saving a 1980 KZ750 twin

So i have been thinking about the design for the muffler, and am wondering what size to make the baffle. The collector I made is 1.875"OD/1.75"ID. I see that Cone Engineering has their "quiet core" mufflers choked down to 1" and they also have the straight through mufflers. Should I make the baffle smaller than the collector? I can't find any 1.875" perforated tube, but I can find some 1.75" Thoughts?
 
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Thanks guys. Hopefully ill have a chance this week to get it on the bike.
 
I have been fiddling around with the foot controls. got the kick-starter painted with a new detent spring and ball, shifter and rear brake arm are drilled and painted. The stock brake lever was bent pretty badly from where the PO layed it down, so I bent it back with fire. I still want it a little closer to the motor but its much better.

The brake linkage is getting fouled by the new swing arm, so I am going to cut the tab on the brake lever where the linkage connects and move it out some. The problem this creates is that the brake pedal linkage mount is now no longer planar to the rear brake drum arm, and has to be bent into a dogleg to clear the swingarm. I mashed on the pedal pretty hard and it didn't seem to bend the dogleg linkage back hardly at all, but it still makes me wonder if its good. I'm thinking about making a new linkage rod out of chromoly and doglegging it. Thoughts?
 

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I decided to get rid off the stock brake pedal push pad in order to bend the brake pedal tucked in closer to the motor. I turned a steel bung and knurled an aluminum the push pad, welded that on and modded the linkage mount. I had some 1/4" - .065 wall 4130 laying around so I made a new linkage by TIG brazing a clevis to one and and threading the other, but the threads are kinda rough and shitty, which has been my experience in machining Cromoly as well. I think I might cut those threads off and braze some stainless "all-thread" on.
 

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rear brake lever and linkage finished and painted. I also turned up and polished a bunch of brass washers on the lathe, for the footpegs, shock mounts, and steering stem bolt. I wanted to try and pull a little gold into the scheme since i put the gold stripe on the tank. Tons of little things have been finished. The list of remaining stuff is short. Here is a bunch of gratuitous pics of it in the sun for the first time in months.
 

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NICE! So many nicely made and well engineered details! Really like the paint scheme, but seems like it needs to be continued onto the side covers somehow - they look like they need some sort of detail since the tank is so striking. I also like the functional fenders, but they look a bit curious - are they factory chrome? They look almost painted silver on my monitor - maybe just the pics. Any plans to add to the pipes? They look super nice, but I'm thinking pretty attention getting!
 
jpmobius said:
NICE! So many nicely made and well engineered details! Really like the paint scheme, but seems like it needs to be continued onto the side covers somehow - they look like they need some sort of detail since the tank is so striking.
I am going to run the original Kawasaki logos on the tank and the "750 Double Overhead Camshaft" badges from the Z2, that was made for the JDM, on the sidecovers.

http://www.ebay.com/itm/2FastMoto-Kawasaki-Side-Cover-Emblem-KZ750-Z2-Vintage-039-74-039-75-Badge-/201560359509?rmvSB=true



jpmobius said:
I also like the functional fenders, but they look a bit curious - are they factory chrome? They look almost painted silver on my monitor - maybe just the pics.

they are factory chrome that i put a unidirectional brushed finish on with scotch bright. front is off a kz1000LTD, rear is from a XS650


jpmobius said:
Any plans to add to the pipes? They look super nice, but I'm thinking pretty attention getting!

I'm working on a stainless muffler
 

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Gorgeous colour and great looking bike! I'm thinking on doing something similar with my fenders - once you'd run the scotchbrite over the chrome did you clear coat over it? Or will the chrome still hold up (not rust or tarnish) without it?

Thanks man, and kudos on one heck of a nice looking ride
 
Thanks guys.


The Jimbonaut said:
once you'd run the scotchbrite over the chrome did you clear coat over it? Or will the chrome still hold up (not rust or tarnish) without it?

Just brush them with red scotchbright. No clear. It's near impossible to go through the chrome with the scotch bright
 
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