We have really done it this time! Nick from Troy laser/fab and myself have become obsessed with the motorcycle powered Smart Cars on you tube and have decided to build one! I am starting this thread as sort of a journal on the build process. I am going to post everything- disassembly, mock-up, fabrication, etc. I am also going to post the crazy ideas that may or may not work, false starts, re-do's and all of the other stuff that go's along a project of this magnitude.
I plan on someday to offer this as a kit as well as a turn-key conversion.
We have purchased a very nice 2005 Suzuki Hayabusa engine complete with airbox and wire harness, 5,000 miles. Purchased from E-bay for $2700 shipped. It is in very nice shape, a few scratches on the stator cover, but otherwise perfect.
A differential with reverse was very important to us. We have chosen the Powertec/Quaife unit. It is the same one as the Smartuki kit. This piece is really nice and really really expensive ($3,200 shipped!) This is by far the most expensive single component of the conversion but well worth it. It has a reverse gear, limited slip differential, and you can have all 6 speeds in reverse if you are crazy enough ( which we are)
We are going to start building and engineering in a couple weeks, here is a few pictures of my ugly mug and the parts we have bought so far.