'83 GPz750 Resto-Mod (pic heavy)

Streetfighterkz

Been Around the Block
Made my way back into the chilly garage today. Luckily I had enough propane left to get me almost all the way through the tasks I did today.

I was browsing eBay a good bit ago for some modern-ish rearsets for the GPz since the upper left mount for the stock bracket was interfering with the swingarm. I was looking at the cheap Chinese ones when I stumbled upon some "ZX12 CG REARSETS ADJUSTABLE" for $99.99 or Make Offer so I made an offer...and the seller accepted it.

For the left side, I placed the rearset as far back as I could so that I could see how close to the swingarm the lever bracket would be. Then I set the right to as far forward as possible to see side-cover interference with the master cylinder mount. Then it was a balance game to make sure I could place the mounting bungs in the same spot on both sides of the chassis. Here's the final result.
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The Gilles rearsets came missing a few parts, including a left peg and shifter lever, so I had to order a lever bearing, a toe peg, and shift lever. I could have ordered a left peg but I had some left over aftermarket pegs from my Kz900 project that I decided to try and use. I cut off the pivot and then drilled and tapped for a M8 bolt. Works well and was way cheaper than ordering an actual replacement peg.
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I fired up the Hobart welder and finished welding the mounting bungs. I stood on the pegs and felt no flexing and heard no cracking/groaning from the welds. I believe they're solid enough for me.

Final result...
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And I couldn't help myself so here's a small sneak peek of something I will be fabbing toward the end of the build.
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Later, Doug
 

Streetfighterkz

Been Around the Block
Got more propane and as a result more motivation so back into the garage this past Sunday.

I started by removing the front fairing and stock GPz front end.

After comparing the GPz stem and the Zx11 stem, the GPz stem's OD was a close fit for the Zx11 ID. I was going to press out the Zx11 stem but I don't have a press and beating it out with a 4lb mini-sledge didn't work. So I chopped off the Zx11 stem with a band saw and used a flap disk to smooth out the remains flush with the lower tree. Then the GPz stem's weld to its lower tree was ground down and that stem beat out.

I lightly cleaned up the GPz stem and drove it into the Zx stem and lower clamp to the right depth. Fired up the welder and joined the two.
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Bearings are on the way but that doesn't mean i couldn't dry fit it.
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It's hard to see but I have about 1/8" clearance to the oil cooler with the Zx11 steering stops. I haven't tried clearances with the gas tank on but I'll get to that later today.
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The GPz ignition switch bolts right to the Zx11 upper clamp but I'm unsure what to do with the stock gauges. They originally mount to the upper triple clamp but the Zx11 doesn't have the mounts. I can fab something but I was also thinking about mounting the cluster to the fairing bracket so it doesn't move with the forks. Any ideas?
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And here is how I left it...
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I haven't did anything to the GPz as far as fab work, since Sunday due to really cold temps but it seems like I spent too much on parts the last couple days while being held up inside. Right now I'm waiting on what's suppose to be a '94 VFR 17" front rim, steering stem bearings, front brake hoses with splitter, front M/C, clutch perch and lever, another windscreen (because I broke a huge chunk out the existing one :doh:), inner fairing panel (never came on a '83 but did on the '84/85), Katana indicator light unit (since the stock GPz ones won't play nice with the Zx upper triple), and a Turbo model cam cover that doesn't have the emission crap on it.

I also did a quick budget analysis and I have about another $250-300 in parts to buy IF I don't have to replace the tires I'm using for mock-up. But at least my list of things to buy and parts to fab is growing shorter.

Later, Doug
 

Streetfighterkz

Been Around the Block
I made my gauge mount. I decided to mount it to the fairing stay as the indicator light pod I'm using kept me from fork mounting. I tried to keep it in the style of the fairing stay to help it blend in. It's nothing fancy but it'll do.
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With the gauge mount finally finished I turned to the speedo drive. The VFR is driven from the countershaft so the front wheel doesn't have provisions for a drive. So I took the road less travels and am going to use the VFR speedo drive on the GPz engine. The VFR counter shaft is tapped and uses a bolt to hold the sprocket on and drive the speedo drive. I found an appropriate bolt and turned it to be a press fit in the GPz output shaft that only has a small blind hole.
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I shortened the bolt to a length that placed the mating surface of the speedo drive at a distance that will allow me to make a trick sprocket cover that can support the shift shaft.
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My VFR parts bike only came with a 6" long broken speedo cable attached to the speedo drive. I took a gamble and ordered a used one from eBay. I got it and have good news and bad news. Good news is that the Honda cable screws to the GPz gauges. Bad news is that it's at least 3" too short. I think I found the longer speedo cable I need though. It's from a very early 1970's CB750. It's suppose to be 38" long (3" longer than a VFR's). If it ever needs to be replaced, the modern day superseded part number fits a Xr650R so finding another one should be easy as it'll be a production OEM cable. If 38" isn't long enough then eBay has some +6" and +8" custom speedo cables for CB750's with chopper front ends. I ordered the CB one and hopefully it'll be here this week.
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The stock mirrors just seemed too large and bulky so I dug through my box of extra goodies and found some smaller Euro mirrors. Only problem is that they use a 10mm screw-on stem but the stock GPz uses a plate. Not a problem. Took some steel plate and shaped , drilled a few holes and welded the stem to the plate. While I was at it I installed the lower replacement windshield I picked up. The bike has a lower and more streamlined look now, IMO.
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Next, I cut off the helmet locks and roughly smoothed out the welds. Then I got around to fitting the taillight I bought way before I started working on the bike. I also stole the license plate bracket from the Vfr I'm parting out, trimmed it to fit and drilled a couple holes. It was suggested by a buddy that I mount the plate on the swingarm to keep the nice clean lines but I'm undecided. I also still need to finalize the style of turnsignals I want and make some mounts.
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Sorry for all the updates. I sometimes forget to post as I go.

Later, Doug

Later, Doug
 

Floegstad

between 8.30 and half past eight works well for me
updates are allways welcome mr,an at least nothing to be sorry about ;)
Nice progress!
 

D4N63R

Been Around the Block
Subscribed. There's an $800
Running version of this staring me in the face on kijiji hahaha.
 

Streetfighterkz

Been Around the Block
I didn't feel like going out to the garage Sunday but that didn't mean I was productive. I scuffed, primed, and painted the triple clamps and clip-ons. The lower was satin black but the upper and clip-ons were a gun-metal. Now they're all gloss black. The upper didn't turn out quite right but I can always repaint it later.
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Since the lower was painted I installed the new lower bearing and seal. I wasn't happy with the little bit of slope due to the stem being 24mm and the hole in the upper being 25mm so I made a nice little bushing.
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Here's the upper all assembled. I sat on the bike and it seems really comfortable. I guess only when I actually get it on the road and moving will I know if I will like it.
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Since the bearings were in place I was able to judge if I'd have enough tank to fork clearance...the answer is NOPE! I'm really close though. I may either make a new frame plate (preferred option) or dent the tank (don't want to).
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And now that the front end is actually able to be assembled properly, I once again had to do a small dry fit.
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Later, Doug
 

iGreek

Been Around the Block
I like that little exhaust preview, haha. Looking good so far man. I dig what your doing so far.
 

Streetfighterkz

Been Around the Block
I didn't realize its been 6 month since I had a relevant post here. I started a new job,moved twice (with the second time being to a permanent location) and got married and had a bunch of house chores to do. But I've slowly been making progress.

If you take a look at some of the previous pics, the top triple has a big recess for the Zx11 stem nut. Since I did the stem swap, the ugly GPz stem bolt is exposed. So I made a nice little cover. I'm undecided on painting it black to blend in, leave it natural, or polish it.
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I figured out a way to keep my steering bolt cover in place. Simply drilled a hole and then threaded it for a small button head screw.
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On the bike...
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Found some flush mount from signals in a parts bin. They were meant to be Gsxr mirror block-offs but the mounting bolts are almost exactly the correct spacing.
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They fit perfectly They almost mimic the shape of the stock turn signal base but are smaller.
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Being smoked they also tend to blend in with the blue paint so they aren't real noticeable when not lit.
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I also made some plates to fit an early Cbr900RR fender to the Zrx forks.
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The odd bolts will be replaced with some nicer looking ones when the time comes.
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Finally finished up my steering stop. I could have went with bolts but I had already painted the lower triple clamp and the frame is far from stock at this point anyways.
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Got the exhaust off without any trouble. Four studs came out and the other four stayed in. No drama otherwise.
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I also scored a Zr7 oil cooler from eBay for a pretty good deal. It's a little bigger but the fittings are the same just the hoses are a tad shorter. I still have to make new mounts as the GPz and Zr7 holes don't match up.
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Also cut out the stock battery box brace and welded on a tab for rear M/C reservoir.
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My "before final welding" to-do list is growing shorter.

Later, Doug
 

Streetfighterkz

Been Around the Block
A little more progress...
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I used the bracket I cut off that was made for the battery tray and cut it to be the same height as the bung used for the upper mount. My weld beads look like crap IMO but they'll blend in with the crap factory welds so no biggie.
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And the cooler hung from all the mounts.
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Later, Doug
 

Streetfighterkz

Been Around the Block
Been a while but I picked up a really cool set of goodies on eBay that were so super cheap I just couldn't pass up.
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Also built a battery box/cage/holder thing-a-ma-bob.
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Tabs tacked up.
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Plenty of room.
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Mounted up a Zx10 R/R in the stock location with a simple bracket.
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Later, Doug
 

Streetfighterkz

Been Around the Block
I was originally planning on using a Jardine GP-1 muffler from a Gsxr. It looks OK from the side but not great fitment. I will only have about 4.5" of ground clearance with it tight to the oil pan. Plus I will have to make a custom header as the MAC 4-1 that came with the bike ends way too far back to use it.
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So I dug out a slightly shortened D&D I was going to throw on my Gsxr750. The MAC header went back on.

Too steep...
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Little less steep...
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Took a midpipe I had and used it to see what kind of room I had with the rearsets. I should have plenty. I will have to make a midpipe as the one I found is way too small to mate with the header.
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Also started on a small fenderette thingy. Not sure if I'll stick with it or not.
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Later, Doug
 

Streetfighterkz

Been Around the Block
I'm just going to throw up some of the major updates but if you guys want more pics or info on something particular, I'm sure I have them.

Electrical Panel...
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Indicator light panel...
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License plate and turns signal bracket...
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Fabricated mid-pipe...
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Started -AN oil cooler lines...
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Top mount steering stabilizer (with temp fitting bracket)...
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Custom rear caliper bracket for a Brembo caliper from a Ducati...
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More in a following post...

Later, Doug
 

Streetfighterkz

Been Around the Block
Still haven't finished the wiring but scored a free fairing and windscreen, just had to pay shipping. Started by mocking up the position that I wanted. Kinda tough as I was dealing with handle bar, tank, and fork/lower triple clamp clearances.
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Started making my own custom fairing mounting brackets as I would have to modify the stock one too much for what I'm planning.
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Some prep work and a small fill panel.
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Fiberglass.
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Sand, fill, repeat. Sand, fill, repeat.
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Still need some spot putty in places but close.
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More in a following post...

Later, Doug
 

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