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Author Topic: 75 kawasaki kz400d cafe conversion (australia)  (Read 5583 times)

Offline deepwaterimports

  • Posts: 797
Re: 75 kawasaki kz400d cafe conversion (australia)
« Reply #45 on: Apr 18, 2012, 07:37:09 »
crazy hay lol.

 Good progress mate, she should be nearly done when you finish the seat yeh?.

 I dropped the frame and swing arm off to a local performance bike shop to see if he could free the swing arm bolt and am yet to hear from him. I rounded the head of the bolt used heat wd40 40$ worth of penetrating oil and the mofo still didn’t move so he’s going to use excessive heat or worst case cut it off...... hmmmm not kewl. but new swing arm bolt is on its way, hit a hump at the moment with this swing arm and garage full of wood.(and now water thanks to the rain hahaha) 

Offline STRETCH-CB

  • Posts: 62
Re: 75 kawasaki kz400d cafe conversion (australia)
« Reply #46 on: Apr 22, 2012, 08:34:10 »
its still a way off being finished, am going to rebuild motor and de tab and paint frame, lighten up on the wiring, got a bit on my list still.

thats a bummer about your swing arm bolt, its always nthe way with old things, i like to think it is all worth it in the long run though.

i got a bit done this weekend, i painted all my parts.

bare metaled the tank.




then started to paint.




















will hopefully get them in some clear tomorrow, pretty happy with it so far, im glad to two differant greens work together, was a bit worried.

Offline MotorbikeBruno

  • Posts: 1864
Re: 75 kawasaki kz400d cafe conversion (australia)
« Reply #47 on: Apr 22, 2012, 11:57:59 »
Very cool man. The different greens came out great.

Offline STRETCH-CB

  • Posts: 62
Re: 75 kawasaki kz400d cafe conversion (australia)
« Reply #48 on: Apr 25, 2012, 06:47:32 »
Very cool man. The different greens came out great.

thanks man, your bike is coming along quite nicely too, had a day off today so i started de tabbing and sorting out my electronics, will have to wait untill the weekend to finish though. here are some progress pics.

some of the tabs grinded


used a street sign to mock up a plate for underneath, was going to use it but its just a little to think to work with,


started to drop the gauges but i want to play around with a few things before i commit to a height.














finally my grips match the rest of the bike haha

Offline STRETCH-CB

  • Posts: 62
Re: 75 kawasaki kz400d cafe conversion (australia)
« Reply #49 on: Apr 25, 2012, 07:52:19 »
can anyone point me in the direction of mounting my seat in a way that it can be removed easily, im going to make a plate that goes in the bottom of the frame so i can fit my battery in and hide the wiring but i also want a compartment for spare fuses ect. i just know some guys have done it but there are alot of build on here. really aching to get the seat on so i can ride it around again, now that ive de tabbed it i cant ride it haha

Offline teazer

  • Site Supporter
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  • Posts: 5051
Try to make that underseat plat dip down between the frame rails as a shallow box. Layout the electrics that you want under there and work out how deep it needs to be.  you need some air in there to keep things cool.  IT will probably not have to be below the frame rails though and painted black it will be invisible.

for teh seat mounts, grab a couple of the tabs you just ground off and weld 2 vertically towards the rear of the seat to bolt through the seat into those brackets.  At the front I'd either weld a 12mm wide piece of steel across the frame for the seat to rest on and bolt it through that, or I'd design a tongue arrangement just behind the tank for the seat to engage in.   


Offline six206

  • Posts: 57
My tail and seat pan are out of aluminum so I used aircraft fasteners (dzus fasteners) So I can take it off with a coin or the other end of a key if need to get to the battery or the fuses. There's a photo of them on the first page of my build thread.

Offline JustinLonghorn

  • Site Supporter
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  • Posts: 4030
  • No Purple Hearts, No Blue Ribbons
I really dig the paint, man.
"Art is never finished, it is only abandoned."

"Motorcycles do not define a person's character." -BigRich

My Dearest Darling -Sold

CB400F

Offline BriMed1983

  • Site Supporter
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  • Posts: 152
She polished up real nice, digging the green machine
DTT Blue CB360 Club - We discriminate!

Offline STRETCH-CB

  • Posts: 62
She polished up real nice, digging the green machine

thanks but it isnt polished, straight off the gun, cleared them at work,













thanks for the seat tips, will have a go at it this weekend, going to make some templates for the aliminium plate under the seat tonight, see if i can go and cut it up at a mates shed, see if i can be bothered after work though. haha

Offline neeko1979

  • Posts: 57
75 kawasaki kz400d cafe conversion (australia) SEAT MOUNTING TIPS??
« Reply #55 on: Apr 26, 2012, 01:05:37 »
Omg. This bike is absolutely stunning!
1982 xj550 seca

Offline STRETCH-CB

  • Posts: 62
75 kawasaki kz400d cafe conversion (australia) SEAT MOUNTING TIPS??
« Reply #56 on: Apr 27, 2012, 00:17:07 »
Omg. This bike is absolutely stunning!
thanks man, it's finally getting to the rewarding part. Will fit the seat and get my battery and all the electronics in position this weekend. I've come up with an idea how to mount the seat. Just have to search through Bunnings (kind of like home depot I guess) tonight to find the bits haha. On the lookout. Will post some more pics soon. Also I wrapped my headers last night and dropped the gauges down lower. Is looking good. It's going to be hard to strip it down again to paint the frame. I just want to ride it all day everyday.

Offline valvesprung

  • Posts: 1029
Hell yeah that looks great!
'77 KZ400

Offline 78kz

  • Posts: 1202
Great job on the KZ.
 8)
Rob. 
'78 KZ650C2 99300 kms and counting
'77 KZ650C1 - newest project
'78 KZ650C2 - older project
'79 KZ650C3 - some bits left
http://www.dotheton.com/forum/index.php?topic=90.0

Offline STRETCH-CB

  • Posts: 62
got a whole heap done this weekend, made all my plates for under the seat and pop riveted them in, got my battery in under the hump and all the wiring done, will take some photo's of all that tomorrow if i get the chance, came up with a way to mount my seat will show some pics of that too, here are just a couple of snaps i took.









its nice to finally be able to ride it again, cant wait until its finished.