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Author Topic: saving a 1980 KZ750 twin  (Read 54119 times)


Offline doc_rot

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Re: saving a 1980 KZ750 twin
« Reply #61 on: Jan 10, 2016, 05:00:36 »
Thanks! Chipping away slowly.

Offline doc_rot

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Re: saving a 1980 KZ750 twin
« Reply #62 on: Jan 25, 2016, 03:04:16 »
The project bikes are back in storage for a few months but i kept a couple parts for to me to work on until I get a garage again. The lathe that i have access to just got rebuilt so i thought id finally machine a couple simple things on this to get started, as my skills progress I will attempt some more complicated stuff. I remade one of the front wheel spacers out of 7075, waiting on some stock to make a speedo plug for the LH side.

 

 I also turned a starter plug for the case; because the starter motor leaves this big gap on the front of the motor I really want to  put an oil cooler there, so I drilled and tapped two holes on the outside of the plug to help with the cooler mounting down the road.





 I cut off the factory gauge mounts and polished it out.



I got a Speedhut GPS speedo and tach. Nothin fancy on the gauge face but i but for about $20 extra they will give you a template and they will print whatever you want on a gauge face, so I designed my own.



Im thinking about turning up a cover for the back of the gauge and want to try cutting threads in a tube. Do the machinists out there know what kind of thread this is or any tips on cutting ID threads?



 Im gonna use this 63-74 sportster headlight with a custom composite bucket that i originally made for my 1000 project. I am kinda digging the old school diffuser but if i go HID or LED i will use the clear lens. I think the screws at the bottom of the rings are kinda crude. Any suggestions to make it looks a bit cooler? I was thinking about some type of clamp or something.



I just mocked it up real quick so i can start brainstorming ideas on how i want to tie this all together.



« Last Edit: Jan 25, 2016, 03:50:37 by doc_rot »

Offline doc_rot

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Re: saving a 1980 KZ750 twin
« Reply #63 on: Feb 03, 2016, 03:06:09 »
Just a quick update, I finally had a chance to hop on the lathe and turn up the speedo delete. In just these two small parts i shaved almost half a pound from the front end. I'm really enjoying messing around on the machines. I picked up a tool blank to grind into the profile for the buttress thread on the tach/speedo. I practiced on some brass and think i have the thread cutting thing figured out well enough to attempt the internal thread.

Offline Signal

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Re: saving a 1980 KZ750 twin
« Reply #64 on: Feb 03, 2016, 03:54:49 »
Joined this forum in 2013, frequent visitor, this is my second post.
I really like what you are doing with this bike and how you are going about it, thank you for posting.
Hope you get some more machine time soon.

Offline canyoncarver

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Re: saving a 1980 KZ750 twin
« Reply #65 on: Feb 03, 2016, 12:20:45 »
If you spin up an extra speedo delete or tach plug, let me know.
--
KZ400 The Rabbit
YZF750/1000R The Fly
KZ 750 Twin
ZRX 1100
65 Norton, My damn Shovelhead chop
more YZF750R's, the KZ's, a Zephyr750...and the unfinished 75' CB550 cafe.
--

Offline doc_rot

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Re: saving a 1980 KZ750 twin
« Reply #66 on: Feb 11, 2016, 07:46:31 »
Started working on the headlight ears by machining up these bits and welding em up. I made a sleeve out of aluminum to keep the tubes from going out of round while welding. now it's clear should have used steel for the sleeve because its stuck in the second. I'm going to slit them tomorrow on the mill and will cut through the sleeve too, hopefully that will help me get the sleeve out.

Offline Tune-A-Fishİ

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Re: saving a 1980 KZ750 twin
« Reply #67 on: Feb 11, 2016, 08:25:48 »
The Eastwing only made it tighter. Weld a thick plug to the end with waffle marks and drive it out with a wood dowel from the inside, I would go into why but it just is always better to extract press fit aluminum rather than push it.

For the same reason I always tap the inside of valve guides, thread a bolt in and press the bolt surface to extract them... never galls the head or leaves aluminum on the guide  ;)
"I didn't come here and I ain't leavin"  Willie Nelson

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Online irk miller

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Re: saving a 1980 KZ750 twin
« Reply #68 on: Feb 11, 2016, 08:50:05 »
Yup.  The aluminum mushrooms easily.  CRC freeze off might help too. Shrink the aluminum to get it out.

Offline doc_rot

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Re: saving a 1980 KZ750 twin
« Reply #69 on: Feb 12, 2016, 04:58:34 »
thanks for the tips guys, that was a dumbass move on my part hammering the end. I ended up welding the end up like a coil pot to try and help shrink it down. the sleeve came out with some pounding, after slitting, but it galled some parts of the tube. I dressed it up and they mount great. Never done a slitting operation on the mill before. VERY satisfying. Now that these are finished I can start doing some prototyping.
« Last Edit: Feb 12, 2016, 07:16:18 by doc_rot »