then I just didn't have that possibility. This resulted in a carbon fiber rear swing that is actually about 800g heavier than the original, but the lesson learned and the design advantage weighs much more to me.
I am well acquainted with working in composite materials, so that was the most natural thing for me to use for all the remaining parts missing for the bike, like the footrests, airbox, headlight mounting, expansion chamber for the cooler liquid, and so on.
Finally, I also had to make a new exhaust that would fit under the bike and a new electrical wiring, that would move all the electronic boxes to a common place underneath the seat.
All this was new to me.
The single muffler underneath the bike was first build in thin DMF plates by me and then welded in stainless steel by an external company.
After all the bits and pieces were built and sourced, I wanted to paint the bike. By myself. Did I learn something from it? Yes, to let someone else do it next time. I'm happy with the result, but the amout of time it took me to achieve the result was crazy.
All the big parts of the body are painted in a turquoise-green-blue candy hue, that i blended after having seen this color on a painting.
All the other parts are just clear coated or polished. But all in all, all the carbon parts are visible, to prove their authenticity.
I actually consider painting parts of the bike in a solid color eventually.