The Free Kawasaki Z650 Project

[Luugo86]

Glad to hear you are feeling better. The roller looks good.

 

[Maritime]

looks great so far. Love those Avons.

 

[pidjones]

Shame such a great build has to go on hold. If you want to keep it upright instead of dependent on a wall to lean against, consider adding wood blocks to a furniture dolly to just raise the bike under the engine carriage (similar to how you had it on the bike lift) and ratchet strap it to the dolly. Then it is supported, stable, and mobile.

 

[Maritime]

Shame such a great build has to go on hold. If you want to keep it upright instead of dependent on a wall to lean against, consider adding wood blocks to a furniture dolly to just raise the bike under the engine carriage (similar to how you had it on the bike lift) and ratchet strap it to the dolly. Then it is supported, stable, and mobile.

This is a great way to store a bike for sure. Dolly's are cheap to buy or make.

 

[Bevelheadmhr]

Oh, its only a temporary problem, got a new kick stand bolt almost finished in stainless, my cheap die cant cut the thread correctly, so have to take it to a mate, and he'll let me use his capstan lathe and its Coventry box to cut the thread.

But with the green Z650 paused, can continue work on the other Z650, which I rolled out of the garage today..

 

[doc_rot]

love the custom wheels and engine covers!

 

[teazer]

Love it. It embodies the Old Skool Kool look with new school refinement. Excellent and that's where the high end market is trending now - high quality restomods.

 

[JadusMotorcycleParts]

Damn that is gorgeous! It reminds me a little of an AC Sanctuary build - just missing the hand built titanium exhaust system

 

[Bevelheadmhr]

Damn that is gorgeous! It reminds me a little of an AC Sanctuary build - just missing the hand built titanium exhaust system

Yes a Sanctuary RCM build was the inspiration for this bike, though couldn't justify the £3000 cost of a Nitro Racing Ti exhaust system.

 

[sandmanred]

Nice job!

 

[Bevelheadmhr]

Another day, another new Zed Project ... only a frame , import from the US, but got to start somewhere...

 

[Bevelheadmhr]

One of the side panels had a broken mount, very common it seems as all the ones on Ebay I found had the exact same problem. So, bought a rod of 15mm ABS, the side panel is ABS, then shaped one end to match the other mounts. Next had to cut the rod down to the correct length, and shape the other end, to follow the curve of the inside of the side panel.

Finally glued it into place using Plumbers PVC cement, supposed to work well with ABS. Waited 24 hours, and seems to be a good repair.

 

[porcelanowy]

Hello
Small things pushing the jab forward - satisfying
Thanks for the tip about plumbers PVC cement.
Very clean builds in this thread - I enjoy it and your YT channel very much

 

[pidjones]

You can still buy ABS cement on Amazon. I went to a local dealership service department, and they gave me a pile of ABS parts from wrecks. One supply has lasted five years. They have mounting pins, tabs, curves and flats. Living near the Tail of the Dragon helps.

 

[Bevelheadmhr]

I've since been told that Acetone works well with ABS, it melts two parts together, though I'd be worried of melting all the way through the side panel.

 

[Bevelheadmhr]

Hello
Small things pushing the jab forward - satisfying
Thanks for the tip about plumbers PVC cement.
Very clean builds in this thread - I enjoy it and your YT channel very much

Your welcome, as for YT never know if the vids are too long or too short or have too much detail or not enough.. in the end decided to stop worrying about it and film what I thought was interesting. Got a vid soon of the side panel fix, and of the results of my recent 'retail therapy' lol

 

[Bevelheadmhr]

The engine rebuild will start soon, but in the meantime, there are still some small jobs to do. First the side stand bolt was worn, so I bought a new one, only to find it didn't fit the frame. On closer inspection, it seems the mount had been tapped out at sometime in the past. I bought a small length of stainless hex bar and a M12 x 1.25 die and we made a new bolt. It;s made longer than original so I can use a nyloc nut behind the frame mount

I had a similar problem with the engine mounts, they were rusty and battered, while one was just a threaded bar.. they had to go. Using a length of 10mm stainless bar, I cut and threaded a new set of bolts. I need to have each to have a hex nut welded to one end, then skimmed on a lathe before they are completed. No pics yet.

 

[Bevelheadmhr]

I needed a new tacho/speedo unit for the Z650, as can't use the original anymore, because the speedo drive can't be used, now I've fitted R6 discs.

Bought a combined speedo/tacho/idiot lights gauge made by Daytona, a Velona model, which I needed to make a simple bracket to mount to the existing bosses on the top yoke. Took a morning of cutting and filing, and with the final coat of satin black paint cured, it can go on the bike.

 

[Luugo86]

Clean dash setup.. your mount turned out great

 

[Bevelheadmhr]

Started to dismantle the engine today, which has been sitting unloved in a corner for nearly two years. The cases have been damaged from a crash, where the points cover was ripped off. It can be welded, machined and retapped I think.

A cam needs to be replaced, but the pistons and bores look good. Camchain was very worn and will be replaced along with the hyvo chain. Couple of broken exhaust studs and a broken fin found so far...