1976 KZ400 Cafe Transformation - Almost finished

[slushie07]

Re: 1976 KZ400 Cafe Transformation (First Motorcycle) - Cafe Seat Complete

Yep, I'll be putting the kicker in the vise to torch and bend it a hair to clear the rearset.

Yea I was thinking about that, and was wondering if it would work. It seems like the kicker is rather brittle and maybe covered in a light coat of chrome or something. I was worried that it might crack, but if you do decide to do it tell me how it goes.

 

[slushie07]

Re: 1976 KZ400 Cafe Transformation - Mock Up Pics

Here are a few recent pictures of some frame modifications and mock up that I did over spring break.

Here are my rearsets from Thailand mounted

Here is a close up of the gauge cluster and you can see a little aluminum bracket with three LED's that are going to replace the old ugly idiot light cluster

I mounted my seat and made a simple hinge for it using the pins from the stock seat

It won't be able to open fully but it will open most of the way which is good enough for me. I will also be reusing the stock lock to lock the seat down to the frame

A couple shots of the garage after a long day of work

 

[diesel450]

Re: 1976 KZ400 Cafe Transformation - Mock Up Pics

Lookin' good man! Glad to see you back at it! I like the seat mount.

That is a big ass battery, dude. You gonna strap that down? Go smaller?

 

[slushie07]

Re: 1976 KZ400 Cafe Transformation - Mock Up Pics

Lookin' good man! Glad to see you back at it! I like the seat mount.

That is a big ass battery, dude. You gonna strap that down? Go smaller?

Well I just bought the stock size battery. I guess later on I can always change it out for something of the same base dimensions but not as high. I do plan to strap it down. Any recommendations for a shorter battery that has the same base dimensions as a stock motorcycle battery?

 

[MeatTooth]

Re: 1976 KZ400 Cafe Transformation - Mock Up Pics

I'd buy an agm battery so you could lay it on it's side.

 

[diesel450]

Re: 1976 KZ400 Cafe Transformation - Mock Up Pics

There's guys here with way more knowledge on this subject than me but I do know there are a lot of options. I think you just need to figure how many amp hours you need, you could just take the specs from the battery you have and plug them in to a search. You should be able to find a sealed battery half that size that will allow you to mount in any position and ease your placement issues. Maybe one of the gurus will chime in.

 

[Blueturnswhite]

Re: 1976 KZ400 Cafe Transformation - Mock Up Pics

This is looking really nice so far. I can't wait to see the whole fabrication finished up. Nice work keeping the seat on the hinges and utilizing the stock seat lock. That's something that I've been wanting to do with my seat build.

 

[JRK5892]

Re: 1976 KZ400 Cafe Transformation - Mock Up Pics

man looking so clean! did not know you where in town bud you should have hit me up for a ride

 

[blkcorvair]

Re: 1976 KZ400 Cafe Transformation - Mock Up Pics

Looks great so far. I noticed the battery too. I know on my honda Im trying to keep my battery over the frame rails. Gota a real small AGM batt like the ones from Dime City. Mounting it low Id be afraid of it bottoming on the tire on a big bump. Not sure what the clearance on the KZ is, but not comfortable enough on my CB

 

[Roiber]

Re: 1976 KZ400 Cafe Transformation - Mock Up Pics

i think its going to look crazy when its done...it has some really nice details on it...keep it up man!

 

[Dazza]

Re: 1976 KZ400 Cafe Transformation - Mock Up Pics

I like the way you made your seat and it looks like it has come out real nice, well the second time round... I'll be making up a seat for my build and will be looking over your process very closely.

 

[slushie07]

Re: 1976 KZ400 Cafe Transformation - Mock Up Pics

I like the way you made your seat and it looks like it has come out real nice, well the second time round... I'll be making up a seat for my build and will be looking over your process very closely.

Good luck with the seat build, just make sure you get the plug as close to perfect as possible.

 

[slushie07]

Re: 1976 KZ400 Cafe Transformation - Engine in Painted Frame

So I recently got the engine installed into the frame. I ended up spraying the frame with a cheap acrylic enamel viper red color. Overall I am pretty happy with it especially since it is my first experience with a spray gun.

Here is a picture of the booth I setup in my garage. it consists of one inlet furnace filter, and two outlet filters with a box fan and a bunch of plastic drop cloths

Some parts blasted and ready for primer

The frame already primered and wetsanded

The frame hangin up in the booth and ready for a base coat

The frame post basecoat next to the engine ready to be installed

My rebuilt, painted and polished carbs

New bearings

Spokes ready for primer

Painted engine brackets

The paint supplies

Engine partially in the frame

Engine fully in the frame and securley mounted

A bunch of polished parts

The frame ended up coming out with some texture and I think it was mainly due to the fact that I did not reduce the red enough and so it did not atomize as finley. When I paint the tins I will make sure to reduced the colors enough but for the frame I kind of like the textured feel.

 

[JRK5892]

Re: 1976 KZ400 Cafe Transformation - Mock Up Pics

looks great man! what kind of paint did you use on the carbs? if it is not an epoxy base or powder they will peel and run from the gas fumes, sucks, i have been there... hit them with a clear motor paint and heat them up a bit, that will help a bit on protection on the paint. everythign looks great, that motor looks awesome! love the booth!

 

[slushie07]

Re: 1976 KZ400 Cafe Transformation - Mock Up Pics

looks great man! what kind of paint did you use on the carbs? if it is not an epoxy base or powder they will peel and run from the gas fumes, sucks, i have been there... hit them with a clear motor paint and heat them up a bit, that will help a bit on protection on the paint. everythign looks great, that motor looks awesome! love the booth!

I used duplicolor engine enamel semi gloss black, so I think I should be fine. Also on all the engine and carb paint I soak the can in hot water before spraying which I think in effect fufills the heating them up component of curing the paint fully. I think I actually got that tip from you!

 

[JRK5892]

Re: 1976 KZ400 Cafe Transformation - Mock Up Pics

no man that just makes it spray easier... you still need to cure the paint with heat, by either an oven or letting the motor run if not it is really brittle till it cures... let us know how that works out on the carbs for ya once you get her running. i know that in the shop we get pretty many carbs that are painted and rough that we have to strip down to coat, but to be honest i have only tried the one time and when it did not work never tried it again

 

[diesel450]

Re: 1976 KZ400 Cafe Transformation - Mock Up Pics

Looks good Man!! You should be riding soon!!

 

[jordy_g_77]

Re: 1976 KZ400 Cafe Transformation - Mock Up Pics

How did you get the engine in wit hout scratching the hell out of the frame, my buddy did a kz400 chop and we made a mess of the paint on the frame. Lay it on its side and jimmy it in or very carefully slide it in up right?

 

[slushie07]

Re: 1976 KZ400 Cafe Transformation - Mock Up Pics

How did you get the engine in wit hout scratching the hell out of the frame, my buddy did a kz400 chop and we made a mess of the paint on the frame. Lay it on its side and jimmy it in or very carefully slide it in up right?

There were a few minor scratches but nothing clearly visible. Ill probably go back later and touch it up. But I pretty much wrapped all the tubes around the engine with that pipe insulation stuff and taped them in place. At first I tried getting the engine in on its side, but I had trouble and thats when I had a few scratches. Then I remembered that when I took the engine off I removed the breather cover on top of the engine. With the engine laying on its side I was able to fit it in. It was still a tight fit with the breather cover removed but it made it much more doable. Also I think that is one of the steps in the manual to removing the engine.

 

[StopBreakingDown]

Re: 1976 KZ400 Cafe Transformation - Mock Up Pics

any updates on this thing?