R6 Fork Triple Tree Modding

[fazil]

Planning to fit R6 usd forks to my Fz6.
Almost everything is ready except for the R6R stem nuts.
Here is the upper triple yoke mod with pictures:

After some cutting, drilling and painting. It looks clean

The story begins with cutting the ignition barrel for fitment.

After some grinding of the old paint it is almost ready for a new paint.
I used synthetic matt black paint and varnish after all.

Outlaw 22mm handlebar clamps are very cheap ($20)and quality is perfect. fit like a glove to the existing holes with some drilling. Bolt size is M12. Outlaw part number: 12-041

I tried to reinforce the inner yoke with putty epoxy but it didn't dry and i had to take all the mess out of the yoke. Can anyone recommend me an epoxy for metal filling? Can i trust this yoke without reinforcement as is ?

And finally after painting here is the triple tree:

 

[Gelvatron]

This is really cool thread,

I have yet to get that deep into the r6r forks

If you are worried about that triple tree breaking id would box it out with welds and a piece of metal cut to fit that dish.

Colors look really nice as for mock up does it clear the tank?

 

[fazil]

Thanks Gelvatron for your interest.
I don't think fuel tank will be an issue.
There is enough clearance.

For the welding, i don't have a chance to make any welding at the moment.
R6 forum guys tell that it is strong enough without any filling. But may be i can use some epoxy to be sure that it won't brake any time.
But i don't know which epoxy to use.
That's a big dish to fill

 

[FinalImpact]

As mentioned, my first choice would also be to weld in aluminum fillets. A machine shop that repairs cylinder heads could do this. And it need not fill the entire void just some thickness to the mounting area to gusset it.
OR How about just weld the blocks to the triple??

There is product called ALL METAL. Its polyurethane and aluminum. Its used in the auto world for filling between structural components. Should do the trick. You'll want to get the excess filled down right after cure begins because after that it gets pretty hard. Mix a small blob and confirm cure time and hardness BEFORE application. If you go this route, use a rotary bit to grind grooves in the inside so it has something to adhere too.

 

[txinfidel]

Looks great!

 

[fazil]

Can i use something like this just to fill the dish ?

 

[FinalImpact]

Just read the manufactures application - I do feel this is only giving a false sense of security. Its not gong to do anything for pull out. If it were a compression situation - it would keep it from crushing. << On that note: if you are set on using filler, insert some LARGE washers as the FIRST item on the bolt and FILL underneath of the washer. Perhaps doing two separate applications.

^^ Does that make sense? Use the large OD washer, maybe even bending the sides down to make it fit and/or grinding them down. With the filler it can't pull out through the top. Hope this makes sense.

If you do two separate batches, understand that you need to rough up the surface for proper adhesion between layers.

 

[fazil]

Yes i understand. But may be i should leave it as is.
It feels solid to me lately.
After i thought messing with epoxy.

 

[fb40dash5]

I agree, without welds or bolts, you're not going to be adding much of anything but weight. Not seeing how epoxy type stuff would be of any structural help in this application.

Honestly, it looks like you took out so much of the old mounting bosses to fit the bolts, you might as well remove them flush with the bottom of the yoke, and just bolt them to the top of the web.

But, engineer I ain't, YMMV.

 

[Gelvatron]

I just don't think your adding strength to the bracket by purring epoxy in the dish I think you just filling it like I said I'd you box it out with a piece of sheet metal cut to fit I think you would better off just leaving it alone

 

[fazil]

I used some jb-weld.
I hope it gets dry...

 

[stink989]

I would recommend getting a "comfort kit" top tripple clamp. They are made for the handle bar risers. http://www.topyokes.com/comfort_kit/457

 

[fazil]

I would recommend getting a "comfort kit" top tripple clamp

An affordable option but modding existing yoke is cheaper and more fun.

 

[FinalImpact]

I used some jb-weld.
I hope it gets dry...

That looks tasty! JB Triple Swirl Chocolates!!! :BLAA:

 

[fazil]

Triple tree is ready for the forks to put on.

:cheer:

No grinding of the frame required to put it on.

 

[Gelvatron]

Looks good future mod for me nice color and pics

 

[fazil]

I finished R6R fork mod at last.
It's worth for all that time and money
Here are the latest pictures:

 

[crofz]

Great modification...Is this original handlebar or FZ1 bar you put on?

 

[fazil]

Thanks

I put Fz1 bars with Rox risers.
Outlaw handlebar mounts

 

[david323]

I've been on the fence about the R6s or R6r forks for a few months now. Could you maybe put together a parts list of what you used? I'm especially interested in what year/type forks, triple, steer tube and bearings you used. Also, did you swap out the risers you used? The original pictures show the black risers, but the clamp on top of your bars is silver in the last pictures...