Sorry it's taken me so long to get back to this thread. Life just seems to get in the way. Anyhow, the bike progressed last fall where I did a front end swap, finished the cafe seat, paint and a few other mods. I ended up purchasing a ZX7R front end from a forum member living on the Left coast. It's not the easiest swap because allsballs does not make a lower bearing to do the swap. The do make the upper. However the price was right and I was really wanting to further upgrade suspension and braking. The forks are 43mm with 320mm rotors, had SS brake lines, clipons and both trees so I couldn't resist and jumped on it. I can't even begin to tell you how much of a difference these changes made.
I weighed a bunch of options and the best solution for the lower bearing was to use the Gold wing bearing and make a shim for it to fit the ZX7 stem. The shim was made from hardened steel and had to use a press to fit it onto the stem. I ordered the conversion bearing for the upper from allsballs and I was in business. The front end had been sitting for a very long time and everything was pretty nasty. Brake lines we plugged pretty much solid, both calipers were sticking, and lots of corrosion everywhere. So I cleaned brake lines, rebuilt both calipers, replaced the wheel bearings and lots of elbow grease to get her cleaned and shined. Later I will post a photo of my wheel bearing removal tool (concrete anchor)bought from Ace hardware for less than a couple bucks. Absolutely awesome way to remove wheel bearings btw. I painted both the front wheel and the rear wheel, made another fiberglass seat, painted it, the tank, and side cover. Ordered a new tail light, and made a couple modifications to the rear hoop and repainted it. Decided to hide the huge side covers by painting the one black and ditching the one over the gas tank. I cleaned the tank and put on a fresh coat of appliance epoxy since it was going to be the new side cover.
Since I never replaced the rear wheel bearings those were replaced as well. Once I got things buttoned back up it was time to do a few shake down miles, load up and head to Alabama for the DTT get together and Barbers. Rode her for about a month then put her away for winter. This spring I've been working on her a little here and there when I get time. So far I've finished the two up seat, it's now at the upholster getting covered. I've added a steering damper, and mounted the fairing. I've been working on some new(to me) used Fox shocks that I can't wait till done.
I have to say even though this is my all around and touring bike, I couldn't be happier that I've given her a sportier edge. The handling and braking are unreal. For long trips the saddle bags and fairing can be easily added or removed. So once AI get to where I'm going the bike can be lightened and turned back into the naked bike she was always meant to be. It's like having the best of all worlds. On to some photos: (I'll post these in groups so I don't crash my computer and lose the entire post)