2020 ROYAL ENFIELD INTERCEPTOR INTERCHOPPER

STARTED LIFE AS AN ORIGINAL INTERCEPTOR I BOUGHT NEW IN FEBRUARY AND WITHIN A WEEK AND 46 MILES THE ENGINE WAS OUT ON MY WORKBENCH HOME IN MY GARAGE.
ORDERED A HARDTAIL FRAME DESIGNED FOR THE LIKES OF A SMALLER CB250/400 ENGINE FROM A QUALITY UK FRAME BUILDER AND THEN THE FUN AND GAMES STARTED, HAD TO MAKE MULTIPLE SPACERS ETC TO ADAPT THE 17MM REAR SPINDLE TO FIT CENTRALLY THE REAR WHEEL SO I COULD START ALIGNING THE FRAME,REAR SPROCKET AND ENGINE, WOW WHAT A MISSION. GOD KNOWS HOW MANY LASER LEVELS,RULERS,STRING AND TAPE MEASURES I USED BUT AFTER MULTIPLE EVENINGS OF TWEEKING I TOOK THE WELDER TO MY FIRST CUSTOM HANDMADE MOUNTS AND WITHIN A COUPLE HOURS ALL TACKED IN THEN TOOK THE FRAME TO WORK AND FINISHED OFF THE WELDING WITH MY BIG WELDER.
ONCE THE ENGINE WAS SAT IN THE FRAME I COULD THEN START SEEING A FINAL PICTURE OF WHAT I WAS TRYING TO DO.
THE OIL TANK WHICH WAS 2 FIRE EXTINGUISHERS CUT DOWN THEN WELDED TOGETHER HOUSES ALL MY ELECTRICS AND ECU, CUSTOM BATTERY BOX WITH EXTENDED TERMINALS.
THE FUEL TANK IS OFF A 2016 ROYAL ENFIELD CLASSIC EFI WHICH IVE MODIFIED ALL MOUNTS TO FIT,I HAD TO COME UP WITH A CLEVER IDEA TO ADAPT THE ORIGINAL 2016 FUEL PUMP AS THE CLASSICS RUN 2.9 BAR FUEL PRESSURE BUT THE INTERCEPTOR RUNS 3.5 BAR SO THE FUN BEGAN. HAD TO FIND A FUEL PRESSURE REGULATOR TO SUIT MY APPLICATION AND OF COURSE NO DIRECT FITS EXISTED SO I HAD TO COME UP WITH A PLAN.I ORDERED A DUCATI FUEL PRESSURE REGULATOR FOR 3.5 BAR AND THEN I WENT TO MY LOCAL ENGINEERS AND ASK THEM TO MAKE ME AN ADAPTOR TO HOUSE THE DUCATI REGULATOR THEN FIT INTO ROYAL ENFIELD PUMP, GOD KNOWS HOW MUCH MONEY LATER BUT BOOM ONE HURDLE DONE.
THEN THE NEXT PROBLEM WITH TRYING TO MOD MODERN EFI, I WENT TO FIT THE THROTTLE BODIES AND GUESS WHAT? HIGH PRESSURE FUEL RAIL CONNECTOR HITS SMACK BANG IN THE MIDDLE OF THE NEW FRAME, AAARRRGGGHHH. ALMOST PULLING MY OWN TEETH OUT NOW AS SO CLOSE YET SO FAR SO I CHOPPED THE FUEL RAIL IN HALF AND MACHINED AN ADAPTOR TO FIT INSIDE THE RAIL WITH DOUBLE ORINGS SO I COULD SWIVEL IT, 1/8TH NPT QUICK RELEASE FUEL HOSE CONNECTOR AND BOOM, SORTED.
KEPT THE ORIGINAL LOOM AND ABS SO HAD LOADS OF WIRES TO PLAY WITH, CHOPPED OUT,SHORTENED AND ADAPTED AS MUCH LOOM AS I COULD TO MAKE SMALL AND NEAT
HAD A CUSTOM STEM MACHINED SO I COULD ADAPT FRONT END TO FIT AND BOLT STRAIGHT ON USING SUZUKI BANDIT BEARINGS.
I COULD TALK ABOUT WHAT IVE DONE TO THIS BUILD FOR WEEKS BUT DONT WANT TO BORE YOU, HOPEFULLY YOU CAN SEE FROM THE PICS THAT THIS WAS NOT A SMALL TASK.
ALOT OF LATE AND SLEEPLESS NIGHTS HAVE CREATED WHAT I THINK IS A 60S LOOKING MACHINE WITH ALL THE RELIABILITY OF MODERN BIKE AND NO OIL LEAKS.
THANKS FOR READING THIS AND HOPE I DIDNT BORE YOU TO MUCH

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