Updated Cost Breakdown

Now that I've managed to get into the bulk of the conversion project, I have a much clearer idea of actual cost. I thought, as a service to those considering this route, I'd give an updated cost projection. This only includes items that are part of the conversion, not unrelated items that I am doing in the course of my project.

• Powerplant: 2007 GSXR600 engine (with ECU, etc)
• $675 (actual)
• Exhaust system - Header, manifold, pipe, muffler
• $500 (hard quote)
• Power Transmission - I've opted to go with direct drive. Sprockets + hardware.
• :$200 dollars (actual, rounded)
• Motor Mount - basic mild steel
• $100 (estimate, but a high one)
• Clutch, Throttle, Shifter cables
• $200 (actual, rounded for clarity)
• Paddle shifter + mechanical throttle blipper (still in design/thinking stage)
• $200 (High estimate -- aluminum plate and bar stock)
• Power Commander 3 (I still think I can manage this)
• $125 (used) (Actual)
• 530 chain
• $50 (hard quote)
• Two new Facet low pressure Fuel Pumps
• $100 (hard quote)
• New Fuel lines
• $100 (estimate)
• New silicone radiator hoses
• $100 (hard quote)
• Remote Oil Filter  (adapter, filter assembly)
• $175 (actual)
• Fuel Surge Tank (modified from old welding cylinder)
• $100 (estimate)
• Oil Pan modification -- not going with a billet solution. Baffled, modified stock pan
• $300 (actual)
• Upgraded heat shielding and firewalls (because burning to death sucks)
• $200 (estimate)
• New Fuel Pressure Regulator
• $150 (actual, rounded)
• Stock GSXR gauge assembly
• $65, ebay,used. (actual)
• Wiring Harness Modification
• $200 (actual)
• DOM Tubing
• $100 (hard quote)
• Misc Hardware
• $300 (estimate)
• Sold old clutches, exhaust, motor, etc
• -$800 (estimate, however $650 is already collected)

Okay, so. Total project cost, and most of this is already quoted or actually spent:

$,2940

Contrast this with the estimate for what it would have cost me to do a 593 conversion, which was 22-2500 dollars, depending on what I could salvage from the current setup.

So. A rebuild of the old 494 was going to run me 600-800 dollars: Net cost increase, ~$2240
And, it's only 700 - 400 more than a 593 conversion.

You're going to see lots of competing figures and opinions presented as 'facts' when you're researching this issue. The above is a true, accurate conversion cost. I'll post my final numbers when I'm finished, but I would bet dollars to donuts that I come within 10% of the 2940 estimate. Don't let the people quoting 5k to 8k scare you off.