DO THE TON

Blood Sweat Tears and Grease => Projects => Specials => Topic started by: doc_rot on Mar 18, 2014, 15:34:49

Title: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Mar 18, 2014, 15:34:49
I have been posting over on KZ rider, but I also check out this site time to time so id thought id share here as well. Im still in the early stages of this build, it is my first ground up build, so alot of the 2 step forward 1 step back shuffle is going on.

A little history; I bought this bike when i was in college, fixed it up a bit and rode it. When i graduated i did 17,000 miles on it through the US and Canada. lots of gravel roads and jeep trails. Needless to say it got quite abused. (my poor kerker!)  i limped home on low compression. My original intent was to rebuild the motor, but once i got the engine out, things started to get out of hand.
(http://i735.photobucket.com/albums/ww356/VictorWilkens/DSC_0273.jpg)
(http://i735.photobucket.com/albums/ww356/VictorWilkens/DSC_0175-2.jpg)
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Mar 18, 2014, 15:38:48
So I decided to go all out and build my dream bike. Im trying to keep the flavor of the original, but make it a bit sportier. I'm justifing the cost as an excuse to teach myself things i dont know.  ;D

heres some pics of the build so far.

swapped wheels, excell rims, stainless spokes. first set of wheels i have ever built. I now find i really like building wheels and have built several sets for friends. also 530 chain conversion.
(http://i735.photobucket.com/albums/ww356/VictorWilkens/DSC_0433.jpg)

Works shocks

(http://i735.photobucket.com/albums/ww356/VictorWilkens/DSC_0435.jpg)

Tarrozis

(http://i735.photobucket.com/albums/ww356/VictorWilkens/DSC_0436.jpg)

braced stock swingarm
(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMAG0223.jpg)

custom headlight bucket  with HID
(http://i735.photobucket.com/albums/ww356/VictorWilkens/DSC_0278.jpg)
(http://i735.photobucket.com/albums/ww356/VictorWilkens/DSC_0300.jpg)
(http://i735.photobucket.com/albums/ww356/VictorWilkens/DSC_0299-1.jpg)
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Mar 18, 2014, 15:47:22
frame mods, subframe raised, shock mounts lowered. the living crap braced out of it. Very disconcerting to be banking into a turn at 80+ and feel the frame twist, hopefully this will cure that along with beefed up engine mounts.

(http://i735.photobucket.com/albums/ww356/VictorWilkens/DSC_0454.jpg)
(http://i735.photobucket.com/albums/ww356/VictorWilkens/DSC_0455.jpg)
(http://i735.photobucket.com/albums/ww356/VictorWilkens/DSC_0456.jpg)
(http://i735.photobucket.com/albums/ww356/VictorWilkens/DSC_0459.jpg)
(http://i735.photobucket.com/albums/ww356/VictorWilkens/DSC_0481.jpg)
(http://i735.photobucket.com/albums/ww356/VictorWilkens/DSC_0329-1.jpg)
(http://i735.photobucket.com/albums/ww356/VictorWilkens/DSC_0327-1.jpg)
(http://i735.photobucket.com/albums/ww356/VictorWilkens/DSC_0326.jpg)
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Mar 18, 2014, 15:55:22
custom side covers. one set for pods, one set for airbox depending on what im running. vacuum bagged fiberglass layups for freshness.

for pods
(http://i735.photobucket.com/albums/ww356/VictorWilkens/DSC_0432_zps48274639.jpg)
(http://i735.photobucket.com/albums/ww356/VictorWilkens/DSC_8070_zps325a54c3.jpg)

 for airbox
(http://i735.photobucket.com/albums/ww356/VictorWilkens/1023130349_zps025feefb.jpg)

mold making process
(http://i735.photobucket.com/albums/ww356/VictorWilkens/0831130049_zps54d716ce.jpg)
(http://i735.photobucket.com/albums/ww356/VictorWilkens/0831130113_zpsc414e5cd.jpg)
(http://i735.photobucket.com/albums/ww356/VictorWilkens/0903131901_zpsde51bd06.jpg)
(http://i735.photobucket.com/albums/ww356/VictorWilkens/0918131956a_zpsda1d994b.jpg)
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Mar 18, 2014, 16:03:14
Engine plans are: welded crank, undercut trans, wiseco 1075, mild cams, 29 smoothbores. MMMMMMM, moriwaki.
 (http://i735.photobucket.com/albums/ww356/VictorWilkens/DSC_0327.jpg)

got a sweet deal on these ZRX forks so thats gonna happen soon.
(http://i735.photobucket.com/albums/ww356/VictorWilkens/DSC_0491.jpg)
(http://i735.photobucket.com/albums/ww356/VictorWilkens/ScreenShot2012-11-06at53149AM.png)

Thats where im at. I have been distracted by this KZ650 project, but thats pretty much done, just waiting to get my paint back so i can tune the little guy and get him out of the way and roll the 1000 back in.

(http://i735.photobucket.com/albums/ww356/VictorWilkens/ROT_7583_zpsb50422ac.jpg)
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: fury413rb on Mar 18, 2014, 17:26:47
what color blue is on that 650? That is exactly what I am looking for
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: M.B Co on Mar 18, 2014, 18:43:44
whoa. loving this one
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: JustinLonghorn on Mar 18, 2014, 18:51:07
I'm on board.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: Goonz on Mar 18, 2014, 19:23:59
Bookmarked!
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: Joe Suzuki on Mar 19, 2014, 00:25:24
Wicked fab skillz!  I'm a sucker for dimple dies.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: DesmoBro on Mar 19, 2014, 02:05:12
Hmmmm modified Kz1000  ill take it
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Mar 19, 2014, 02:32:04
what color blue is on that 650? That is exactly what I am looking for
I have no clue on the blue. The side covers and tail are stock, the tank is a PO repaint, looked very purple in person. I was gonna wait to paint it but it was driving me crazy. My paint guy matched the color on the tail and i saw the sample its really close. I can post a photo and get you the paint code once i get it back


Wicked fab skillz!  I'm a sucker for dimple dies.

Thanks. I scored a set of dimple dies at an estate sale for $30. I fit all the tube and gussets but had my buddy Eric at Performance Welding in Bothell, WA weld them in. AS you can see from his beads this aint his first rodeo, my skills are no where near his.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Mar 21, 2014, 04:09:10
got the tail and sidecovers trimmed to fit. Even with the coremat in the composite, a side cover weighs in at a scant 4.5oz.  gotta start makeing up for the wieght i added with bracing somewhere ::) scheming on how i want to attach them and the seat

(http://i735.photobucket.com/albums/ww356/VictorWilkens/ROT_7778_zps12b1d009.jpg)
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: pjdave on Mar 21, 2014, 04:53:06
Great job, great fibre glassing skills
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: sanu29 on Mar 21, 2014, 04:57:52
Wow like the way this one is going!!
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: valvesprung on Mar 25, 2014, 15:29:01
Beauty so far!
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: Jrbrownie00 on Mar 28, 2014, 09:50:36
i will find myself a kz1000 some day...
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: Bozz on Mar 28, 2014, 10:19:35
Nice!
I'll be watching this one for sure...
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Apr 04, 2014, 07:48:08
thanks guys. Sailing in unknown waters right now so alot of head scratching going on as each hurdle approaches, but i did get the seat pan made. i painted it black to help me visualize the lines the seat will create. side cover mounts are close to finished, pics soon.

(http://i735.photobucket.com/albums/ww356/VictorWilkens/ROT_7815_zpscd814165.jpg)

(http://i735.photobucket.com/albums/ww356/VictorWilkens/ROT_7818_zps764847ff.jpg)

(http://i735.photobucket.com/albums/ww356/VictorWilkens/ROT_7820_zps4122e351.jpg)
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: pacomotorstuff on Apr 04, 2014, 08:50:52
Hi!
I started reading this thread particularly for the "nothing is safe" tag in the subject line but... wow, was I ever pleasantly surprised.
Looks for all the world like you're building a superbike, similar to what I saw at Daytona / Mosport / Shannonville back in the 70's - great look and still practical enough for some serious road miles.
Lucky you, scoring some dimple dies - I had to get a machinist to make me up a couple - great way to get some serious stiffness in a flat piece of metal and save weight too.
You said you fitted up the new tubing yourself before getting your bud to do his magic welding - looks like you did an excellent job and isn't fishmouthing tubing fun?
Cool vacuum bagged parts and your comment re: coremat is right on - it can really add weight if you're not careful, which is why I don't use it.  Your lightweight side panels made me wonder how light some of my stuff is, so I grabbed a set of Z1R side panels I made awhile back (wet layup, no coremat, no vac bag) and took them with me to the shop this morning to weigh on the shop scales.  If I got my conversion from the metric system correct, 4.97 and 4.83 ounces respectively - so I'm wondering how much lighter you could make the covers without coremat?
Neat that your bike will be instantly recognizable as a Kawasaki but a keen observer should be awed at the amount of changes you've made and still keep the character of the bike.
A lot of excellent ideas for other builders to emulate.
Can't wait to see what paint scheme you come up with.
Great build.
Pat
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Apr 04, 2014, 19:09:37
thanks for the kind words Pat. This is very much a learning experience for me as I have never done most of the things i have done here. But the internet is my friend so i have been teaching myself.  In retrospect i went a little too rigid with the side-covers since they serve no structural purpose. I could have gone with half the fiberglass and without the coremat but in the end it would have maybe saved me 2-3 oz per cover, so right now its not worth the effort and money of redoing them. The mounts i'm working on right now will add a bit of weight as well, but oh well.

Vintage superbikes are my favorite. I have been searching for a GS1000 or GS1100E to add to the stable. My goal with this bike is to leave no aspect un-altered, but to do so in a way that retains the spirit of the original as that is what I fell in love with. Also functionality is very important to me. I like the look of some of the brat and cafe bikes on here,  but you ain't doing no 600+ mile day on those. When this thing is done I think I might do a high speed burn up to Alaska, who knows. every ship needs a maiden voyage.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Apr 11, 2014, 07:27:22
I got the sidecover mounts figured out. i just need to make and weld in a small bracket for the lower ones. pics soon. I also cut out the stock gusset in the front of the bike (major PITA).  I did this for a couple reasons, 1. it was preventing the front down tube braces from being welded completely around. 2. By moving the gusset forward to the down tube braces it creates a bit more room up front to mount the HID ballast which has to be within 18" of the lamp, and more room for a big ass horn. 3. the stock gusset had bends in it which negate some of the effect of the gusset as it gives a point to flex at. mine will be a real gusset so it will increase strength. 4. another excuse to use the dimple dies.  8) I also fitted a brace where the stock one was before because I had to cut that out to remove the stock gusset. The gusset is going to look something like this.
(http://i735.photobucket.com/albums/ww356/VictorWilkens/ROT_7836_zps46b54de2.jpg)

(http://i735.photobucket.com/albums/ww356/VictorWilkens/ROT_7839_zps394a2e6d.jpg)

Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Sep 12, 2014, 16:51:45
I have chipping away at the fab. I saw this Vice news documentary on the political assassinations in the Philippines. It shows kids making semi auto handguns with shitty hand tools and files! inspired me to dress up the motor mounts i made. I nearly have my brake setup together, had to get some custom discs with a crazy offset for the KZ wheel. I have a bunch of pictures stuck on my phone that is busted so i'm trying to figure out how to get them off. Should have a better update soon. 
-vic
(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0059_zps053c4763.jpg)
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: slug on Sep 12, 2014, 22:43:01
Doc_rot, very nice stuff here. I too like the use of the dimple dies. I have a decent set of dies from my rock crawler / 4wd days that you have inspired me to bust back out.

Whats the specs on the tubing you are using?

I really like the fiberglass work as well. Good thinking on the vacuum bag setup. Keep up the killer work.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: VonYinzer on Sep 13, 2014, 00:00:17
Wow man. Killer stuff here. Really looking forward to seeing it all come together.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Sep 13, 2014, 21:58:34
Doc_rot, very nice stuff here. I too like the use of the dimple dies. I have a decent set of dies from my rock crawler / 4wd days that you have inspired me to bust back out.

Whats the specs on the tubing you are using?

I really like the fiberglass work as well. Good thinking on the vacuum bag setup. Keep up the killer work.

tubing is 4130 1"OD .065"wall
also have some 7/8"OD .065" wall in the mix where appropriate.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: pacomotorstuff on Sep 14, 2014, 11:25:39
Er, ah, would that be 0.065 inch wall?   Which is a tad over 1/16" wall thickness.
How did welding the thin wall moly reinforcements / braces to the stock frame tubes (mild steel, nearly twice the wall thickness) go?  What welding rod?
Pat
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Sep 14, 2014, 17:13:21
whoops yep, forgot a zero there. .065" wall. I just fit the tubing, my buddy Eric at Performance Welding in Bothell, WA did the welding. I'm not sure what rod he used, but i did watch him weld it up with no problems.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: HollywoodMX on Sep 15, 2014, 04:11:20
Yoshimira made a frame brace blue print for kz1000. My kz is pretty close to that. I think you can still buy the kit for that too.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: cyclhed on Oct 28, 2014, 23:55:59
Cool bike, on board!


Sent from my iPad using Tapatalk
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Oct 31, 2014, 00:15:33
Ok i have been procrastinating on updating here for a while. I finally got the photos off my broken phone. I have still been chipping away at the fabrication.

Final gusset
(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0168_zps8f53a847.jpg)

rear fender....
(http://i735.photobucket.com/albums/ww356/VictorWilkens/0717141724_zps5c2c97ca.jpg)

(http://i735.photobucket.com/albums/ww356/VictorWilkens/0722142249a_zps1c724a43.jpg)

(http://i735.photobucket.com/albums/ww356/VictorWilkens/0724142129_zps19648cad.jpg)

cut down to fit.
(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0164_zpsb9b734c9.jpg)

Rear brake torque link remade. I cut off the clevis off the old arm and welded some threaded rod to it so i could use this swedged aluminum tie rod.

(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0013_zps0988ebda.jpg)

(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0166_zpseadaf7bc.jpg)

(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0167_zps239164ef.jpg)

mounts on airbox/sidecovers/tail finalized.

(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0045_zps69b768d3.jpg)

(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0046_zps72339687.jpg)

ZRX 1200 forks.... steering stem swapped and axle modified by a fellow member over at KZrider. Renthal pro taper, Brembo 16mm MC for the Grimeca calipers.
(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0105_zpsdf96e98f.jpg)

 wheel spacers and speedo delete by another friend.
(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0169_zpsda245e40.jpg)

Its good to have friends with heavy machinery....
(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0134_zpse684236d.jpg)

Prepping for 2 part hydrocal mold.
(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0136_zps0f5a413b.jpg)

(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0137_zpscf3bb515.jpg)

coddles in place and seams sealed
(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0138_zps373a6d8e.jpg)

Part 2
(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0141_zps27c21f27.jpg)

Finished mold. 3 coats mold wax, followed by 2 coats of PVA to prep for mold release.
(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0143_zps12b8694e.jpg)

(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0145_zps845eb3ec.jpg)

Vacuum bagged with strechalon to help get into that hard  concave edge. I bag the whole mold instead of trying to seal the seams.

(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0146_zps975f0bc7.jpg)

trimmed and fitted.
(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0148_zps1c7b8655.jpg)

(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0147_zps297a86de.jpg)

Gauge mount. I fit all pieces and My buddy welds it up.
(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0153_zps65fd3c99.jpg)

(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0156_zps28815361.jpg)

Made some fork clamps. Found some ID tube that was close to the 43 mm forks.I cut out a quarter inch from the circumference, annealed it, and hammered it down to size. lugs welded on then cut. Pinches the forks very well with no gaps. Mocking up different headlight ears.
(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0165_zpsc7890504.jpg)

one of many drawings
(http://i735.photobucket.com/albums/ww356/VictorWilkens/4a123a3a-a834-4fdf-b09f-371365805be2_zps83f0469c.jpg)

I had my photo booth set up for some other stuff today so i decided to snap some photos of a couple things.

(http://i735.photobucket.com/albums/ww356/VictorWilkens/moto3_zpse14f2d1e.jpg)

(http://i735.photobucket.com/albums/ww356/VictorWilkens/gauges_zpsd08638a7.jpg)

(http://i735.photobucket.com/albums/ww356/VictorWilkens/ROT_8901_zpsc5b38826.jpg)

(http://i735.photobucket.com/albums/ww356/VictorWilkens/ROT_8899_zps2b1da3aa.jpg)

The bike had finally been christened. I need to get some photos of the bike with all the finished body work on it.
(http://i735.photobucket.com/albums/ww356/VictorWilkens/8c4fa2e0-fd2d-416e-8a12-0b474109441f_zpsc380a575.jpg)
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: pjdave on Oct 31, 2014, 04:06:07
Top skills, love this build. Good to see some updates.pj
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: pacomotorstuff on Oct 31, 2014, 08:35:38
Aha!  You have discovered the magic of the plaster mould!  I first did some plaster moulds back in the '70's (wish I'd kept them)  and still keep a (big) bag of Hydrocal plaster in the shop.  I liked Ultracal better but either it's not available any more or my local supplier won't order it for me.
About the only suggestion I could make to your outstanding plaster mould work is, to make the moulds last a little longer, spray the mould face with one of the spraybomb urethane / varathane / whatever your local paint store has clearcoats, as soon as you can pull the mould off the master - when the plaster is still warm is best.  Keep doing light coats - you'd be amazed how far it penetrates in.  Also seals the plaster from the PVA if you have any areas that are a bit thin on wax coats.
Still on cuppa coffee #2 so not banging on all cylinders yet, but did you mention what you used for a release agent on the master?  The last plaster moulds I made (last summer), I used a "PAM" type kitchen spray, just a couple of light coats and hey presto, off came the mould, easy-peasy (the fact that the hydration reaction of the plaster with the water makes the mould "grow" a little bit rather than shrink like almost all toolmaking resins helps too).
BTW, isn't Hydrocal used in the dental industry?
Great build.
Pat 
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: cobraace2 on Oct 31, 2014, 12:05:24

shit even the drawings are first class very nice  8)
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Oct 31, 2014, 19:08:46
Paco, thats good to know about the clear coat. I made another hydrocal mold for the headlight bucket but didn't seal it well enough and had to break the mold to remove the bucket. Most of my plaster/mold making skills come from ceramic industrial processes, so its been interesting applying it to fiberglass. Also WAYYYYYY faster and cheaper to make the mold out of hydrocal than fiberglass. I spent only an hour prepping and pouring the molds and it cost me a couple bucks in hydrocal. Mold making is one of those skill sets if you can get a hold on, you can apply it to a wide range of different materials. As far as sealing the master; I put a very thin coat of mold release on the aluminum plug. I make my coddles out of acrylic so plaster isnt sticking to those, and the base is polished polyurethane so not sticking to that either.  Here is the mold i made for the headlight bucket with the retaining ring sitting in it.
(http://i735.photobucket.com/albums/ww356/VictorWilkens/DSC_0288.jpg)
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: pacomotorstuff on Nov 01, 2014, 08:26:50
Doc,
Something you can do if you are making a larger mould out of plaster and don't want to do the monolith block thing, is "throw" a coat of a fairly runny plaster on the master to form a thinnish layer against the part - like gelcoat, and then lay up reinforcing that has be soaked in a fairly thin mix of hydrocal.  It all should be done as one continuous process, before succeeding coats are fully cured.
I use burlap cloth for reinforcement - bought a bunch of offcuts from a place that made burlap bags for farmers and will never run out, but almost any open weave fabric would probably work.  The composites industry makes (made?) a grade of fiberglass cloth for use with concrete and that would probably be the best, but maybe a little expensive for a mould to make one or two parts?
Have fun with your build.
Pat
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Nov 06, 2014, 19:29:54
Custom ISR disks. Just gotta whittle a carrier for the calipers and brake setup will be nearly complete.

(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0172_zps7710457e.jpg)

(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0173_zps5c629883.jpg)
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: Erskine on Nov 18, 2014, 20:08:52
Awesome stuff.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: crackerman on Nov 19, 2014, 17:39:03
Great build. Loving the side and rear tail molds. Impressive stuff.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: CrabsAndCylinders on Nov 19, 2014, 21:44:05
Excellent work, great build!
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Nov 21, 2014, 05:09:45
Thanks guys. been chipping away. should have an update sometime soon.

BTW CarbsAndCylinders have you posted any more pics of your Harris Z1? that has been a dream of mine for a while. probably easier to build a replica than find one of those. nice bike.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: CrabsAndCylinders on Nov 21, 2014, 14:26:44
I will take some more pics of it.  The PO who built the bike, spent a lot of money and time on it.  I am really looking forward to watching your build!

Brian
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: rundown on Nov 21, 2014, 22:09:55
Glad to see those molds were for the gauges, for a minute I thought you were making some kind of strange brassiere, didn't know what DTT was coming to.  Great work.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: m511y on Nov 21, 2014, 22:42:28
I'm keeping an eye on this one. Such amazing fab work. Your giving me tons of ideas.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: HollywoodMX on Dec 10, 2014, 13:15:21
Nice build and cray detail. Please tell me you are going to ditch the pos stock rear break though.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Dec 11, 2014, 01:28:31
Nice build and cray detail. Please tell me you are going to ditch the pos stock rear break though.

Thanks man. I didn't like the looks of the factory A1 caliper when I first swapped it. It is a bit bigger than the stock LTD caliper. However its looks have grown on me. I think it matches the Grimeca calipers pretty well and and looks like the most seventies caliper i have ever seen.  Its a 43mm dual piston caliper so it will have no trouble locking up the rear wheel if I want to, probably when I don't want to as well.   ::) The only real performance benefit that would come from a swap is weight savings. Which I may do in the future because i'm too stupid to leave things alone. I just rebuilt/painted it. It was pretty roached. both pistons were shot and the only replacements I could find came from the UK so it was not inexpensive. I also rebuilt the MC and painted that as well. I used Gun Kote, which is IMHO the only caliper paint worth a shit because it is completely impervious to solvents, and I have yet to bleed a caliper and not get brake fluid everywhere. I also had the rear disk refinished and drilled. It had pretty deep grooves and some run out. Blingin!
(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0175_zpsd9171844.jpg)

(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0263_zps115c3f84.jpg)

(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0250_zpsa966fe35.jpg)

(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0264_zps09cefea4.jpg)

I swear its the small stuff that takes the longest. I got the turn signal mounts, taillight mounts, tailpiece mounts, and tank mount finalized. I also made a steering stop, but my buddy thought it was a bit crude so he spent like 2 hours remaking it. Glad he's on my team, the damn perfectionist...

(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0213_zpsc0505181.jpg)

(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0212_zps165b6abc.jpg)

(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0211_zpscb9500d6.jpg)

(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0210_zps1afe82b1.jpg)

(http://i735.photobucket.com/albums/ww356/VictorWilkens/940b585f-847b-4df7-9876-6db4f5bf7d9c_zps444e4bec.jpg)

I have now turned my attention to the seat. I remade my seat pan. and bought a bunch of foam.

(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0246_zps9c86be3f.jpg)

(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0260_zps97030284.jpg)


I have sewn a bit, but it is not my strongest suit. I ran a couple test seams on some vinyl with sew-foam using different weights of thread, and trying out a couple different stitch patterns. I was struggling to use my mothers sewing machine so she offered to help me with the final. I need to make a pattern first. Stay tuned, I should have the seat finished this weekend.  8)

Two stroke sewing machine...

(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0261_zps5b5e7601.jpg)

(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0262_zpsd4ac832c.jpg)

Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: HollywoodMX on Dec 11, 2014, 19:00:46
Thanks man. I didn't like the looks of the factory A1 caliper when I first swapped it. It is a bit bigger than the stock LTD caliper. However its looks have grown on me. I think it matches the Grimeca calipers pretty well and and looks like the most seventies caliper i have ever seen.  Its a 43mm dual piston caliper so it will have no trouble locking up the rear wheel if I want to, probably when I don't want to as well.   ::) The only real performance benefit that would come from a swap is weight savings. Which I may do in the future because i'm too stupid to leave things alone. I just rebuilt/painted it. It was pretty roached. both pistons were shot and the only replacements I could find came from the UK so it was not inexpensive. I also rebuilt the MC and painted that as well. I used Gun Kote, which is IMHO the only caliper paint worth a shit because it is completely impervious to solvents, and I have yet to bleed a caliper and not get brake fluid everywhere. I also had the rear disk refinished and drilled. It had pretty deep grooves and some run out. Blingin!
(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0175_zpsd9171844.jpg)

(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0263_zps115c3f84.jpg)

(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0250_zpsa966fe35.jpg)

(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0264_zps09cefea4.jpg)

I swear its the small stuff that takes the longest. I got the turn signal mounts, taillight mounts, tailpiece mounts, and tank mount finalized. I also made a steering stop, but my buddy thought it was a bit crude so he spent like 2 hours remaking it. Glad he's on my team, the damn perfectionist...

(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0213_zpsc0505181.jpg)

(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0212_zps165b6abc.jpg)

(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0211_zpscb9500d6.jpg)

(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0210_zps1afe82b1.jpg)

(http://i735.photobucket.com/albums/ww356/VictorWilkens/940b585f-847b-4df7-9876-6db4f5bf7d9c_zps444e4bec.jpg)

I have now turned my attention to the seat. I remade my seat pan. and bought a bunch of foam.

(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0246_zps9c86be3f.jpg)

(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0260_zps97030284.jpg)


I have sewn a bit, but it is not my strongest suit. I ran a couple test seams on some vinyl with sew-foam using different weights of thread, and trying out a couple different stitch patterns. I was struggling to use my mothers sewing machine so she offered to help me with the final. I need to make a pattern first. Stay tuned, I should have the seat finished this weekend.  8)

Two stroke sewing machine...

(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0261_zps5b5e7601.jpg)

(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0262_zpsd4ac832c.jpg)
Sweet update.

Try it out but I think that rear caliper setup works like ass. On my z1 in mint shape it was terrible.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: Erskine on Dec 11, 2014, 19:20:17
Top banana.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Dec 12, 2014, 18:00:12
Sweet update.

Try it out but I think that rear caliper setup works like ass. On my z1 in mint shape it was terrible.

The Z1 never came with a rear disk. If you had this caliper, the entire rear end would have to be swapped, and a bracket for the MC / pushrod pivot made. No offense intended, but I wonder if you had the correct components set up properly, mint or not. I hardly ever use my rear brake, except in emergency braking situations, or on dirt/grass/gravel. In any of those scenarios you do not want an aggressive rear brake or the rear will lock up. I'm sure this setup will have plenty of brake force.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: xb33bsa on Dec 12, 2014, 20:52:05
The Z1 never came with a rear disk. If you had this caliper, the entire rear end would have to be swapped, and a bracket for the MC / pushrod pivot made. No offense intended, but I wonder if you had the correct components set up properly, mint or not. I hardly ever use my rear brake, except in emergency braking situations, or on dirt/grass/gravel. In any of those scenarios you do not want an aggressive rear brake or the rear will lock up. I'm sure this setup will have plenty of brake force.
that huge boat anchor heavy KZ disc and caliper is just horrible though  :-[ :-\
why not put something svelt on it ? and your swingarm bracing is a bit over the top as well,too deep it doesn't look right
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Dec 12, 2014, 22:02:45
Horrible how? Disk and caliper are definitely heavy, no arguments there. Like I said, i may do a swap down the road but considering I have a working rear brake that is fully rebuilt, it will not be considered until this bike is on the road and tuned. The swing-arm bracing is admittedly a bit overkill, too many braces, maybe a bit too low. However I think it looks fine, and if you dont....  ;D
https://www.youtube.com/watch?v=pWdd6_ZxX8c
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: Drewski on Dec 12, 2014, 22:32:44
Horrible how? Disk and caliper are definitely heavy, no arguments there. Like I said, i may do a swap down the road but considering I have a working rear brake that is fully rebuilt, it will not be considered until this bike is on the road and tuned. The swing-arm bracing is admittedly a bit overkill, too many braces, maybe a bit too low. However I think it looks fine, and if you dont....  ;D
https://www.youtube.com/watch?v=pWdd6_ZxX8c



Haha! Good on ya doc!! Steady On Sir!   ;D

Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Dec 15, 2014, 18:37:43
So making a seat for the first time was A LOT of work. I did all the sewing, the only assistance needed was figuring out how to put the damn sewing machine in low gear, and someone pulling as i fed the final piping seam through because the machine was bogging down.
(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0279_zps18c8f77a.jpg)

(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0280_zps18365702.jpg)

(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0281_zpsadb476e8.jpg)

(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0282_zps10c6e5cd.jpg)

(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0283_zps5bb630af.jpg)

(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0284_zps07405853.jpg)

(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0285_zps562f07dc.jpg)

(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0286_zpsc7e3f553.jpg)

(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0288_zpsb53ca056.jpg)

(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0298_zpsa0ff1152.jpg)

(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0291_zps7b13af55.jpg)

But it turns out I made a huge mistake, I didn't leave enough room for the vinyl to wrap under the seat pan and now it wont fit down all the way. GAHHHH!!!  I spent two full days working on this seat i probably have about 12-14 hours in it. I really don't want to re-do the seat, so I have been thinking about possible solutions.
(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0292_zps570ae1de.jpg)

I trimmed all the excess foam off the bottom and riveted it as tight to the edge as possible. I think the easiest/cheapest thing to do would be to re-fit the top subframe rails. Any suggestions? I will remake the seat if that is my only recourse..... I'm floundering over here!!
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: xb33bsa on Dec 15, 2014, 18:39:22
that looks fantastic  :D you can do mine ??
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: CrabsAndCylinders on Dec 16, 2014, 04:41:45
I agree, that looks great.  Can you say a little more about the upholstery you used, where would one get something like this?  Also, what kind of wood are you using for the rear suspension?
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: fury413rb on Dec 16, 2014, 08:21:34
that huge boat anchor heavy KZ disc and caliper is just horrible though  :-[ :-\
why not put something svelt on it ? and your swingarm bracing is a bit over the top as well,too deep it doesn't look right

doesnt look right or wont function right
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Dec 16, 2014, 16:44:23
I agree, that looks great.  Can you say a little more about the upholstery you used, where would one get something like this?  Also, what kind of wood are you using for the rear suspension?

thanks! Ill try and keep it brief. I'm not an expert i just read on the interwebs about how to do it. I bought my foam from Friendly Foam in Seattle, WA. i used the stuff they recommended. I started with 1.5" pink closed cell foam for the base. then I folded .5" gel-foam over that. I used RP2020 as a spray adhesive. its super strong. I then shaped the foam with an angle grinder with a flap wheel to rough it out and then smoothed it out with a orbital sander. I bought some marine grade vinyl and some 92 weight polyester thread. The thread is crazy strong. I then sewed .5" sew-foam to the vinyl. Sew-foam has a fabric backing so the thread will not pull out or cut the foam; it is what gives it the ridges. Its hard to see in the pics but i used a one stitch zig-zag instead of a straight stitch to spread the load out more. Once i had the ridges sewn i entrapped some plastic cording in vinyl for the piping. sew that loosely to one side, then sew the final pass tight against the cording. If you're really good you just sew it in one pass but I did it in three; progressively getting closer to hide my previous seams. I then sprayed the top of the seat with RP2020 and stretched the seat cover tight over the foam. I predrilled holes in the pan and used 1/8th" pop rivets to snug it down.

Whew! if  you have any questions I can elaborate further.

BTW that is some of the northwest's finest 1x2 pine. Looks great alothough it makes the ride a bit wooden  ;D
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Dec 16, 2014, 16:46:26
here is a close up of the one stitch zig zag (aka firestone stitch)

(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0301_zps4d9e6462.jpg)
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: CrabsAndCylinders on Dec 17, 2014, 18:54:35
Very nice
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Dec 19, 2014, 19:34:23
I have been real busy.  I  finalized my headlight ears. I decided not to go with the small 4.5" headlight. it just looked weird with the big gauges. I got this nice 7" headlight and promptly started cutting it up  ::) I didn't like the mounting points so Eric welded some washers in  with silicon bronze.  I cleaned up the seams with some filler and am much happier with it now. I spent about 3 hours filing and sanding down the headlight ears to get them where they are. I also turned a some washers for the turn signal mount. I need to figure out how i want to route the wire from the turn signal now. I think i'm going to go into the headlight bucket with it. Im very happy with how the headlight/gauge cluster is turning out. Its such a great feeling to have an idea in your head finally come to fruition after a couple years.

(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0276_zps4701f76b.jpg)
(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0266_zps257ad1cb.jpg)
(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0268_zps967a64ea.jpg)
(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0275_zps49430c8c.jpg)
(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0277_zps49393ed0.jpg)
(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0294_zps39e9ecef.jpg)
(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0303_zps6f7541e9.jpg)
(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0304_zps82e8d021.jpg)

I also refitted the frame rails 1/8" in on each side. was real easy. seat fits great now. I also did a down and dirty rattle can job on the frame to see what it would look like white before i commit to some good paint. I wasn't sure about the white frame i thought it might be too garish for my taste, but it highlights all of the frame mods we have done, and really pops. I think i will go with white for the final paint on the frame.  I also mocked everything up to see what other frame mods will be necessary before i do the final paint on the frame. I still need to do something about and exhaust hanger, horn mount, mount for HID ballast, and carb support.  Super stoked with the way it is looking.  8) 8) 8)
(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0302_zps41d87434.jpg)
(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0310_zps7ea82945.jpg)
(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0311_zps514c1c55.jpg)
(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0312_zps1e8f54a2.jpg)
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: fury413rb on Dec 19, 2014, 20:13:01
NICE!!!!
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: jcw on Dec 19, 2014, 22:00:23
Nice nice build!
better welds than most...

my compliments to the weldor.

the headlights clamps are the tits
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Dec 21, 2014, 10:50:09
thanks guys. getting close. i have a bet with my brother to finish it by july 1st. cant loose!
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: HollywoodMX on Dec 22, 2014, 00:19:42
The Z1 never came with a rear disk. If you had this caliper, the entire rear end would have to be swapped, and a bracket for the MC / pushrod pivot made. No offense intended, but I wonder if you had the correct components set up properly, mint or not. I hardly ever use my rear brake, except in emergency braking situations, or on dirt/grass/gravel. In any of those scenarios you do not want an aggressive rear brake or the rear will lock up. I'm sure this setup will have plenty of brake force.
Sorry kz1000 and from a distance it looks to be the same. A back break is useful. People down play needing an effective rear brake. I just think with all the effort in the build, keeping the stock rear brake short changes the build.
that huge boat anchor heavy KZ disc and caliper is just horrible though  :-[ :-\
why not put something svelt on it ? and your swingarm bracing is a bit over the top as well,too deep it doesn't look right
Yes it is very heavy indeed and another vote for its terrible performance.

Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Dec 22, 2014, 03:16:57
Derp. should have guessed you were talking about your KZ1000A1. you had/have this caliper. Like I said, i will probably change it down the road, but this is more than adequate for the moment. I also want to ride this bike, messing with something that works fine at this point is a great way to get derailed. i don't want to loose the bet!
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: canyoncarver on Dec 22, 2014, 16:11:06
nice ears man
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Dec 30, 2014, 21:00:39
Just a quick update. I was over at my buddies place using his sheet brake, its a cheapo but gets good results for small stuff. I made a couple of small aluminum brackets to hold various electrical components. I also thought i'd share a pic of a titanium kickstand he has been fiddling with for weeks. Think its for an Aprilla race bike.

(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0328_zps3422aabc.jpg)
(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0329_zpsac9caf6d.jpg)
(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0326_zps214582b3.jpg)
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: HollywoodMX on Jan 08, 2015, 20:40:09
Just a quick update. I was over at my buddies place using his sheet brake, its a cheapo but gets good results for small stuff. I made a couple of small aluminum brackets to hold various electrical components. I also thought i'd share a pic of a titanium kickstand he has been fiddling with for weeks. Think its for an Aprilla race bike.

(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0328_zps3422aabc.jpg)
(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0329_zpsac9caf6d.jpg)
(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0326_zps214582b3.jpg)
Looks like a nice skid plate!

Ya I will need a modified kickstand on my Kz too. She sits pretty low compared to stock.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Jan 18, 2015, 05:18:38
My late birthday present came 8) 1.75" over stock to even out the geometry and gain ride height. They are much nicer than the Works shocks  I previously was planning on using. They are beefier everywhere and 6oz lighter per shock.

(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0350_zps9b14096e.jpg)

Because of the over length shocks I need a chain slider on the swingarm. Eric turned up this chunk of derelin and I fish-mouthed it so It uses no fasteners, as it is entrapped when the swingarm is mounted. I may need more sliders, but that can be addressed later if need be.

(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0365_zps1f297d5c.jpg)
(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0368_zps07998c73.jpg)

All the remaining tabs needed are welded on. The bungs for the exhaust hanger are welded in. A couple nasty welds have been cleaned up.  The kickstand has been moved up to the bottom engine mount, the detent spring peg had to be relocated so the engine bolt could fit. The kickstand was shorted because it is now farther out from the center. I have plans for something trick to replace the stock solid one.

(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0386_zpsad89e6f1.jpg)

I then turned my attention to the rear sets. These Tarrozis were meant to be  bolt-ons so they had to compromise a bit, like using the huge stock brake pivot. I also wanted to retain the use of my kickstart and the brake pedal was solidly blocking it.

(http://i735.photobucket.com/albums/ww356/VictorWilkens/55b65f37-f156-4bc8-926d-96b4031fbcf9_zpsf8a392fb.jpg)

 I saw on a XS650 forum where people had cut a channel in the pivot to allow the pedal to be brought back out of the way temporarily. To do this you had to leave everything a bit loose to allow the pedal and pivot not to bind. I didn't want any slop in my footpegs so Eric and I came up with a solution i am very proud of. I cut a piece of 1"tube with .065" wall thickness and it made a perfect bushing for the footpeg and pivot.  As a safety feature a spring loaded pin was added on the pedal so that the brake lever cannot be accidentally kicked up when riding. You simply compress the spring and pull the pedal up. Eric turned most of the parts, while grumbling about his "clapped out" lathe, and did the amazing welding as usual. I'm nearly done finishing the parts, I just need to clean up some if the holes I drilled. I also cut the threads off the footpeg mounting studs and drilled and tapped them to use some stainless countersunk washers. I also had to file down the Tarrozi bracket mounts to remove the counter sunk flange on the casting. I also took the opportunity to remove the casting marks. I have ordered folding footpegs from Fast from the Past, so I should have plenty of clearance for the kicker.

(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0403_zpsa2e10c3a.jpg)
(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0408_zps44adbecb.jpg)
(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0410_zps6265bc8a.jpg)
(http://i735.photobucket.com/albums/ww356/VictorWilkens/0719695e-c444-4c0c-804d-a5369c24effa_zps35eaf00a.jpg)
(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0420_zps38ed8af2.jpg)
(http://i735.photobucket.com/albums/ww356/VictorWilkens/d32a74e3-9ba4-4a94-ad43-e05850a18058_zps3a3cb800.jpg)
(http://i735.photobucket.com/albums/ww356/VictorWilkens/43139774-d568-47e2-8877-9f65a0dabbb2_zps0a8e5bd9.jpg)
(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0411_zpsc60e89de.jpg)
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: xb33bsa on Jan 18, 2015, 08:40:21
lookin good love those shocks  :D
yeah the chain is going to be very loose at full drop and even when riding a lot of the time it is going to be flapping around quite a bit
a stationay roller placed up front under the bottom run can work pretty well to take out a lot of the droopslack if strateegically placed
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: CrabsAndCylinders on Jan 18, 2015, 15:21:25
More great work!   :)
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Jan 18, 2015, 19:20:15
thanks guys. I'm hoping it wont need a chain roller. The bike that inspired me to go balls out on this has 2" over shocks and he does not run a slider or roller. Its kinda hard to see in the photo but there isn't even that much slack in his chain. I will have to wait and see once the bike is on the road and address it if needed.

(http://i735.photobucket.com/albums/ww356/VictorWilkens/left-224976868288182592aa76455ad9768b_zps1abf6bec.jpg)(http://i735.photobucket.com/albums/ww356/VictorWilkens/np1_800_zps432a0770.jpg)
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: Tune-A-Fishİ on Jan 18, 2015, 23:20:33
Nice work, the attention to detail is bar none. I'm sure the geometry was well planed, but that swingarm bracing does cause me to turn my head sideways.

Did I hear that you were taking orders for the dimple die brace panels? Do i need to send materials or can you source that and just send the invoice?

RD :o
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Jan 19, 2015, 00:31:29
Nice work, the attention to detail is bar none. I'm sure the geometry was well planed, but that swingarm bracing does cause me to turn my head sideways.

Did I hear that you were taking orders for the dimple die brace panels? Do i need to send materials or can you source that and just send the invoice?

RD :o

thanks man. Yeah the bracing is a bit low, too late now though. I wasn't planning on taking orders for dimpled steel, if you can't find a shop to do it for you let me know and we can work something out.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: LBC on Feb 23, 2015, 00:26:41
The fiberglass and other fab work on this build got me motivated to push ahead on my KZ400 despite the frigid garage. Top notch stuff.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Mar 05, 2015, 06:27:14
The fiberglass and other fab work on this build got me motivated to push ahead on my KZ400 despite the frigid garage. Top notch stuff.
Thanks man. I like coming here to get inspired by some of the cool shit i see. its good to know it works both ways.

Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Mar 05, 2015, 06:28:38
Finally stopped procrastinating and started final assembly of the motor. Wiseco 1075 pistons and APE heavy duty cylinder studs. I picked up the caliper mounts from the machinist. He made them out of 7050, an alloy I had never heard of before. He showed me a coil chip left over from machining, and man it is tough stuff! I need to get some appropriate hardware to mount them. I also had him machine and knurl some parts for a stainless kickstand. I will finalize the foot of the kickstand once i have a rolling chassis.

(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0602_zpsoagk7qgi.jpg)

(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0562_zps3uzsyfux.jpg)

(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0566_zpsdgpdmcut.jpg)

(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0568_zpszagw5zxc.jpg)

(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0570_zpscvkaw28u.jpg)

(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0574_zpsor193hl9.jpg)

(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0575_zpsfmuccq08.jpg)


Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: grandpaul on Mar 05, 2015, 23:59:06
Very nice work.

Gotta love a Z bike...
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Mar 22, 2015, 20:36:14
Another small item off the check list. I shaved the stock fender mounts and made a bracket off the caliper bracket. very pleased with how it turned out.  Just need some cool fasteners to finish the front end off. I was thinking about 12 point flange bolts for the fork/caliper bracket. Maybe some button or allen head screws for the caliper and disk? Any suggestions on some trick hardware?
(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0672_zpslzrbgoh1.jpg)
(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0670_zpsydxshuyi.jpg)
(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0671_zpszqu6njox.jpg)
(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0669_zpsutjanuch.jpg)
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: YogiBear on Mar 23, 2015, 14:04:46
I'm stoked to have found this build. I can't wait to see the finished product  :)
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Mar 28, 2015, 00:46:32
A member over at KZR recommended these bolts. they are gun drilled flange bolts from a first gen R1 caliper. Yamaha used them on many bikes over the years. the devil is in the details.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: Tune-A-Fishİ on Mar 28, 2015, 08:42:34
Bolt porn... I think I am nurturing an addiction for titanium fasteners and been making brackets out of Ti drops I find on Ebay, the stuff is nice to work with, and just the right contamination in the welds make em look cool haha
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Mar 28, 2015, 15:24:27
after seeing the Ti header you modified for your 750 you got me thinking... I bought a GSXR header for $50 bucks that i am gonna chop up for a high pipes on my 750 twin project. I couldnt buy that much Titanium stock for $50
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: Tune-A-Fishİ on Mar 28, 2015, 18:27:00
Yeah! if you watch they go even cheaper DL the mybidder auction sniper app it's free for one snipe at a time and it works sweet!
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on May 08, 2015, 21:43:40
I was hoping to have the engine in the frame for this update, but... I was degreeing the cams when i discovered the cam chain was too short, did some research and found that the MKII motor uses a 124 link chain. I bought the wrong one with 122 link, probably back when i thought i had a 78 motor.  This means total teardown to install the correct chain.   :( Sometimes i wonder if there is something or somebody out there secretly conspiring to keep me from finishing this project. But seeing as this is my fourth time taking it apart/ putting it back together i think i will be able to do it in an afternoon once i have the cam chain.
(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0831_zpsqkehpn7v.jpg)

Some good news; I ended up powder coating the frame gloss black, and it was probably one of the smarter decisions i have made so far. White was just too overpowering for some of the other cool stuff going on, also a nightmare to keep clean. I also did my first bit of TIG welding on this and finished the foot for the kick stand. I still need to find a stainless ball bearing to weld on the end like the stock kickstand.
(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0784_zpsbzu89umd.jpg)

(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0770_zpsmkngtc8z.jpg)

(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0772_zpsixhvpr1r.jpg)

(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0773_zpslu2rkvcr.jpg)

(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0776_zpshyzp2g8m.jpg)

(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_0777_zps7miac3zw.jpg)
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: xb33bsa on May 08, 2015, 22:51:41
 use a masterlink , no complete teardown needed
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on May 08, 2015, 23:48:56
Is that strong enough?
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: xb33bsa on May 08, 2015, 23:53:54
Is that strong enough?
no difference the master links are a tight fit then you just barley peen the edges of the protruding pins, that is all it takes there are no forces trying to wedge it apart
 lots get carried away and peen the fook outa them but this can damage the link plate
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on May 09, 2015, 00:05:30
Good call. I see Z1enterprises sells master links for the Tsubaki cam chains, this will save me a ton of time. Thanks XB!
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: xb33bsa on May 09, 2015, 00:12:59
your bike looks awesome too !!
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: grandpaul on May 09, 2015, 10:56:20
I always use masterlinks, even on drive chains on my ZRXs & KZ.

You just need to be very careful to get a good peen that will last, without damage to the link plate. They sell tools for that.


Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on May 09, 2015, 18:18:44
Thanks for the reassurance grandpaul. I have a chain breaker/riveter that i use for drive chains but it was sold as a "cam chain tool", it seems to have what i will need.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: xb33bsa on May 09, 2015, 18:26:16
Thanks for the reassurance grandpaul. I have a chain breaker/riveter that i use for drive chains but it was sold as a "cam chain tool", it seems to have what i will need.
all you need is a heavy backup and careful few hits with a ball pien hammer,on the masters that have not got the pin turned down where it protrudes all you need is a couple tiny dings and it will never sepearate
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on May 09, 2015, 18:35:26
that sounds dicey. is it not preferable to use the chain riveter?
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: xb33bsa on May 09, 2015, 18:38:16
that sounds dicey. is it not preferable to use the chain riveter?
no it is not dicey,not in the least
some masters are not riveter friendly depends what type riveter , what type master
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on May 09, 2015, 18:39:46
I'm gonna call Z1 on monday to order the part, ill see what they say about installing the master link as well.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: xb33bsa on May 09, 2015, 18:46:09
yeah if you dont understand the actual concept it is an issue
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: ABCanuck on May 09, 2015, 18:48:54
Or maybe he does, and isn't comfortable.  What's wrong with that?


Sent from my iPhone using Tapatalk
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: xb33bsa on May 09, 2015, 18:58:38
Or maybe he does, and isn't comfortable.  What's wrong with that?


Sent from my iPhone using Tapatalk
i was just making an observation, nothing wrong with educating ones self ,in fact that is a good thing
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: ABCanuck on May 09, 2015, 19:12:25
Sorry, I think I read that wrong haha.  Not enough sleep!!!


Sent from my iPhone using Tapatalk
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on May 09, 2015, 19:43:27
Lol. I get it. I want to know what Z1 suggests for my own edification. I'm just a bit wary of doing this myself as a cam chain failure would be catastrophic. I'm gonna have my buddy come over and give me a hand as well. He is a amazing bike mechanic, so I will feel more comfortable doing this, having never riveted/peened a cam chain before.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: Tune-A-Fishİ on May 09, 2015, 20:53:25
I have used them, and will again in a few days, you will be no more than manually duplicating what the dude at the factory did, but with slightly less expensive tooling. Like XB says, no much lateral stress on the pin/link.

I use a double drift method, on heavy flat held by the wife or rags (it wont get far) and a hard hollow tip... one peen the same as a punch dimple and yer done. the breaker and anvil has failed me in the past as it is attempting to "press" a shoulder on the pin and tends to bend it or the tool fails it's self.

Just my 2 cents... worth the same, about a penny. Think of all the stress a final drive chain takes with that little clip holding on  :o
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Aug 08, 2015, 02:35:39
Well its been a while since i had time to work on this, unfortunately it got triaged into the corner for a while, however i recently tore the motor completely back down, installed a new cam chain (couldn't find a new Tsubaki and no masterlinks for the D.I.D.)  and got it built back up. A friend of a friend has graciously let me borrow his huge shim kit to degree the cams. hope to have the motor buttoned up and in the frame by next week.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Aug 21, 2015, 03:52:44
this motor fought me all the way to the end. Had to heli-coil three screws in the camshaft holders, but it is finally finished. I hope to have it in the frame soon.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Aug 22, 2015, 15:13:14
Huge milestone right here
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Aug 23, 2015, 17:19:05
Paint turned out real nice. I want to do some pinstripes down the road.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: trek97 on Aug 23, 2015, 17:33:54
everything is gorgeous.   8)
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Aug 23, 2015, 18:07:45
Thanks man.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: jpmobius on Aug 23, 2015, 19:54:02
Looks Beautiful! did you do it yourself?  What material?
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: Bootsey on Aug 23, 2015, 20:43:28
Nice work, this thing is going to look the tits.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Aug 23, 2015, 21:41:09
Looks Beautiful! did you do it yourself?  What material?

Thanks guys.

I used;
PPG DCU2021 urethane clear.
Deltron 2000 base - Ford magnetic metallic that i added quite a bit of silver toner to.
PPG DP90LF epoxy primer.

I got this LVLP gun a bit ago and am so impressed with the results over my HVLP guns. Almost no orange peel at all. very little overspray. I think i might get another 2; one as a standalone clear gun, and one for primers, etc. Metallics are like herpes, once you put them in a gun you never really get them out.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: r.s.hutchinson on Aug 24, 2015, 09:09:58
I've been following this for a while, great to see it finally coming together!

Looking amazing. 


Got a link to the LVLP gun you're using?
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Aug 25, 2015, 02:40:28
Heres the gun I am using although I also have the 1.8 tip set that i was using for the primer and sealers. Relatively inexpensive for a solid gun.

http://spraygunworld.com/products/Astro/Astro%20Pneumatic%20-%20EVO4014.htm
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Dec 26, 2015, 05:43:50
I dont have a garage so my projects have been in storage. I currently have a little bit of time to work on them but progess will be slow for a while :(
I finally have some time to work on the bike and started assembling a couple more things. Very pleased with how the rear sets worked out, but I need to modify the kick for more clearance, and perhaps get some folding footpegs. which are a good safety feature as well for a street bike. My buddy also gave me this sweet stainless stand he welded up years ago for his track bike.

Also here is a design feature I'm trying to work out; I need to finish the back of the turn signal off a little more elegantly. I'm thinkin of triming the bolt down, using a flanged nut, and then routing the wires straight to the headlight bucket with a small hole and a grommet. Im not really satisfied with this solution as i think seeing wires bridging a gap like this doesnt look great, but im am stumped and not willing to remake the headlight ears. I was thinking about getting some cool expandable sleeve to dress up the wires a bit. thoughts?
(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_1865_zpswljcunyb.jpg)
(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_1915_zpsp2muddt0.jpg)
(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_1916_zpsdg9kpua5.jpg)
(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_1919_zpscnakpeie.jpg)
(http://i735.photobucket.com/albums/ww356/VictorWilkens/IMG_1914_zpsyoa9ayrc.jpg)
(http://i735.photobucket.com/albums/ww356/VictorWilkens/s-l1600_zpsxwyvqs0q.jpg)
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: CrabsAndCylinders on Dec 26, 2015, 19:04:41
Looks very nice!
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: jpmobius on Dec 26, 2015, 20:39:10
I like the flange nut idea and trimming the exposed threaded post accordingly (and the notion of taking the time to improve this minor item at all).  I thought perhaps routing the wires themselves through some nicely curved metal tubes would look pretty clean.  Possibly leave the threaded stalk long enough for the tube to slip over to station the one end, and run the tube through a tight fitting grommet in the headlight bucket.  The grommet would hold it in position and still allow for some flexibility and headlight aiming adjustment.  The wires would be protected and rigid tubing would take away the unfinished look of having them exposed.  You could paint them black or polish them if stainless or aluminum.  Alternatively, you could simply relocate the signals themselves to make them the mounting bolts for the headlight bucket which of course is common on many bikes, though the general aesthetic would change.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: CrabsAndCylinders on Dec 26, 2015, 22:27:29
Something like this?

http://bluewireautomotive.com/products/stainless-steel-door-jams
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Dec 26, 2015, 22:59:49
Alternatively, you could simply relocate the signals themselves to make them the mounting bolts for the headlight bucket which of course is common on many bikes, though the general aesthetic would change.

Yeah i usually like that look but because the headlight bucket is fairly long it sticks out a good way from the triples, I originally mounted the turn signals at the headlight mounting point but it looked weird with them sticking so far out. This was a compromise. I like the tube idea, I'm going to play around with some stock i have and see what I can come up with. Once the gauges are bolted on this feature is not readily noticeable but the details matter to me.

CarbsandCylinders - those lines are sweet, I think i have some stainless sleeve sitting around. i might try that as well.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Sep 06, 2016, 21:57:20
The forgotten child. I finally got off my ass and made some good progress on this. There were some fitment issues that I was dreading dealing with but my friend Eric sorted them out. Because this was the first seat pan I ever made I accidentally went a little too thin on it and when the seat cover was stretched over the pan it caused the whole back end to bow up and had an unsightly 3/4" gap to the tail. Eric bent a piece of titanium (according to him it was because he didn't want to paint it ::) ) and riveted it to the back pulling the gap shut, he also attached the mounting hardware and the seat fits great, in fact it is probably the easiest seat to remove I have ever had. I welded up a stainless exhaust mount using the hardware I turned on the lathe a few months ago and it is rubber mounted. I also go the instrument cluster mounted so I can figure out where i need to start drilling holes in things, I think I have about 50 hours in the instrument/headlight cluster alone. The rear fender turned out real nice as well, too bad you cant really see it. This project has been bumped up in the triage list and is now a top priority. I'm getting near the end of stuff that needs to be done; I can see the end!

https://youtu.be/a6d8e-H5zCY
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: Tune-A-Fishİ on Sep 06, 2016, 22:12:13
Racetech  :'(
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: canyoncarver on Sep 07, 2016, 00:39:23
You have great taste in bikes.  Really love the under tail treatment. 
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: Tune-A-Fishİ on Sep 07, 2016, 08:45:05
It's inspiring to say the least.

That kick stand is atrocious tho  ::)
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: Kanticoy on Sep 07, 2016, 10:48:48
Beauty of a bike man! Color me impressed!


Sent from my iPhone using DO THE TON (https://siteowners.tapatalk.com/byo/displayAndDownloadByoApp?rid=89466)
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Sep 07, 2016, 12:41:24
thanks guys. hope to make some more progress soon.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: xb33bsa on Sep 07, 2016, 18:57:12
thanks guys. hope to make some more progress soon.
shes a flamin beauty doc
got any plans of documenting  ,her weight ?
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Sep 08, 2016, 01:59:47
shes a flamin beauty doc
got any plans of documenting  ,her weight ?
I will once its a rider, my target was 480 wet, very curious to see what it will be.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Sep 22, 2016, 03:14:03
I'm torn in-between doing vinyl pinstripes and clearing over them or painting the pinstripes on and then clearing. I'm worried that if i paint them they wont be very crisp and the red will take many layers to get it bright over the grey. Vinyl is so easy to apply. I bought this vinyl pinstripe but the red is semi-transparant and not nearly as bright as I want it to be. maybe hand pinstriped?
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: Tune-A-Fishİ on Sep 22, 2016, 08:17:26
Lots of clear then cut and buff to get the vinyl buried. if you use 3/16ths or even 1/8th pinstripe to mask the paint lays down with no blowouts or bleed, my last tank the lines are amazingly crisp just wish they mirrored better
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: jpmobius on Sep 22, 2016, 10:01:39
I'm torn in-between doing vinyl pinstripes and clearing over them or painting the pinstripes on and then clearing. I'm worried that if i paint them they wont be very crisp and the red will take many layers to get it bright over the grey. Vinyl is so easy to apply. I bought this vinyl pinstripe but the red is semi-transparent and not nearly as bright as I want it to be. maybe hand pinstriped?
It's a familiar problem.  You can try an alternate brand of vinyl to see if it is less transparent/brighter.  Paint is always some sort of trouble due to the transparency.  You might try masking the stripes and using some sign painters paint which is bright and covers pretty well.  Hand laid stripes are awesome but do look hand painted and still need to be cleared over to last.  A lot of trouble to mask, but it certainly can be done.  Just place the stripes with whatever width fine line tape you want and then lay another row against both sides and peel out the original.  Might be worth an experiment using a fat brush and masking to see if you get the results you are after.  Or you can spray it -  try shooting white first before the red.  That's what I did the last time I faced a similar issue where I wanted the brightest possible red and it worked great, but I did realize it before I started and shot that first and masked off the stripes from the beginning which you obviously can't do now unfortunately.  Paint or vinyl, it will take a lot of clear to really bury it flat as I'm sure you know.  Likely you will have so much paint getting the brightness up the stripe will be as thick (or thicker!) as vinyl.   I'd probably pick the best vinyl and shoot enough clear to protect everything and call it a day.  I've found about 2 medium coats is good over stripes.  It's a long way from being able to obtain a flat surface over them, but any more and the clear ponds up near the edges and looks lumpy.  Really great bike your building here.  Nicely engineered and pretty to boot!
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Sep 22, 2016, 19:05:11
I will pick up some One-shot this afternoon and give that a try. I also will look for a different brand of pin-striping tape.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Sep 23, 2016, 01:51:53
Im finally tackling another one of the things I have been dreading to deal with. When I had the machinist make the caliper mounts he made them so there was not enough clearance between the fork bosses and the holes he milled. Every time I bolted them on they would sit in a different position and didn't seem to be parallel to the disk. I realized the mounts were binding on the fork tubes so I sanded them down so they wouldn't bind. After that the calipers hit the spokes. I put them on the shelf for 2 years.

I drew up a new bracket in CAD and laser cut the profile out of  .060" acrylic so I could stack them to get the correct spacing. After some tweaking I have finalized the design. I think its better than the original as i put the bracket behind the fork bosses and caliper so everything tucks in tighter. I am taking one out of Slikwilli's book; I'm going to have the bracket waterjet cut out of 7075 and then manually mill the rest.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Oct 10, 2016, 00:57:32
So I decided to paint the pinstripes with 1 Shot sign paint. they make a special hardener (4007) and reducer (6001) so that it can be applied under urethane clears. I sprayed a test piece out and prepped the rest of everything.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: jag767 on Oct 10, 2016, 08:57:30
Other than that little bleed it looks fantastic!
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Oct 10, 2016, 15:29:41
Thanks! Yeah the bleed was from me being sloppy because it's a test piece, I got some good 3m vinyl tape for the real thing
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: CrabsAndCylinders on Oct 10, 2016, 18:52:45
Other than that little bleed it looks fantastic!

+1 :)
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Oct 13, 2016, 03:55:37
Im laying down the pinstripe tape and wondering if i should do the fender as well?
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: Tune-A-Fishİ on Oct 13, 2016, 06:39:29
Yay.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: CrabsAndCylinders on Oct 13, 2016, 19:23:50
This is a beautiful bike!
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: Brodie on Oct 13, 2016, 20:37:48
Lines look odd on the fender but if they were straight I think it would look the part.

Nice work.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: jimmer on Oct 13, 2016, 21:26:33
Cool bike. I 'll be back to go through the whole build and watch the rest of the progress.👍👍
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Oct 15, 2016, 15:44:08
Lines look odd on the fender but if they were straight I think it would look the part.

Nice work.

good idea. There was something off but i couldn't quite place it.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: xb33bsa on Oct 16, 2016, 16:18:07
that really looks bitchen :)
i have huge respect for you painters, huge
back to my normal self,have you addressed the chain slack
??
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Oct 16, 2016, 19:44:02
thanks. I wouldn't consider myself a painter, I do buy good products/tools to compensate for my skills so that I can get the results I desire.

The paint turned out pretty good. there are a few blemishes here and there that you will only notice if you really scrutinize the paint, but I'm OK with it. There is some weird stuff going on with the clear around the stripes so I'm going to do a light sand to knock back the high spots and then another coat of clear before I buff it out.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Oct 16, 2016, 19:51:32
here's a few process shots
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: CrabsAndCylinders on Oct 16, 2016, 19:56:43
I can see now that Brodie was right about the straight lines on the fender.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Oct 16, 2016, 20:30:35
yeah that was a good call on that, thanks Brodie.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: xb33bsa on Oct 16, 2016, 20:31:38
here's a few process shots
lol see i'm lucky to rattle can without it lookin like citrus froot  ;D
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: Brodie on Oct 17, 2016, 09:23:13
No wukkas. Paint turned out really nice. Good effort.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: Tune-A-Fishİ on Oct 17, 2016, 11:33:04
Think the painter on mine buried the graphics in 5 coats of clear then "cut and buffed" the whole surface. Zero line definition result.


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Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: Tune-A-Fishİ on Oct 17, 2016, 11:33:33
Love the paint color and scheme BTW


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Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Oct 17, 2016, 15:42:35
thanks guys. starting to get pretty close to finishing this thing.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: HerrDeacon on Oct 17, 2016, 17:10:42
Beautiful paint, looks custom but with a stock Kawi feel, perfect.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: Tune-A-Fishİ on Oct 23, 2016, 09:15:40

thanks guys. starting to get pretty close to finishing this thing.

Looking at all of the recent paint work leaves me to wonder if the shop is open for business :o


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Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Oct 23, 2016, 14:23:45
Sorry Tune, bike stuff is mostly just a hobby for me. If I was trying to profit off of it it would make it less fun. I actually really do not enjoy painting, it stresses me out. so much can go wrong with so much money in material on the line.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Oct 25, 2016, 03:38:31
The front wheel spacer My buddy turned for me left a little to be desired, but at the time this was the only stock we had so not his fault. I remade it to cover the oil seal and make it a bit more sanitary.
I got a start on the brake mounts. I bored all the holes and then used a thread former to cut M10x1.25 threads. It was my first time using a thread former, and man they are trick. produces no chips, so no backing up every quarter turn, longer tool life. better in every way. I'm never going to by a traditional tap again. I also bored the recesses for the caliper and cut them out of the plate. II still need to clean up theoutside and I want to do some pocketing, How much material do you think i can safely remove? I was thinking about having 1/4" think walls and bottom.

(http://i1043.photobucket.com/albums/b436/doctorot/IMG_3541_zpsee2uvolp.jpg)
(http://i1043.photobucket.com/albums/b436/doctorot/IMG_3542_zpsxyxsnvwe.jpg)

(http://i1043.photobucket.com/albums/b436/doctorot/IMG_3532_zpsagmimudf.jpg)
(http://i1043.photobucket.com/albums/b436/doctorot/IMG_3530_zpsccwnytp9.jpg)
(http://i1043.photobucket.com/albums/b436/doctorot/IMG_3544_zpsclhofdbb.jpg)
(http://i1043.photobucket.com/albums/b436/doctorot/IMG_3547_zpswi2oehwk.jpg)
(http://i1043.photobucket.com/albums/b436/doctorot/IMG_3548_zpsookzdfho.jpg)
(http://i1043.photobucket.com/albums/b436/doctorot/IMG_3549_zpsdpg0jqoe.jpg)
(http://i1043.photobucket.com/albums/b436/doctorot/IMG_3550_zpsnt9s2vkd.jpg)
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: Tune-A-Fishİ on Oct 25, 2016, 09:26:47
Spacers cool, but I don't think it should transfer any load to that hub shoulder. Hope you have a few thou clear, most use an abs dust cap no load.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Oct 25, 2016, 15:28:54
Thanks. there is about .03" clearance between the hub and the flange and the wheel spins freely.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: slikwilli420 on Oct 26, 2016, 11:00:20
I do quite a bit of waterjet work, how were your brake brackets cut out? Why only cut them out part way?
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: Tune-A-Fishİ on Oct 26, 2016, 11:58:16
Yeah Doc, I just had to ask  :-[

Look... millings... jet cut, nope yep. lol  But yea... why not cut all the way, maybe you cant to keep shit from flying or to complete end ops (tap holes) in a sturdy cage then release the material for final detail?? What up Doc? lol
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Oct 26, 2016, 13:58:08
I do quite a bit of waterjet work, how were your brake brackets cut out? Why only cut them out part way?

You were the one who gave me the idea to try this out actually,  had them water-jet cut at a local place. It was an experiment. I figured since the parts would need a fixture for the cuts and I have to pay for the drops I would turn the whole sheet into a fixture by just throwing it in the vice. This allowed me to only have to index one hole since I had a cad drawing I could quickly bore and tap the remaining holes using a digital read-out. In the end it didn't really save me much time or from having to make a fixture as I had to make one to finish the outside edge. The connecting parts to the sheet are only on straight sections of the parts so I should be able to mill them flat pretty easily. I maybe have 100 hours on the mill so I'm still learning here.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Oct 30, 2016, 04:18:25
Brake mounts are finished. I started planning out to do the pocketing cuts and shit started getting way too complicated so I just eyeballed em, having a CNC here would be awesome. I'm not a fan of tooling marks unless they are super even (like a CNC), so I blasted the pockets and gave everything else the brushed treatment. I noticed one of the forks is weeping fluid so rebuilding those will be up next.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: The Limey on Oct 30, 2016, 05:03:32
Machine the code numbers off the bolt heads.  They're one of my pet hates.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: Tune-A-Fishİ on Oct 30, 2016, 10:41:56
Looks the part haha! Ti fasteners on final would Ti it all together  ::)
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Oct 30, 2016, 15:01:44
Those bolts were just to check fitment, I have some stainless ARP 12 point bolts that I plan on using.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: xb33bsa on Oct 30, 2016, 15:39:27
Brake mounts are finished. I started planning out to do the pocketing cuts and shit started getting way too complicated so I just eyeballed em, having a CNC here would be awesome. I'm not a fan of tooling marks unless they are super even (like a CNC), so I blasted the pockets and gave everything else the brushed treatment. I noticed one of the forks is weeping fluid so rebuilding those will be up next.
hey man you dun proud with those ,bravO
annndd ,they will speak to you, unlike satins cnc work  :D
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: 1fasgsxr on Oct 31, 2016, 13:30:14
Nice looking mounts !!
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Oct 31, 2016, 15:10:57
thanks guys.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: slikwilli420 on Nov 01, 2016, 12:18:51
Glad it turned out so well. The water jet is my go to, way cheaper than a full CNC mill job and I have a guy local who likes fun projects.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Nov 08, 2016, 03:52:02
Got the paint cut and buffed. I burned through a tiny spot on the tail but its not very visible so I'm cool with it, also some flaws in the stripes on close inspection but not bad for first time doing that or the polish.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: HerrDeacon on Nov 08, 2016, 05:15:07
Beautiful, very classy, can't wait to see it all on the bike.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: irk miller on Nov 08, 2016, 08:51:03
Looks spectacular.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: Bama704 on Nov 08, 2016, 09:13:27
Doc, that paint looks awesome.  This is going to be one sweet KZ once all buttoned up!  Looking forward to seeing it all come together.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: jpmobius on Nov 08, 2016, 10:01:23
Nice!  Man, as much work as it takes to mask it all off so many times, painting those stripes sure was worth it!  That red looks awesome.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: canyoncarver on Nov 08, 2016, 13:09:17
Hell yeah!
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: Saturdays Wrench on Nov 08, 2016, 13:56:57
Awesome build! Nice work so far.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Nov 08, 2016, 14:33:56
thanks guys.

only one last major hurdle before start up, the dreaded wiring.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: 540Nova on Nov 08, 2016, 14:37:58
The wiring was my favorite part on my build. Very satisfying when you turn the key the first time, and everything works!


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Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: CrabsAndCylinders on Nov 08, 2016, 14:40:03
The wiring was my favorite part on my build. Very satisfying when you turn the key the first time, and everything works!


Sent from my iPhone using Tapatalk

That burble when she turns over for the first time is so sweet.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: YogiBear on Jan 06, 2017, 16:45:36
Can't wait to see more progress on this one.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Jan 06, 2017, 21:14:26
Don't worry I haven't forgotten about this. The last 2 months have been super hectic, dealing with finals, work, the holidays, then I was in Mexico for a week and now I'm farting around doing some upgrades on my buddies kz650. I almost have his bike finished and the 1000will become a major priority as I plan on using some of the parts I made for it in my portfolio to get a better job this summer. I just finished polishing his engine covers up, turned out nice.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: canyoncarver on Jan 06, 2017, 23:34:35
Right on Doc!
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: grandpaul on Jan 07, 2017, 12:14:07
That paint job is up there among the best I've personally seen. (That may not be saying much to some, but to me it's significant)

PLEASE keep it up!
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Jan 07, 2017, 15:09:20
Thanks for the kind words Paul. Pics hide the blemishes so it's not as nice as it seems.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: Tune-A-Fishİ on Jan 08, 2017, 11:48:01
Are you done with this thing yet.... jeese!
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Jan 08, 2017, 12:47:16
Slow roasting for extra flavor  8)
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: flip_rip on Jan 10, 2017, 13:54:39
Whoa! Just found your thread when looking for inspiration for my KZ project!

Dang super super impressive! You're killing it!

Those are 17in wheels right?
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Jan 10, 2017, 14:50:51
thanks. the wheels are 18"  i didn't want to sacrifice too much ride height.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Jan 16, 2017, 17:15:19
Ok time to get back on this thing.

I have made a list of stuff I need to do to get the 1000 back on the road.
> rebuild the forks.
> Re-install head. (I had to take of the head to drill and tap the emission ports for some set screws to plug them, also there were two stripped screw holes that i didn't see the first time around. so that needs to go back on.)
> Install carbs
> Finalize battery tray/ electronics position
> plumb the brakes
> install new chain
> WIRING
> tuning
> burnouts

Also here is kz650 I have been working on. polished the cases, new rotors, new seat cover, and a tune up. body work is out for paint currently. Im jealous, this thing runs sweet.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: canyoncarver on Jan 17, 2017, 23:20:03
Ok time to get back on this thing.

I have made a list of stuff I need to do to get the 1000 back on the road.
> rebuild the forks.
> Re-install head. (I had to take of the head to drill and tap the emission ports for some set screws to plug them, also there were two stripped screw holes that i didn't see the first time around. so that needs to go back on.)
> Install carbs
> Finalize battery tray/ electronics position
> plumb the brakes
> install new chain
> WIRING
> tuning
> burnouts

Also here is kz650 I have been working on. polished the cases, new rotors, new seat cover, and a tune up. body work is out for paint currently. Im jealous, this thing runs sweet.




What?  That's only like an hour or two's work.  Get on it man!.    That little 650 is a beauty. 
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Jan 22, 2017, 03:15:49
Battery/electronics trays finished and rubber mounted! gotta pull them off to massage a couple small spots and then paint. With the sidecovers on it will form a pretty big storage space which is something I loved about the stock bike. I can easily fit a sixer in there  8)

Also got the head back on and the motor buttoned up.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: cbrianroll on Jan 22, 2017, 13:20:23
Looking good man! I gotta start my tray building here pretty quick.....
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Feb 01, 2017, 04:47:30
Rebuilding the forks turned out to be a bit of a debacle. when I got the dust seal off there was deep pitting on the stanchion tube which is what caused the fork seal to leak. It was surprising considering the condition of the forks otherwise. Tracked down a new set and am waiting on new bushings before putting them back together. Fork legs will get new paint.

Because I remade the caliper mounts with them on the inside of the fork legs I had to remake the fender mounts. They will get paint soon as well.

I splurged on these RS34 carbs this summer.  I got them test fitted to check my cable length, and to figure out a support for them. Any suggestions where I should start with jetting? motor has Wiseco 1075, mild cams, street port and polish, and free flowing header.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: canyoncarver on Feb 01, 2017, 12:50:26
I splurged on these RS34 carbs this summer.  I got them test fitted to check my cable length, and to figure out a support for them. Any suggestions where I should start with jetting? motor has Wiseco 1075, mild cams, street port and polish, and free flowing header.


Totally worth the splurge on those carbs for that motor. 
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: CrabsAndCylinders on Feb 01, 2017, 15:07:11
You continue to do fine work!
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Feb 06, 2017, 03:30:30
Got some good progress in this weekend. Forks painted and rebuilt with new seals and bushings. I broke down and bought the motion pro seal installer; its a super nice tool, no regrets. Rear brake is bled. brake front brake setup is nearly complete just waiting on a hose. carbs back on; cables and fuel lines finalized. exhaust massaged and back on. I got some repop switches for a kz900 as mine were completely worn out. Folding foot-pegs on. With the moveable brake lever there is plenty of clearance for the kick starter but I will likely bend the kicker for a little more room. Something about kick starting 100+hp excites me.... in a sexual way. hahaha. Still lots to do but its getting close. Hope to start it up by the end of the month.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: Tune-A-Fishİ on Feb 06, 2017, 09:43:45
So Sexeh  :-*

These: run into the PT bar clamp without bottoming  :o

http://www.ebay.com/itm/252402221185?_trksid=p2057872.m2749.l2649&ssPageName=STRK%3AMEBIDX%3AIT

or these: for less $$

http://www.ebay.com/itm/261499124624?_trksid=p2055119.m1438.l2649&ssPageName=STRK%3AMEBIDX%3AIT

Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: Bootsey on Feb 07, 2017, 20:20:55
Looking good! What are those gauges off again?
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Feb 07, 2017, 21:23:21
They are Speed Hut gauges with faces I designed.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: 2scars on Feb 08, 2017, 15:51:46
Beautiful bike, incredible workmanship.  I can't wait to hear the beast getting kicked over and running.

Brandon
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Feb 09, 2017, 01:55:02
I tackled the cluster wiring tonight. I have been dreading dealing with this, bunch of fiddly stuff. The gauge glass is now sealed with silicon to keep water out. The covers have a small hole drilled in the bottom so water can escape if it does get in there some how. I'm quite pleased with how sanitary it is looking. wiring is not my forte.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: CrabsAndCylinders on Feb 09, 2017, 15:59:46
Those gauges and dash look very classy, like the rest of your fine build!
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Feb 15, 2017, 04:16:48
I bought these CRG bar-end mirrors years ago. I never liked the look of bar end mirrors... but these are convex glass and very nice; so I made some stems from scratch. The Brembo MC and clutch perch had a M10x1.25 left hand thread which is damn hard to come by in the US so I drilled and tapped them for 7/16"-20 but I needed a lock nut and anything off the shelf looked too big so I got OCD and made some locknuts from scratch out of SS304. These may be the only 7/16"-20 nuts with a 14mm wrench in the world. I also made some small locknuts for the upper part where the mirror connects, but for those I used some 304 hex stock I had laying around. I used silicon bronze to join everything together because its all different metals and figure it will help with stress cracking. Pretty happy with how they turned out, a lot of time in something most people will think I bought  ::)
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: der_nanno on Feb 15, 2017, 08:12:26
I splurged on these RS34 carbs this summer.  I got them test fitted to check my cable length, and to figure out a support for them. Any suggestions where I should start with jetting? motor has Wiseco 1075, mild cams, street port and polish, and free flowing header.

#17.5 pilots, #135 mains, needle on the middle notch, accelerator pump standard.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: canyoncarver on Feb 15, 2017, 12:26:35
Really nice work on those mirrors.  You're right, most will never know unless you tell them.   Not that it matters, you'll know and so do we!
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: CrabsAndCylinders on Feb 15, 2017, 13:44:54
Really nice work on those mirrors.  You're right, most will never know unless you tell them.   Not that it matters, you'll know and so do we!

+1
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Feb 15, 2017, 13:50:57
#17.5 pilots, #135 mains, needle on the middle notch, accelerator pump standard.

thanks for that. the carbs came with 1.5 pilots, 125 mains, needle on the middle. so I will buy some  bigger mains for testing
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Feb 16, 2017, 04:37:51
Lots of small things have been finished,including all the wiring in the front. Two things of note; One, I made some spools for the rear stand after knocking the bike off the stand. Luckily it fell into me and no damage was done but it damn near gave me a heart attack. With the spools and the stand it is VERY sturdy and cannot slip off as it did before. Two, I wasn't happy with the foot of the kickstand I made so I cut it off and remade it, the shoulder bolt also took some machining to get the spring to clear it. I made the stainless ball from scratch on the lathe for a throwback to the original kickstand. I think I might still need to add a tang on it to make it easier to kick out.

The only things left are:
Replace a few bolts with ARP to match
install clutch cable
install left footpeg/linkage
finish wiring.

6 YEARS LATER AND ITS ALMOST DONE
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: valvesprung on Feb 16, 2017, 12:05:27
Looks incredible. Just a perfect balance of modern finishes and materials with a truly classic look.

But tell me more about that 750 twin in the background! :D
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Feb 16, 2017, 15:24:24
thanks man. the 750 is coming along, only needs a muffler and foot pegs to be fabricated and then final assembly. You can check out the build thread here >http://www.dotheton.com/forum/index.php?topic=66016.msg756802#msg756802
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Feb 19, 2017, 18:47:11
Well taking these photos might be putting the cart before the horse as I haven't gotten the bike running yet, but I had reserved this gallery space to take photos of this bike and a bunch of other large scale work so it went down. All that remains is a some wiring. This week is gonna be insane for me, I got a big commission coming in so the project bikes are gonna live in the house for a little bit as my garage is gonna be full. I may not get to start it up for the first time till next week. So close i can smell the burnt hydrocarbons. enjoy the gratuitous photos.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: cbrianroll on Feb 19, 2017, 19:07:57
Good work man...is very rad!
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: jpmobius on Feb 19, 2017, 19:56:19
Really nice work sir.  Lovely craftsmanship and very properly engineered.  Lots of well executed "worthy of factory" details most folks won't notice but those that do will appreciate.  Great pics as well!  And thanks for documenting!
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: ChocolateLab on Feb 19, 2017, 19:57:09
Damn this thing is sweet. Hell of a job.


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Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: 540Nova on Feb 19, 2017, 20:58:49
I'm on a bunch of forums every day, all throughout the day. This bike is better than every bike I've seen, except one, (the red Bimota tribute), in the last year.


Sent from my iPhone using Tapatalk
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: jcw on Feb 19, 2017, 21:56:16
+1

You have a way of modding the bike yet keeping it clean and finished looking throughout the process.

Every change seems like it was made for the bike. It looks like how it should have rolled off Kawasaki's assembly line in the first place. ;)
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: advCo on Feb 20, 2017, 01:24:54
Fantastic work mate.


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Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: Bootsey on Feb 20, 2017, 02:09:13
Exceptional build! Look forward to hearing the first start up video.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: canyoncarver on Feb 20, 2017, 02:23:52
Well taking these photos might be putting the cart before the horse as I haven't gotten the bike running yet, but I had reserved this gallery space to take photos of this bike and a bunch of other large scale work so it went down. All that remains is a some wiring. This week is gonna be insane for me, I got a big commission coming in so the project bikes are gonna live in the house for a little bit as my garage is gonna be full. I may not get to start it up for the first time till next week. So close i can smell the burnt hydrocarbons. enjoy the gratuitous photos.






Stunning.  This bike is going to blow up the internet.   (looks like it needs oil though... lol )   I could stare at it all day.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: Maritime on Feb 20, 2017, 11:09:58
Nice Job! She's a looker. BOTM nominee as soon as the thread goes up!
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Feb 20, 2017, 12:39:46
Thanks for following along guys. This forum has been an inspiration to keep me motivated.

Stunning.  This bike is going to blow up the internet.   (looks like it needs oil though... lol )   I could stare at it all day.

It's on the kickstand, it's full of oil.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: 1fasgsxr on Feb 20, 2017, 13:08:56
That thing is just sexy as hell !!  Great job
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: advCo on Feb 21, 2017, 12:11:35
Hey doc, I just nominated you for March BOTM. Someone go second this fine machine.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: Green199 on Feb 21, 2017, 14:31:37
Impeccable work doc. Almost too nice to ride!  ;D
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: Maritime on Feb 21, 2017, 14:36:19
Hey doc, I just nominated you for March BOTM. Someone go second this fine machine.

You beat me to it. I'll go second.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: Maritime on Feb 21, 2017, 14:37:17
Ha never mind Jordan took care of it. Good luck! This thing deserves a win.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: der_nanno on Feb 22, 2017, 13:25:46
Nice work!

But there's a question nagging on me: What's the tail-light from? I know that I know the bike, but I just can't work it out?   ::)
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Feb 22, 2017, 13:53:45
Its an aftermarket light for a Harley Dyna
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: der_nanno on Feb 22, 2017, 15:53:37
Much appreciated!  :)
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Feb 24, 2017, 01:01:18
sure dont miss those bar mounted turn signals
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: Maritime on Feb 24, 2017, 10:22:34
What an improvement when you see the old and new side by each!
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: CrabsAndCylinders on Feb 25, 2017, 16:12:40
What an improvement when you see the old and new side by each!

+1
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Apr 03, 2017, 02:08:23
The wiring is finally coming to a close. I have never done any serious type of wiring job, so as per usual I decided to jump in at the deep end. I was really struggling and shit wasn't working so after letting it sit for a couple weeks, I decided to take it down to a local DIY moto place and get some help. It was worth it as one of the guys there was a major help and even drew up a lattice diagram for this bike. Its very close to first start up at this point.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: Maritime on Apr 03, 2017, 09:28:52
Nice, now you can be nominated for BOTM next month!
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Apr 08, 2017, 02:50:44
https://youtu.be/Wfrf_0eXT0U
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: irk miller on Apr 08, 2017, 08:44:08
(http://www.radiangames.com/wp-content/uploads/2012/09/its_alive.jpg)
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: canyoncarver on Apr 08, 2017, 22:55:31
I love that sound.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: Maritime on Apr 11, 2017, 13:04:41
Ok It runs now, is it close enough to nominate for BOTM?
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Apr 11, 2017, 16:28:28
haha, is it already time to nominate?. hopefully going on the first ride thursday. its been killing me to have to let it sit since Saturday but I'm dealing with finals and year end review in school so shits kinda hectic right now.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: Maritime on Apr 11, 2017, 16:30:48
 think we missed this month, but next for sure now if it's ridable!
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Apr 11, 2017, 16:42:26
Right on. I'm a tortoise kind of guy anyway; i'll get there, it will just take me a while.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Apr 21, 2017, 01:36:41
Went for the first ride tonight. First impressions are; HOLY MOTHER OF TORQUE! this thing rips! I did a couple pulls up to 7k and it gets going quick! I haven't even had a chance to mess with the carbs yet. I have to say its running remarkably well for literally doing nothing to the carbs from the factory. last couple things to deal with are; I need to sync the carbs and the cam end plugs are leaking, which hopefully I will have time to address tomorrow. last time I rode it was in December of 2010.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: canyoncarver on Apr 21, 2017, 02:11:52
It was all worth it then.  7 years is awhile.  Right on
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on May 05, 2017, 04:17:51
Im done with school for the summer! So I synced the carbs and did about 20 miles today and it was running pretty good. I changed the oil, and I still have the filter that I want to cut open and inspect. Still some hiccups in the low end. Tuning will take a while as I have little experience here. I have been thinking about scheduling some dyno time.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: BicycleBobe on May 26, 2017, 00:50:19
Just read through this entire build, great work gorgeous bike!
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on May 30, 2017, 01:29:06
thanks! Chris James took this photo of the bike recently
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: CrabsAndCylinders on May 30, 2017, 03:27:18
Fantastic photo of a fantastic bike!
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: Brodie on May 30, 2017, 04:34:46
Holy crap that looks great!
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: canyoncarver on May 30, 2017, 12:25:50
It's a panty dropper for sure.   
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: Green199 on May 30, 2017, 13:38:56
It's a panty dropper for sure.

Mine are down...
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: grandpaul on Jun 13, 2017, 11:59:16
Dang nice work.

I'd like to see that lattice wiring diagram.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: Supergyro on Jun 15, 2017, 01:15:27
Sick sick beauty!
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: JadusMotorcycleParts on Jun 15, 2017, 16:51:26
Man, stunning work.  Love it.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Jun 19, 2017, 00:48:58
I have been slowly sorting out the issues that come with putting a bike on the road. One of the issues that has come up has me puzzled; it is very difficult to down shift coming to a stop or stopped. it simply will not down shift sometimes even with me rocking the bike so I have to slip the crap out of the clutch to get going in 2nd or 3rd. I suspect it may be something to do with the APE heavy duty clutch kit as i have read others have a hard time finding neutral with that. I also have Tarrozi rear-sets and am wondering if the positioning of the throw is making it difficult to shift, but i have tightened everything up to eliminate as much slop as i can. Thoughts?
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: irk miller on Jun 19, 2017, 01:03:46
Can you add length in that shaft to push the clip-on arm back so it's more parallel with the shifter arm?  Believe it or not, your oil can be a factor in all of this too. 
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Jun 19, 2017, 01:10:53
Yeah i can, I will try that. I'm using "Bikemaster" conventional 10w-40
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: J-Rod10 on Jun 19, 2017, 02:45:33
Ideally, you want as close to a 90ş angle as you can get with your linkage, to the attachment points on both ends.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: jpmobius on Jun 19, 2017, 12:35:05
Surprisingly, slop (within reason) in the pedal mechanism has little impact on how well it shifts the transmission.  If the clutch drags even the slightest bit, 1st, 2nd and neutral can be super hard to sort out when the bike is not rolling so investigating that is in order, and I'll second the notion of the oil having a potentially big impact on the clutch.  The angle of the bellcranks, rod and foot lever do make a difference.  You have the pivot on the front crank arm arranged so that there is a limit on the angle it can work through before it binds so make sure that it doesn't if you haven't already.  The whole mechanism is more bendy and deflects a lot more in actual use than you might expect working it by hand so make sure there is an excess of available motion.  As long as there is no binding, I think the way you have the front pivot is fine.  There can also be binding at the pedal pivot as there are side loads in actual operation that you don't tend to notice in hand operation.

Also keep in mind that your foot and ankle orientation, and the angle your ankle has to rotate has a big impact on how hard or easy things seem - not to mention it is easier to push down with your foot than it is to lift up with your toe.

It is challenging to explain the impact of orienting the angles between the crank arms, pedal lever, and rod without some diagrams, but using your photo as a base I'll give it a shot.  Starting with 900 between the elements is always a good idea as J-Rod says, but because the amount of rotation of the cranks is large compared to their lengths, more info is useful.

First though, go back and get the original shifter pedal and compare its length to the new one.  If it is longer, your trans will be noticeably harder to shift with the new shorter pedal assuming the two crank arms on the new mechanism are the same length.  You can restore the original leverage by changing the length of the crank arms.  If your original pedal is 20% longer than your new one, you need the driven crank arm (the one attached to the shift shaft) to be 20% longer than the drive arm.  If this adjustment is not a complete solution, you still have some big tuning capacity in the crank arm angles.

Look at your pic and observe the angle between the drive crank arm and the connecting rod.  The angle is much greater than 900.  Consider the effort required to move the rod in each direction.  When you lift up on the pedal, the angle will increase.  As it does, the mechanical advantage over the rod will increase, so pedal effort needed will decrease the farther it rotates.  This makes the bike easier to upshift force-wise, but you pay for this with longer travel distance of the pedal.  When you down shift, the angle becomes more acute as it comes up to 900, and the force becomes greater, and the pedal distance traveled becomes shorter.

This principle works in reverse at the other end of the push/pull rod.  In your pic,  the angle is less than 900 and as the rod pushes the crank, the angle becomes more acute and the force required to rotate the crank increases.  As you pull on the rod, the force needed decreases until 900 is reached, and then the force required will increase as the angle gets farther away from perpendicular.

The effect of the angle between the rod and crank arm is opposite depending on if it is the drive arm or driven arm.  A bit hard to tell from your pic due to lens distortion, but it looks like the two crank arm are pretty close to parallel.  This has the effect of canceling each other out.  When the drive arm has greater mechanical advantage when pushing the rod due to angle, (or less when pulling) the driven arm has less advantage when being pushed (or more when pulling) and the force on the shift shaft is the same as the pedal shaft - it's a wash.

This only works for fairly small deviations from 900.  Consider the crank on the shift shaft.  If you rotated it counterclockwise a bit, it would have a 900 angle with the rod.  Consider pushing on the rod.  At 900, 10 lbs of force will displace the crank against the spring a certain distance.  If you re-index the crank clockwise, the force required to achieve the same displacement against the same spring pressure will go up.  As the rotation goes up, the force needed goes up very rapidly.  In fact, imagine having to rotate the crank a full 900 - as the crank arm comes up to 900, the force needed to rotate it goes to infinity.  So fairly small deviations from the 900 relationship between the various parts can have a very noticeable effect.

So work on the easy and obvious stuff first.  Check the mechanism for binding, and fix any pedal length issue.  Try some new oil - you probably want to change oil on a new motor anyway.  If your still not happy, you can make a big difference by fooling around with the crank angles.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Jun 20, 2017, 01:54:55
Wow, big improvement from adjusting the crank angles. Thanks for the replies guys! Its still a bit tricky to get it into first, but much more rideable. I think with a little more adjustment it will be even better. However i have noticed that it doesnt really "pop" into first gear like i seem to remember it doing, but it has been 7 years ::) could this be a symptom of the clutch not disengaging fully?

I'm loving the evening rides when i get home from work even if they are short, like today. The sound of the flat-slides clacking when you roll on the throttle sounds so mean!
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Jun 21, 2017, 02:06:33
getting the jetting dialed in.  Doing full throttle plug chops gets the ol' adrenaline going, it rips to 100mph pretty fast. I'm still having issues with it shifting but it is better. The APE clutch pack comes with an extra fiber and steel disk, I'm going to pull them to see if that makes a difference.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Jun 21, 2017, 04:09:15
I pulled off the clutch cover to remove some plates and this circlip falls out. Feck. This is my worst nightmare, so much so that after reading a post about the need to orientate the piston pin circlip openings I tore apart the top end of my motor to check. The  circlips I couldn't move to the correct position I replaced. Fearing the worst after finding that clip I tore the top end off the motor to find out that I'm an idiot. All the pistons have their circlips installed still. My only thought is I accidentally dropped one of the old circlips in the motor and when I was replacing them out of paranoia and didn't realize it. Now that has come back to bite me in the ass. The good news is there is no damage and the motor looks like its breaking in very nicely. ::) Once i have a new base gasket and head gasket this thing will be back together in a couple of hours, I have gotten real good at tearing this shit down and putting it back together again. 5th times a charm. D'OH!
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: irk miller on Jun 21, 2017, 08:22:29
Man.  At least you can tear it down in-frame. 
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: Tune-A-Fishİ on Jun 21, 2017, 10:02:04
Don't want to bash APE but those clutches are SHIT! get it out and run a dang Barnett set.


Sent from my iPhone using DO THE TON
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Jun 21, 2017, 11:55:14
Don't want to bash APE but those clutches are SHIT! get it out and run a dang Barnett set.

Ill have to take a look at those. I have been reading that the OEM clutch plates are actually really good as well.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: canyoncarver on Jun 21, 2017, 12:19:28
I used a Barnett in my Z and it's happy.  I've always heard good stuff about stock too.  Tune, what have you heard is wrong with the APE clutches?

Doc, glad it didn't go south on you. 
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: Tune-A-Fishİ on Jun 21, 2017, 15:13:25
I used a Barnett in my Z and it's happy.  I've always heard good stuff about stock too.  Tune, what have you heard is wrong with the APE clutches?

Doc, glad it didn't go south on you.

Stack the clutch plates on a hard surface and you will likely see the segments are not the same all around and I think the wear plates are too soft (grippy) and will chatter out of the box and burn up prematurely. They may be fine for drags but on the street I think you go with trusted old school Barnett and Valvoline 10/40 lol


Sent from my iPhone using DO THE TON (http://r.tapatalk.com/byo?rid=89466)
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: Tune-A-Fishİ on Jun 21, 2017, 15:14:34
Oh Dang... I mentioned a brand of OIL!


Sent from my iPhone using DO THE TON
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: Bozz on Jun 21, 2017, 21:01:02
I've had a Barnet clutch in my Z1 for 18 years with no issues.  I do not race it, however.
Barnet frictions, stock steels, Barnet springs & roller hearing throw disc.  Good to go.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Jun 23, 2017, 03:48:41
Well its back together again. I'm starting to think it is indeed the clutch stack because when i removed a couple disks it easily shifted through the gears.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Jun 23, 2017, 12:23:45
I'm headed down to LA this weekend. If you're at Born Free hopefully you'll see this bike in the grass lot.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: canyoncarver on Jun 23, 2017, 12:36:09
I'm headed down to LA this weekend. If you're at Born Free hopefully you'll see this bike in the grass lot.

Damn....I'd LOOOVE to make that show.  Have fun Doc, take lots of pics.  Your bike will be a hit there too.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Jun 26, 2017, 01:04:10
Other than the shifting issue the bike performed very well this weekend. I rode just over 120 miles. Most of that was on the freeway and I was leery of cruising speeds on the fresh motor so I was driving like a total dipshit trying to modulate my RPM significantly. I have a dyno appointment Tuesday to get this thing super dialed in, and see what kind of numbers its putting out. heres a couple of my favorite bike from the show. The black knuckle is made almost entirely out of 316 stainless from scratch.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: canyoncarver on Jun 26, 2017, 11:56:41
That peoples champ Knuckle caught my eye in all the instas coming out of the show. 
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: Rider52 on Jun 26, 2017, 12:35:53
The Stainless Knuckle build threads are on Chop Cult and Jockey Journal
http://www.chopcult.com/forum/showthread.php?t=48039
http://www.jockeyjournal.com/forum/showthread.php?t=199025
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Jun 27, 2017, 16:31:55
Well the dyna session didn't go as planned. The clutch starts slipping at 7500 so we weren't able to do a full pull but he did give me some jetting suggestions and advised to go to the OEM clutch.(got one on the way)  He thought the shifting issue doesn't lie in the shifter Linkage or the clutch stack but thinks the shifter drum/arm is worn or assembled incorrectly. Further inspection required.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Jul 02, 2017, 16:26:20
Any recommendations on a quick turn throttle? I mostly want it to give the me some space from the kill switch as i keep accidentally bumping it off, but also a being able to go WOT without re-positioning my hand would be great.
Title: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: Tune-A-Fishİ on Jul 02, 2017, 16:32:06
Is it push pull? Look at Motion Pro pretty sure they have one with 5 options


Sent from my iPhone using DO THE TON
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Jul 02, 2017, 16:46:47
yeah i saw that one but it requires a different kill switch and is kinda expensive. im seeing a couple on Webike that are a bit cheaper
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: Tune-A-Fishİ on Jul 02, 2017, 16:51:27
Webike is a great source


Sent from my iPhone using DO THE TON
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: CrabsAndCylinders on Jul 02, 2017, 22:23:45
Hey, Webike  is new to me, looks like a good source.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: JadusMotorcycleParts on Jul 08, 2017, 08:54:23
That single cylinder knuckle conversion is rad!

I got my custom push pull cable made up by motion pro I think.  But Venhill also make custom cables to exactly your spec.

Sucks about your dyno session and the clutch slipping!  That happened to both of my SRs in both dyno sessions I did.  The issue was not with the clutch plates - they were fine, totally within spec, it was the springs that couldn't put enough pressure on the plates.  EBC usually have kits with 20% stringer springs, then if that is not enough, you can turn up some aluminium spacers to add even more pressure.  Even after doing this to my bikes, the clutch lever action didn't feel any bit more difficult to pull and the clutch bit really hard and didn't show any more signs of slippage  :D
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: SeekingZero on Jul 16, 2017, 14:43:54
Dude! I saw your project down at Moto Guild SV but I don't know how the two of us never ran into each other. Between my build and yours, you think we would have! Congrats on the banner too, well fucking worth it. You made one gorgeous bike! Hit me up the next time you're around.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Jul 19, 2017, 17:34:32
Thanks man. I need to change some tires soon so I'll be down there
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Jul 24, 2017, 02:54:22
Got the aftermarket throttle on there. I had to modify the switch to get some room but I think it worked out OK. I will fill the letters in with 1 Shot eventually. The throttle throw is better; I can go WOT without re-positioning my hand but its still a pretty long travel so hopefully it wont be too twitchy. I also got the new OEM clutch in, changed the pilots and main jets, and fitted Oury grips. test ride tomorrow.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: canyoncarver on Jul 24, 2017, 12:22:48
Nice mod.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: 1fasgsxr on Jul 24, 2017, 12:59:21
I hope you like those grips better than I do. They are pretty good for damping bar buzz but if you don't wear gloves every single time they feel sticky...at least mine do. I will be changing them soon.  But an awesome build !!
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: irk miller on Jul 24, 2017, 13:40:16
I run those Oury grips on a bunch of my bikes.  I like them.  I like that they have a tack to them.  It's especially good off road, or in rain. 
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Jul 24, 2017, 14:19:23
The oury grips do break down pretty quickly but i love the stickyness of them. i feel like it helps me from over gripping the handlebars, I have been running them on my daily for a couple years now and it really helps when you're cruising.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Jul 25, 2017, 03:40:18
Test ride went pretty good.

One size up on the pilot (20) fixed the stumble off idle, but it think i went one size too lean on the main (127.5), it pulled harder on the 130 i had in there before. The OEM clutch appears to have fixed the shifting issue. I can now still shift through all the gears easily, and I had it up to 8000 RPM in 4th and the clutch wasn't slipping. I think i might put some more gear in it; seems too tall right now, it won't redline before it runs out of power, but getting the jetting perfect will come before that. The cam caps are leaking again, as cool as they look i might switch back to the rubber OEM ones, these ones are super hard to seal anytime i change the valve gasket.

The aftermarket throttle i bought does not have a positive stop so when braking hard my hand will turn the throttle closed past idle and because its a push/pull throttle it will force the intakes closed past idle and the motor wants to die. Any suggestions on dealing with this? Its livable right now but I want to get the throttle as close to perfect as I can.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000) Part Deux
Post by: doc_rot on Sep 22, 2017, 04:19:54
Progress update
The jetting is pretty dialed in with the 127.5 on the main, needle on the middle clip, and 20 pilot. I checked the plugs the other day and they were the perfect "coffee and cream" there is no stumble at all and it pulls hard steadily from 3k RPM and up. I still want to get it on the dyno eventually to see what this thing is pumping out i'm hoping i blew by my modest goal of at least 100hp a the rear wheel. This thing power wheelies in second no problem, but it also has a shorter wheel base ;D. The suspension is a bit stiff  but isn't bad. i need to weigh this thing to see  how much it weighs , have preload that I can take out (need to set the sag front and rear)

Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Oct 28, 2017, 18:53:12
UPDATE

The throttle action is really good now. I moved up to a bigger 36mm throttle tube for even quicker action, and I drilled and tapped a hole in the throttle clamp for a positive stop. works great.

I thought the shifting issue was resolved with the new clutch but it was just better. It still was difficult to down shift. I FINALLY figured out the root cause of the shifting issue. Way back when I was first tearing down the motor I got a used shifter off ebay to replace mine which had worn out splines. What I bought was was listed as a 1980 but actually got a 1981+ the main difference being the over-shift  arm is 5mm shorter not allowing a full down shift. The easiest was to tell the difference between the shifters is the late model shifter has a small relief on the lower arm. The bike now shifts silky smooth with the undercut trans; speed shifting delight!

Finally got the cam plug caps to stop leaking, but when I removed the valve cover a screw fell out! One of the top idler assembly screws had backed out and the whole assembly was close to catastrophic failure. The leaking cam caps were a blessing in disguise because I probably would not have caught this until it was too late. I contacted Liska Racing about it and they sent me a new one free of charge. Hopefully that wont happen again.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: canyoncarver on Oct 29, 2017, 23:07:10
You're like Neo dodging that bullet. 
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Nov 14, 2017, 18:37:57
Well I finally made it back to the dyna. I was close with the carb setup but the guy got it even more dialed in. Final settings are; 22.5 pilot, 132.5 main, needle clip second from bottom, mixture screws 3/4 turns out, and floats at 19mm. overall the throttle response is much crisper with the raised float heights and needle position. I only have 220 miles or so on it so he didn't want to take it over 8000 with the new cams in it. It got to 96.5 HP with another 3500k till redline. He thought it might make 100HP if he tested it higher so I'm calling that a win. I also had a chance to weigh it and its 480lbs with a 1/2 tank of fuel. Thats down 80 from stock!

the next debacle is the head-gasket is leaking oil....it never ends.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: 1fasgsxr on Nov 14, 2017, 19:33:24
That's awesome sir ! I bet it's fun to ride.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Nov 15, 2017, 21:28:11
I haven't had a chance to really put it through the paces but first impressions are good. the torque really makes it fun.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Nov 17, 2017, 23:39:57
Custom chromoly kick lever for extra clearance. I also machined some bits to accept a Tarozzi rubber to match the foot-pegs. Needs final polish before going to plating
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: Pete12 on Nov 18, 2017, 03:51:39
Very nice work.
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: doc_rot on Nov 19, 2017, 03:29:40
thanks Pete.

Finally got out on this thing for a spirited ride. did about 100 miles of twisty roads. I am blown away by how good the brake setup is on this, very progressive with great "feel"
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: canyoncarver on Nov 19, 2017, 03:34:58
It's gorgeous.  Neat kickstand mod too.  I miss the ocean.  Can we get a listen to the pipe?
Title: Re: modified, aftermarket, or custom. nothing is safe (78 KZ1000)
Post by: The Limey on Nov 20, 2017, 11:34:19
That's very, very pretty.