1982 KZ440 Turbocharged, intercooled, and fuel injected Cafe.
- Thread starter KZsAll
- Start date
KZsAll
Big projects completed in small steps.
Re: 1982 KZ440 ltd Cafe drop frame gone
Wayne,
Thanks man. Yeah I was trying to figure out how to be as accurate as possible and minimize the whole sand/fill repeat thing. lol
Well I have been under the weather the last couple days and off to see the doc this afternoon. Didnt get the rough shaping done like I wanted to. I will get the pictures updated as soon as I am feeling better and get that done. Hope everyone enjoyed their turkey day and talk to you all soon.
Alien
Wayne,
Thanks man. Yeah I was trying to figure out how to be as accurate as possible and minimize the whole sand/fill repeat thing. lol
Well I have been under the weather the last couple days and off to see the doc this afternoon. Didnt get the rough shaping done like I wanted to. I will get the pictures updated as soon as I am feeling better and get that done. Hope everyone enjoyed their turkey day and talk to you all soon.
Alien
KZsAll
Big projects completed in small steps.
Re: 1982 KZ440 ltd Cafe drop frame gone
Well whatever was keeping me from working on the bike subsided finally and I thought I would get some work done on the tank before going to my real job today. So these first few pictures are the beginning of the tank shaping. Very big note: Remember to take your time. There is no rush in shaping your project and the time spent here will be worth it in the end. Tools used for this portion were a hacksaw, a hacksaw blade alone (very helpful for bending into a shape or detail cuts), and a good old electric sander. Would have preferred to use an air sander but haven't bought the compressor. YET. lol. In the first few photos I took them to show how I let the foam expand well past where I wanted it. Some areas were a little short but I can fill those. News paper kind of folded in and caused the shallow areas.
Well whatever was keeping me from working on the bike subsided finally and I thought I would get some work done on the tank before going to my real job today. So these first few pictures are the beginning of the tank shaping. Very big note: Remember to take your time. There is no rush in shaping your project and the time spent here will be worth it in the end. Tools used for this portion were a hacksaw, a hacksaw blade alone (very helpful for bending into a shape or detail cuts), and a good old electric sander. Would have preferred to use an air sander but haven't bought the compressor. YET. lol. In the first few photos I took them to show how I let the foam expand well past where I wanted it. Some areas were a little short but I can fill those. News paper kind of folded in and caused the shallow areas.
Attachments
KZsAll
Big projects completed in small steps.
Re: 1982 KZ440 ltd Cafe drop frame gone
So now you have an idea of how that was done. I kept working at shaping the foam gradually and got a general shape established. On the left side of the tank I did dig in a little deeper than I wanted to so i created an are I will have to fill in later. I still have to make sure and get the proportioning right. Plus I have to fine tune the shape so everything matches up.
So now you have an idea of how that was done. I kept working at shaping the foam gradually and got a general shape established. On the left side of the tank I did dig in a little deeper than I wanted to so i created an are I will have to fill in later. I still have to make sure and get the proportioning right. Plus I have to fine tune the shape so everything matches up.
Attachments
KZsAll
Big projects completed in small steps.
Re: 1982 KZ440 ltd Cafe drop frame gone
So here is the last set of photos for this portion. Now you can see the look of the bike starting to take shape. I will of course be posting more photos as I go along. One note I almost forgot to mention. The front portion of the tank hasn't been rough shaped yet. Still have some work to do up there and then all the final details. Fun fun. lol.
So here is the last set of photos for this portion. Now you can see the look of the bike starting to take shape. I will of course be posting more photos as I go along. One note I almost forgot to mention. The front portion of the tank hasn't been rough shaped yet. Still have some work to do up there and then all the final details. Fun fun. lol.
Attachments
Re: 1982 KZ440 ltd Cafe drop frame gone
seriously good work, including documentation. That tank is cool!
seriously good work, including documentation. That tank is cool!
KZsAll
Big projects completed in small steps.
Re: 1982 KZ440 ltd Cafe drop frame gone
Roman_dog,
I would have loved to use a hot wire on this. However that is the first thing the manufacturer said not to do with this particular foam. You know me anything electronic and Im all for it. lol. I think the next bike will be a home cnc cut foam. Now just got to remember where I put that cnc machine. lol.
canyoncarver,
Thank you very much. The tank is coming along nicely. I hope to get out before work tomorrow and get some more shaping done on it. Spent most of today trying to get the foam fuzzies off me. Dang static electricity. lol. Hope your finding the documentation usefull. Let me know if there is an additional information I should include that you think people would find helpful.
Roman_dog,
I would have loved to use a hot wire on this. However that is the first thing the manufacturer said not to do with this particular foam. You know me anything electronic and Im all for it. lol. I think the next bike will be a home cnc cut foam. Now just got to remember where I put that cnc machine. lol.
canyoncarver,
Thank you very much. The tank is coming along nicely. I hope to get out before work tomorrow and get some more shaping done on it. Spent most of today trying to get the foam fuzzies off me. Dang static electricity. lol. Hope your finding the documentation usefull. Let me know if there is an additional information I should include that you think people would find helpful.
KZsAll
Big projects completed in small steps.
Re: 1982 KZ440 ltd Cafe drop frame gone
So yesterday was spent trying to get to a final overall shape outline for the tank. I was able to get the rear portion of the tank shape to a stage where it is ready to be glassed over. Moving to the front the journey began to get the tank shaped for clearance for the forks, top tree, and the other such fun items. Using my trusty 24" flexible ruler I set a nice round area toward the front of the tank kind of as a no go marker. I wanted this curve to mark where the tank would begin to cut in toward the frame. Then I broke out the craftsman palm sander with 100 medium grit sand paper and started shaping. Working in stages I brought it down to a more reasonable dimension. I was able to get good clearance and shape for the left side of the tank and really am beginning to like the profile. This side was the real challenge in that the intercooler notch is pretty good size and I had to be cautious not to cut into it. The right side is giving me all sorts of fits. Apparently when I did the initial foam layout I left alot more room for foam expansion than I needed. As you can see in these photos especially the top view. The right side looks like I just gouged the crap out of it. In reality I just started to get it down to a size that is closer to the left. Still have more shaping to do today. I hope to have the tank shaped by this weekend and ready for its glass protective coat. Once I get to that stage I can begin the high low fixes. Get the proportion for each area identical. Finally doing the prep work for the mold construction. Once that is complete I will be moving back to the tail for its shaping. Then when both are prepped and ready the mold construction begins. This method does take a while but the time spent here results in you having a mold to pull your part from that will provide you with a finished part. No having to do fixes at that stage. Just prep for paint and go.
So yesterday was spent trying to get to a final overall shape outline for the tank. I was able to get the rear portion of the tank shape to a stage where it is ready to be glassed over. Moving to the front the journey began to get the tank shaped for clearance for the forks, top tree, and the other such fun items. Using my trusty 24" flexible ruler I set a nice round area toward the front of the tank kind of as a no go marker. I wanted this curve to mark where the tank would begin to cut in toward the frame. Then I broke out the craftsman palm sander with 100 medium grit sand paper and started shaping. Working in stages I brought it down to a more reasonable dimension. I was able to get good clearance and shape for the left side of the tank and really am beginning to like the profile. This side was the real challenge in that the intercooler notch is pretty good size and I had to be cautious not to cut into it. The right side is giving me all sorts of fits. Apparently when I did the initial foam layout I left alot more room for foam expansion than I needed. As you can see in these photos especially the top view. The right side looks like I just gouged the crap out of it. In reality I just started to get it down to a size that is closer to the left. Still have more shaping to do today. I hope to have the tank shaped by this weekend and ready for its glass protective coat. Once I get to that stage I can begin the high low fixes. Get the proportion for each area identical. Finally doing the prep work for the mold construction. Once that is complete I will be moving back to the tail for its shaping. Then when both are prepped and ready the mold construction begins. This method does take a while but the time spent here results in you having a mold to pull your part from that will provide you with a finished part. No having to do fixes at that stage. Just prep for paint and go.
Attachments
coldfuzion76
Active Member
Re: 1982 KZ440 ltd Cafe drop frame gone
Starting to look vaguely familiar... I can really see the lines of it now. Looking good, man!
Starting to look vaguely familiar... I can really see the lines of it now. Looking good, man!
CherryGryffon
New Member
Re: 1982 KZ440 ltd Cafe drop frame gone
Can't wait to see the update! ;D
Can't wait to see the update! ;D
KZsAll
Big projects completed in small steps.
Re: 1982 KZ440 ltd Cafe drop frame gone
So the start of today was not the greatest. Worked some more on the front of the tank shaping and it is not coming out like I want it to. Rather than driving myself to insanity and really having to rework it I decided to get a little support on the parts of the tank that where at the cover stage. In this stage you would normally cover the plug with a layer of fiberglass then on top of that use your filler to address low spots and get a smooth surface for the primer to go onto. Well I decided to fill my low spots and get some accent shaping done. This had two purposes in my mind. 1) I noticed while shaping the front I was putting little dents in spots on the area's of the plug that where ready for glassing. I wanted to go ahead and get my filler on to strengthen the plug so that further work on the front end didn't damage the rest. 2) This lead me to the thought that if I fill the low areas now I wont have as much filling and prep once I do get the glass on. So the next two posts will show the plug partially covered in body filler. I did the filler in shallow coats to minimize heat on the foam and provide a gradual build up. That what I wouldn't have a bunch to sand off. In these photos you will also notice I raised the center section a little bit more. I wanted the nice flowing raise down the center and the original wood skeleton didn't have as high a profile as I wanted once it was all foamed in. On with the show....
So the start of today was not the greatest. Worked some more on the front of the tank shaping and it is not coming out like I want it to. Rather than driving myself to insanity and really having to rework it I decided to get a little support on the parts of the tank that where at the cover stage. In this stage you would normally cover the plug with a layer of fiberglass then on top of that use your filler to address low spots and get a smooth surface for the primer to go onto. Well I decided to fill my low spots and get some accent shaping done. This had two purposes in my mind. 1) I noticed while shaping the front I was putting little dents in spots on the area's of the plug that where ready for glassing. I wanted to go ahead and get my filler on to strengthen the plug so that further work on the front end didn't damage the rest. 2) This lead me to the thought that if I fill the low areas now I wont have as much filling and prep once I do get the glass on. So the next two posts will show the plug partially covered in body filler. I did the filler in shallow coats to minimize heat on the foam and provide a gradual build up. That what I wouldn't have a bunch to sand off. In these photos you will also notice I raised the center section a little bit more. I wanted the nice flowing raise down the center and the original wood skeleton didn't have as high a profile as I wanted once it was all foamed in. On with the show....
Attachments
KZsAll
Big projects completed in small steps.
Re: 1982 KZ440 ltd Cafe drop frame gone
One thing to mention is that not only did I do this in gradual application of filler I also used a cheese grater type file to bring down areas that were overbuilt before the filler hardened. This is still in a rough stage but you can see the general shape the tank is taking on. I love having that center ridge as well. I won't be working on this Friday so I can take a break before I get in there and finish up the front section with a rested pair of eyes. Hope to have some updates Saturday/Sunday. In these photos you can really see how that edge can make a difference. Enjoy.
One thing to mention is that not only did I do this in gradual application of filler I also used a cheese grater type file to bring down areas that were overbuilt before the filler hardened. This is still in a rough stage but you can see the general shape the tank is taking on. I love having that center ridge as well. I won't be working on this Friday so I can take a break before I get in there and finish up the front section with a rested pair of eyes. Hope to have some updates Saturday/Sunday. In these photos you can really see how that edge can make a difference. Enjoy.
Attachments
KZsAll
Big projects completed in small steps.
Re: 1982 KZ440 ltd Cafe drop frame gone
Thank you. Hope the documentation and photos are helpful. I am going to try and do photos at each portion of the work as it progresses all the way through till the final completion. I will include videos for things like the first fire of the engine and possibly a road test once the engine is broken in. Afterall what would be the point of building a cafe racer without proof of the ton. lol. Maybe ton and a half. Yeah I know keep dreaming. Hope you enjoy.
vtwin650 said:
Thank you. Hope the documentation and photos are helpful. I am going to try and do photos at each portion of the work as it progresses all the way through till the final completion. I will include videos for things like the first fire of the engine and possibly a road test once the engine is broken in. Afterall what would be the point of building a cafe racer without proof of the ton. lol. Maybe ton and a half. Yeah I know keep dreaming. Hope you enjoy.
CherryGryffon
New Member
KZsAll
Big projects completed in small steps.
Re: 1982 KZ440 ltd Cafe drop frame gone
So today as I was finishing up my work in the shop it dawned on me that at the photo rate I am going this will be a 100+ page build thread. Well at least no one can say I didn't provide photos. lol. The work for today consisted of more work on the tank plug. I know this will seem like a lengthy process but I am kind of figuring that should anyone decide to go this route it will provide a yard stick to measure the time involved. The good thing is that if done correctly once the mold is made and the part pulled you dont have any real work to do to it. The first couple photos in this set is an idea given in one of my composite books. I wanted a ridge down the center of the tank so using a 6" body spreader I cut my desired shape into the spreading edge. I then laid a good amount of filler down the center and used this as a template as I evened it up. You be the judge as to how it worked.
So today as I was finishing up my work in the shop it dawned on me that at the photo rate I am going this will be a 100+ page build thread. Well at least no one can say I didn't provide photos. lol. The work for today consisted of more work on the tank plug. I know this will seem like a lengthy process but I am kind of figuring that should anyone decide to go this route it will provide a yard stick to measure the time involved. The good thing is that if done correctly once the mold is made and the part pulled you dont have any real work to do to it. The first couple photos in this set is an idea given in one of my composite books. I wanted a ridge down the center of the tank so using a 6" body spreader I cut my desired shape into the spreading edge. I then laid a good amount of filler down the center and used this as a template as I evened it up. You be the judge as to how it worked.
Attachments
KZsAll
Big projects completed in small steps.
Re: 1982 KZ440 ltd Cafe drop frame gone
I finally decided I really liked how the left side of the tank in the front section looked and worked so it is my final shape. It wasn't exactly the way I wanted it but the forks and trees wouldn't let me have it my way. I went ahead and applied the body filler to it to solidify that area from damage. Only thing left before the outside will be ready for final shaping is to get the right side matched up to the left. In this set I have a side view with the left side all filled up. Then I am including some clearance shots to show just how much room I have, or didn't have depending on your view.
Once the right side is matched up it will be time to clean up the underside and get it ready for molding. As well as returning to the outside for final shaping and mold preparation. Until next time....Or maybe sooner. I did want to say in the side shot the tank appears to be really tall. I have daylight fluorescent bulbs in the shop and they created a glare so you don't see the ridge in the profile view on this one. Sorry about that. I work that out later.
I finally decided I really liked how the left side of the tank in the front section looked and worked so it is my final shape. It wasn't exactly the way I wanted it but the forks and trees wouldn't let me have it my way. I went ahead and applied the body filler to it to solidify that area from damage. Only thing left before the outside will be ready for final shaping is to get the right side matched up to the left. In this set I have a side view with the left side all filled up. Then I am including some clearance shots to show just how much room I have, or didn't have depending on your view.
Once the right side is matched up it will be time to clean up the underside and get it ready for molding. As well as returning to the outside for final shaping and mold preparation. Until next time....Or maybe sooner. I did want to say in the side shot the tank appears to be really tall. I have daylight fluorescent bulbs in the shop and they created a glare so you don't see the ridge in the profile view on this one. Sorry about that. I work that out later.Attachments
coldfuzion76
Active Member
Re: 1982 KZ440 ltd Cafe drop frame gone
If I wasn't so lazy, I'd post my winter project. And threads like these make mine look so inadequate. Lol. I have thread envy.
If I wasn't so lazy, I'd post my winter project. And threads like these make mine look so inadequate. Lol. I have thread envy.
