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Location
Maryland
This place looks pretty legit, never joined because I don’t have a panigale but was urged to jump on here by my buddy Gunny.

started building bikes due to my obsession with panigales and at one point ended up with this:
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don’t know why it’s flipped, but it’s an 1100cc s2r with an 899 subframe and as much panigale bodywork as I could fit.

never really could get it to mesh though, so I stripped it down and focused on making it super light.

while I was building, ended up finding this gem:

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got it for so cheap that I gave myself an upgrade budget of the difference between what I paid and what the going rate was, so I ended up boring it out to 1040cc:
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adding a mostly self engineered dry clutch:

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mucking around with the exhaust and adding farkles(termis have since been placed back on, it was way too loud):

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for some reason I have become obsessed with weight reduction through creative, less expensive solutions than just ordering light wheels, which I eventually caved on anyways.

as she sits now:

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since I ended up deciding on a superlight theme, I picked up a slightly damaged subframe on eBay, chopped it up, and am working on structural composite bodywork at the moment.

a 1098 radiator and oil cooler were added in favor of the double radiator/heat exchanger setup, not only because it drops about four pounds, but it also cleans up the left side of the bike considerably while also making room to tuck all the electronics under the airbox.

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still on the fence about the red hoses, but I really like the look of the aluminum pipes.

there’s a chance I’ll switch back to the streetfighter cooling system which leads me into my next crazy idea:

a buddy of mine convinced me to start looking for a spare motor because I was proposing a lot of experimental modifications, so I ended up picking up a 2011mts1200 motor for relatively cheap, considering the condition.

it has a broken crank between the left side case and cover.

not a big deal, but it gave me the idea to stroke it to 1260cc.

still figuring out the specifics, but once finished, the 1260 motor will go in the streetfighter frame and the 1040 motor will go in an undocumented frame for when I can get myself out of the garage and on the track.

the goal weight for the monster is 325lbs wet and the goal for the streetfighter is 375lbs wet.

the dedicated track bike will be a pure hybrid:

1198 frame
848 bodywork
1040 streetfighter motor with 848 evo cams and pistal pistons
Microtec ecu with the magical touch of ducshop
Ohlins ttx with Kyle racing linkage
Streetfighter exhaust and subframe
848 evo tank
Hypermotard forged aluminum wheels
999/996 hybrid forks
996 calipers(all I had laying around)
999 front rotors with fully floating buttons
Kbike slipper clutch with an s2r1000 clutch housing and hypermotard evo primary gears
Nichols flywheel
Gp shift
I plan on fabricating my own quick shifter using a momentary switch connected to a bracket hanging from the engine, but that’s once everything else is done.

Anyways, long post, I know, but I’m excited to jump in, trade knowledge, and share this beautiful passion!

Alex
 
Great looking bike and legit project!

welcome to THE forum
 
That is the most modified 899 subframe I have ever seen

Almost looks like a chrome moly frame from back when there was no Panigale
 
That is the most modified 899 subframe I have ever seen

Almost looks like a chrome moly frame from back when there was no Panigale
You can’t really see it in the picture, but it was shortened at the engine mount bolts and welded to the frame. Worked fine but was never satisfied with the riding position, so I set out to make something lighter and stronger.

the plan is to use nomex honeycomb as a core with sheets of Kevlar and carbon fiber sandwiched on the outside. Reinforced with an extra layer of nomex at the mounting points and am also working on adding steel inserts to the mount points.
The mounting points will be welded on in a similar fashion as the superbike frames.
 
Heads off the s2r for bigger valves and some light massaging.
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anyone know someone in the dc area that replaces seats and guides? Trying to avoid shipping. Thanks!
 
Cool. Who you gonna have do the crank?

*we posted at exactly the same time

How close are you to Gast? FBG. Paul Gast. He is back there somewhere near DC. They are really good w cyl heads
 
Last edited:
Cool. Who you have do the crank?
This is in regards to the 1200 engine, not the s2r. I’ll start separate build threads to avoid confusion.

The counterweights on the hm1100 crank interfere with the lay shaft and if I use a 71.5mm stroke, it looks like I’ll have to modify pistons or rods.

reached out to Ben fox so hopefully I’ll have a solution soon. Don’t intend to polish or knife edge since it’ll be an understressed engine.

I’m just curious to see if it can be done, no other reason why. If I end up with 1200cc in a streetfighter frame with a friendly torque curve, I will be a happy rider, but 1260 cc is more attractive because I want to test my skills with composites by being forced to customize the airbox and I always could use the practice when it comes to port matching.
 
You dont need kevlar unless you want something for abrasion, the nomex has no strength either, on a part like a subframe I’d make it integral with the seat and tail as well. Also you dont need a core, I’d use 100% carbon, just think about the load paths. The first class method is to make a pattern, take a 2 (or 3) part mould and do it in one go. It’s a bit tricky but totally worth it in the end If you want something really light and strong, no need to infuse just wet bag it. The bonus is when you crash its really easy to make another one and if you use the 899 mounts, you might be able to sell a couple. The quick and dirty method is to make it out of core material, wrap it and go, but thats still a lot of work.
 
Yeah I was planning on bagging it, but I figured the nomex would add rigidity at high stress points. I have a few different weaves and was hoping to do a one part mold for the seat and attaching it to the structural part of the subframe.

my issue is: I chopped the ENTIRE subframe off like an .....(this was my first attempt at a custom and have made a lot of mistakes to learn from) so I have to weld on u joints for the new subframe/tank mount.

I’ve ensured structural rigidity of the chassis, but am still conceptualizing the whole thing.

this will definitely be a one off unless anyone else wants to kill the value of their bike

I appreciate the info though, research and experimentation only go so far as developing the process and outlining the plan, but real experience from others who’ve done it is much better.
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This was my inspiration for venturing into the light subframe, and once I get a good welder, I’ll try to duplicate the double dog exhaust.
 
Dude said:
This will definitely be a one off unless anyone else wants to kill the value of their bike

Same...

And I paid over 3k usd for mine!
 
TBH for the work involved in making a composite subframe, Id just weld it out of ali tube. A lot quicker and probably as light
 
TBH for the work involved in making a composite subframe, Id just weld it out of ali tube. A lot quicker and probably as light
If I could weld aluminum, All of my frames would be aluminum! I have a cheap flux core wire feed welder, so all ive done with it is steel. Looking to upgrade and am doing my due diligence on metallurgy so I can wrap my head around welding other metals.

Youre right, it is a lot of work and takes a lot of patience.
 
God I hate fork shim stacking. Measure five times, calculate six times, and question your life decisions leading you up to this point, I don’t know, let’s say fifteen to twenty times.

oh that shim measured .10 before but now measures .15. Thank you, mister expensive caliper man.

stock showa forks have the weirdest stacks compared to ohlins and race tech.

maybe one day I’ll get back on the road!
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lmao! I helped a friend rebuild forks with upgraded race tech internals. The shim stack instructions were terrible!
 
Last pic of the “1069 Manigale S” before she was torn down for a superlight streetfighter build. Was never able to get it to look quite how I wanted, so I decided to go full minimalist, all black, no logos, quiet exhaust, with a goal weight of 325 lbs.

it’ll be a ghost, no way to identify it, just the way I like it.
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