Gen 2 aluminium subframe homemade

I had a 99 with alloy frame and road two up for many years without any issues. I’d have thought it was the welds that would fatigue and break, those pics above are the castings given way!
 
CraigMcleod said:
Shiiiiit! Did you have standard exhausts fitted when this happened?
Click to expand...

look here

P1020608.1.jpg


fortunately i only had 4 km to go to reach my yard at home.
but
i was standing on the footrests for these 4 km
and my thigh muscles were "very grateful" for this special training - pure irony.
 
Last edited:
When Suzuki blamed cracks on owners Changing the exhausts they were wrong. Standard cans obviously had alloy sleeves and brackets bolted to the rear pegs. These wouldn’t add anything to help support the rear frame and would crumple if it snapped. Yours had steel exhausts and still snapped!
with this in mind a new alloy rear frame needs destruction testing and Proven to carry two up with luggage, 180kg+ Would be a ball park I’d say. Another option would be a rider weight limit.
apologies if it sounds like I’ve highjacked this thread and putting a dampener on it. I’d love an alloy subframe and would be interested in this one if it ever went into batch production as the existing is so heavy! I’d need to know it was safe safe though.
 
CraigMcleod said:
When Suzuki blamed cracks on owners Changing the exhausts they were wrong. Standard cans obviously had alloy sleeves and brackets bolted to the rear pegs. These wouldn’t add anything to help support the rear frame and would crumple if it snapped. Yours had steel exhausts and still snapped!
with this in mind a new alloy rear frame needs destruction testing and Proven to carry two up with luggage, 180kg+ Would be a ball park I’d say. Another option would be a rider weight limit.
apologies if it sounds like I’ve highjacked this thread and putting a dampener on it. I’d love an alloy subframe and would be interested in this one if it ever went into batch production as the existing is so heavy! I’d need to know it was safe safe though.
Click to expand...
I think is safe to say whoever gets one of these is for a more race oriented setup, rather than carry luggage and passenger. It sure is a beautiful piece that the OP built, but I like my givi bags and girlfriend, so stock it is for me, since I don’t want to risk losing my cargo. Lol
 
Berlin Germany said:
it sounds nuts that we all here try to change the ´99 & ´00 alu-subframe to steel
because the alu broke too many times.
i myself had that bad experience at my ´00 some years ago
my girl (68 kg) on the rear seat + topcase (~12 kg)
the result:
View attachment 1619319

~1.5 hrs later the steel was built in.
Click to expand...
Kiwi Rider said:
Here’s my repaired welds on my ‘99 subframe... (please excuse my untidy accessory wiring to the battery, I know, I know, I’m planning on sorting it all out this winter while it’s off the road)
View attachment 1619321

View attachment 1619322

View attachment 1619323

This repair was done long before I acquired this bike, I rode with my girlfriend (80kg) for many rides and it’s never cracked the welds, and they don’t look that good either!
Click to expand...

My solution is don't have a girlfriend if she's big as you. Glad I had the steel tail on there for my last GF, she woulda snapped that like a twig.

I took the rails out on my 14 and all I have are the two square tubes holding the tail up. No luggage, no passengers, no problem. I'd go with an aluminum frame. No 50 year old woman wants to sit on a sportbike anyway. Those heavy duty tail frames are for you young guys.
 
zucchero said:
Me too.I weigh aprox 105kg and mostly ride solo.Sometimes I am accompanied by my son who is 8 years old and weigh aprox 35kg.Will it be safe to go with aluminium frame and should I go for it.
Click to expand...

That's a track bike, not set up for passengers.
The '99 and 2000 Busas had aluminum subframes, but Suzuki went to steel in '01 because of stress fractures in the aluminum.
Your son is precious cargo, and I would keep him on a steel subframe.
I'de get him a back seat with a backrest instead, more security and safety for you both.
 
sixpack577 said:
That's a track bike, not set up for passengers.
The '99 and 2000 Busas had aluminum subframes, but Suzuki went to steel in '01 because of stress fractures in the aluminum.
Your son is precious cargo, and I would keep him on a steel subframe.
I'de get him a back seat with a backrest instead, more security and safety for you both.
Click to expand...
Point noted..!!Will stick with steel subframe.I Truly appreciate your concern and advice.
 
mdpar23 said:
Does anyone know the OP or if he's still an active member on this site?

Thanks,

Mike
Click to expand...
He used to post here once in a while but it shows he was last seem April of this year....I know he spends a lot of time on the track with his beastie so that season might be keeping him busy.....

Throw him a PM and maybe he'll stop by and see it....

This is @Ac41 on the track,,

 
Bumblebee said:
He used to post here once in a while but it shows he was last seem April of this year....I know he spends a lot of time on the track with his beastie so that season might be keeping him busy.....

Throw him a PM and maybe he'll stop by and see it....

This is @Ac41 on the track,,

Click to expand...

Great thank you much!
 
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