1199 rebuild project

Hello, everyone!
Was reading the forum for quite some time, decided to post my rebuild project.

Right now the main task is to make the carbon frame, so working on the little things to loose as much weight as possible.

Stock dampers VS AEM Factory titanium


With stock nuts VS titanium


Stock VS NCR


Stock VS Titanium


Stock VS aluminium carrier with 520 aluminium 41 tooth sprocket


Complete setup gives a weight reduction of 989 grams

I've been wondering this for a while

Approx. cost for the whole conversion?

1090 euro

I have been doing the same and have a bit of a fetish for trying to lighten my bike.

I ended up getting the polyurethane cush drives from sprocket centre. I could not compare their weight directly against OEM as they come already pressed into the sprocket carrier.

The poly urethane ones would actually weigh a little less as they do not have the ti ring around the polyurethane.

But those who want the lightweight without the extra cost of the ti cush drives you can save some money.

I was also keen on the Ti hub cover. I always lusted after one after Trauma got one. But the cost at about 1000 USD was just too much. I keep a spreadsheet comparing OEM to what I replace with or just remove.

The CNC hub cover is not quite as light as the NCR Ti one. NCR Ti = 278 grams vs CNC Alloy = 308 grams. Difference 30 grams. Don't get me wrong if I could afford it I would go the Ti one everyday. Just could not afford it. BTW the CNC hub cover is 119 Euro vs 790 Euro for their Ti one. I bought the Ti colour so I could lie to myself.

As a side not I saved 101 grams removing the two O2 sensor plugs and wires from the exhaust system. Mr Akra kindly supplies Ti bolts and washers to cap these.

Great to see Gecko and I are not the only ones with electronic scales trying to reduce weight gram by gram.

The NCR cover is aluminium, I also believe that 790 euros is way too much for that Ti part.

Made these custom design Ti lambda plugs for the RS13 Termi exhaust


The plan for the brake/clutch lines with dry break staubli connectors.

I've decided to go with Fren Tubo carobotech.

The Robby Moto lower triple has a cutout at the bottom, which I decided to use to bolt on the custom splitter for front brake lines, which will make the lines going to calipers equal length and act as a radiator.

brutALEx said:

1090 euro

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1 euro per gram.

Marmoot said:

1 euro per gram.

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And that really sums up the entire effort, whatever one replaces. Awesome bike porn, regardless.

Well, actually it might be more grams per euro, since they are rotating unsprung mass and each gram of rotating unsprung mass equates to more than a gram, although they are pretty close to the centre line.
And one euro per gram is actually very good

Styler said:

And that really sums up the entire effort, whatever one replaces. Awesome bike porn, regardless.

Click to expand...

And we love bike porn

The funny thing is that if I reach the target a 100% I'll loose maximum 3kg from the rear. But that's only a lousy 20% of unsprung weight and maybe around 13% of rotating, because the complete assembly including hub, spindle, rotor, caliper, wheel, tire and sprocket unit weights ~15-16kg

I'll definitely feel the loss of unsprung weight but I doubt that changes in gyroscopic effect will be that noticeable

Infinitely better than spending that amount in carbon fibre fairings to lose weight, regardless.
Well done.

The fairings will be carbon and hopefully the airbox and swingarm which is the major challenge for now

brutALEx said:

Made these custom design Ti lambda plugs for the RS13 Termi exhaust


The plan for the brake/clutch lines with dry break staubli connectors.

I've decided to go with Fren Tubo carobotech.

The Robby Moto lower triple has a cutout at the bottom, which I decided to use to bolt on the custom splitter for front brake lines, which will make the lines going to calipers equal length and act as a radiator.

Click to expand...

That's fantastic work
Wish I had some skills like that

Thanks for showing what you are doing

Replacing the ignition lock with aluminium mounting posts for ignition cover. I'll compare the weight difference after anodizing.


Since there is no ignition lock and steering lock the new carbon cover was made. Same as MS Production one but without cutouts.

brutALEx said:

Made these custom design Ti lambda plugs for the RS13 Termi exhaust


The plan for the brake/clutch lines with dry break staubli connectors.

I've decided to go with Fren Tubo carobotech.

The Robby Moto lower triple has a cutout at the bottom, which I decided to use to bolt on the custom splitter for front brake lines, which will make the lines going to calipers equal length and act as a radiator.

Click to expand...

Cool that you go for Staubli (they are a few km from my home): Top products!
Sorry to see that your mechanic doesn't have the same flair for details (surface & deburring).
Can't wait to see your bike. Whick brake calipers and MCs did you decide for?

The quality of the plugs is quite disappointing. I had to have them fast, if I find the better mechanic for the job I'll do them properly. But I'm really satisfied with how my design turned out in metal.

For the front end I'll be running:
Robby Moto triples
Ohlins FG670 forks
Brembo GP4 RR calipers
Brembo CNC masters
Sicom rotors

P.S. Once again thank you for the swingarm geometry Ti bolts - they are perfect

brutALEx said:

The quality of the plugs is quite disappointing. I had to have them fast, if I find the better mechanic for the job I'll do them properly. But I'm really satisfied with how my design turned out in metal.

For the front end I'll be running:
Robby Moto triples
Ohlins FG670 forks
Brembo GP4 RR calipers
Brembo CNC masters
Sicom rotors

P.S. Once again thank for the swingarm geometry Ti bolts - they are perfect

Click to expand...

This bike is going to be a real animal, congrats!!! Will you keep OEM electronics?
A couple month ago I was in contact with a geman company that built a Ti rear axel. But it seems to be very difficult and they where not really happy with the result

Is the NCR sprocket flange really lighter than Al models (e.g. AEM)? Okay, it's NCR, who doesn't love this brand

For stage 1 I'm planning to upgrade the engine and electronics to 2015R spec and later decide on the future upgrades.

The NCR flange is Al so I think it's comparable in weight to competitors. I just like the NCR niploy finish which is a good match to nickel finish calipers.

The front Ti axle will be ready soon. We made the calculations to compensate the Ti fatigue issues. It will weight 175gr.

At the moment we are calculating the possibility to make the rear axle from Ti, the stock part weights 1640gr, so even loosing 300-500gr is a good result.