KZ400 with loads of class... (FINAL STAGES!!!)

[chrisf]

Well here's the latest project. I took my inspiration from a fellow KZ400 builder. A good buddy had the exhaust ready to be scrapped so I figured I couldn't justify not trying this out considering the cost.

Materials used:
-worn out stock exhaust from an '81 KZ440D

-cocktail shakers (x2, purchased at ROSS for $6/ea)

-1200 deg header paint
-heat wrap (grabbed from last exhaust)
-Duplicolor 500 deg Ceramic low gloss black (same as frame and engine)

Now the 440 system uses plate baffles rather then stuffing/fiberglass to muffle the sound. It gives the bike a throatier sound then the early bikes, but it's still very quiet.

crappy MSPaint pic to show basic idea:

Basically we cut down below both of the upper plates leaving only the lowest in the pipe. There is now only a plate with an off-center hole baffling the sounds and it's loud...but good loud..."f-ing angry gonna eat your babies" loud, but not quite "open pipe, gonna rupture your ear drum" loud

First cut (quickly moved to power tools...)

Then cut the strainers off of the cock tail shaker caps and slip them into position:

Painted the head pipes with header paint (had some decent surface rust and pitting), wrapped em up, shot the "mufflers" in ceramic black, tossed the caps and chrome shields on and.......

As soon as the new gaskets arrive I'll post installed pics with a real camera and maybe shoot a quick video. For about $42 I'm super happy with the results. The ride I took after a simple test fit felt much more open, sounds great, and and really got the neighbors lookin

This somehow slipped by me. But I have to say this is one of the more innovative ideas I've seen on this forum. Well done.

--Chris

 

[valvesprung]

Let me tell you it sounds bloody awesome too...unfortunately the frame on the bike the exhaust came off of is slightly different then mine and it sits too low on my bike. They drag when leaning hard against the road crown and we can't have that now can we...

I'm likely going to just do the upswept (slightly) peashooters that I've always wanted and have some adapters made so the cans are bolt on.

Thanks for the compliments by the way, not my idea, but it was a fun project and well worth it for the results.

 

[chrisf]

They drag when leaning hard against the road crown and we can't have that now can we...

Well, I think it's fine. It will add some authenticity to the ride. Think of it as a riding scar My vote is to keep it.

--Chris

 

[valvesprung]

Well, I think it's fine. It will add some authenticity to the ride. Think of it as a riding scar My vote is to keep it.

--Chris

Haha well I've already lost one cap completely after contact and it's a seariously unsettling feeling to hit mid corner, really thorws you off. I may try to have these modified just a bit to make em work as I love the fact that they were built not bought per say.

We'll see, I asked for the peashooters for my birthday so we'll see how the fam comes through, that'll be the determining factor.

 

[valvesprung]

updates!!!

Since these photos I've managed to get a NEW exhaust on. I ordered up a set of Norton seamless peashooters and they f-ing rock. They have a super lopey deep rumble at idle and a nice Brit rasp at high RPM. My initial plan was to run them upswept like this:

Unfortunately being a kick only bike I simply didn't have the clearance and realized I like how clean they look tucked against the frame.

And today I threw a new set of bars on. Along with the bars I've also installed proper headlamp ears and lowered the lamp, new signals all around, new plate bracket, new lower gauge bracket, ditched the idiot lights, moved the ignition to the bottom of the headlamp, disassembled and completely refinished the control assemblies, new levers, and some fresh paint on the triples.

It's a lot less cafe now, but damn is it comfy. I'm going to make a more bratstyle seat for it, and some custom slim city bag style saddle bags, hopefully both in a deep chocolate brown to really set of the brit bike style.

(along these lines)

It;s really nice to know I could just jump on, fill up, and ride it all the way to the beach now without cramping up. It's also better for 2-up (as my wife has decided she loves this and needed her own gear) so I'm really happy. The only down side is the look, but it's growing on me.

 

[88]

I have one of those seats (Triumph Thruxton) in black, I brought it for my Gs but it just didn't work. its brand new, still in the wrapping, Yours for US$200 plus postage (I'm in Australia). Your bike has made my mind up..... white tank all the way, very nice work!

 

[valvesprung]

Thanks for the offer, but I have 2 spare seats and will be having the local upholstery shop recover a shaved down seat once I'm ready. It should cost less then $75 and it'll be a direct bolt on.

 

[88]

Cool, Its a great profile but they are a really wide seat. You and SauageMonhoney must turn some heads when (if) you ride together, Two very inspiring bikes.

 

[valvesprung]

Definitely. We've only had opportunity to ride together twice (as his motor blew), but there were plenty of heads turning. He picks it back up tonight and we have our first bike show on Saturday...we're super excited to show em off.

 

[valvesprung]

Well it's been some time since I updated my thread so here are a couple of changes I've made recently.

I added a polished Lucas style tail lamp, reshaped the seat, and had a local upholstery shop rewrap the seat to my specs. (the same shop that did Sausages). For $80 I couldn't be happier. I think with the new bars, mufflers, lamps, seat, etc, it has a much more classic brit look and I love it.

My wife and I bought our first house in September and as soon as I get my garage back under control I'll be tearing her back down for an engine reseal, a complete new wiring harness, and gunmetal powder on the frame.

I'm hoping she'll look showroom new the way it should've been built by spring. Happy New Year all!

 

[JRK5892]

man that looks great!

 

[valvesprung]

Thanks Joe. I wish I could've made the seat much narrower (frame rail width) and shorter, but for building off of the stock pan I'm very happy and it's much more comfy then the last one.

 

[diesel450]

You could totally lay down on that seat if you know what I mean. 8)

I just found this thread I'm going back to read the thing now.

 

[valvesprung]

Don't pay attention too closely, there were a few hasty shortcuts made early on ;D

I know I've mentioned this, but all wrongs will be righted before summer...I'm going to hand build a brand new wiring harness with a bladed fuse box and weather pack connectors and powder the frame if all goes as planned...here's hopin'...

 

[valvesprung]

Don't think I ever posted these, but here are the photos from the day we picked it up for $500

 

[valvesprung]

Here are a couple of "slightly" better shots of the bike since I got some new lights in the garage.

Full side shot:

The new pipes:

The seat (a little closer to the real color):

The new front end (signals that match rear, lower headlamp):

The cockpit (refreshed controls and gauge with custom lowered mount):

Rear:

 

[78kz]

Not usually a fan of white bikes but yours looks great. 8)

Like how you did your initial Rattle Can Master paint job.

 

[Gryph]

Wow I'm loving the changes, didn't think your bike could get better but it has. Let me know if you get the saddle bags sorted, I still haven't tried to mount mine properly, but I can snap some pics of them mocked up if you'd like (if you even remember from my thread months ago lol).

Love the exhaust.

Craig

 

[valvesprung]

Wow thanks man! I would definitely love to see the bags on your bike and the dimensions so I can figure out what size to track down. I'm thinking about just getting some black canvas messenger bags and adding matching leather to the top flaps so it's a dead on match....we'll see.

Went to a really cool little motorcycle show last night, but it was too cold to enjoy standing around outside bullsh*tting...coldest f-ing experience of my life riding 25+ miles home on the highway in January...

 

[Swagger]

Mr.Sprung: Where are you in town? My shop's moved over next to the Hillsboro airport.