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'78 KZ1000 makeover 26 Jan 2012 02:44 #500130

  • Nelson
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Nice work on the jigsaw puzzle pieces on the side of frame. I'm impressed with your patience. I woulda done the easy thing and gooped it up with body filler. But maybe you plan on powder coating, dunno.

Perhaps the reservoir should be as low and forward as possible for weight reasons. Of course you won't feel the diff, but what the heck, every little bit helps. Or if the reservoir looks cool, hang it on the side of frame somewhere and bling it out! B)
Restoring and customizing a KZ1000. Click here to read about it.
Plated KTM, DR650, KZ1000, Former MC mechanic (eons ago). 40 yrs. of dirt and street.

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'78 KZ1000 makeover 26 Jan 2012 02:45 #500131

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porchev914 wrote: While elfmagic was busy coming up with a wity comment about my hose :ohmy: :laugh: , I was outside tacking the tube section to the frame:




:blush: Oh Snap!! LOL
Kenny Hicks
74 Honda CB550
75 Honda CB360 (runs and rides good but not a show bike)
77 KZ650B1 (Runs Great, but needs painted and a little work.)

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'78 KZ1000 makeover 26 Jan 2012 04:25 #500137

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No Nelson, I'm not powdercoating (they couldn't do the color I wanted), I wanted to afford the frame as much strength as I could. Those being the rear motor mount points, the least I could do was replace what was originally there.

elfmagic...just bustin your cherries :P

I was in HF the other day picking around, and came across a digital angle finder. It was kinda expensive (for HF) at $28, but I had this nagging little doubt in my mind about how flat everything was, so I picked it up. Tonight after tacking the reservior mount, I got the bike jig/stand down and leveled it. After getting the bike on it, I put a level across the twin top frame tubes with the angle finder. It was 0. Whew! then I put it on a machined flat spot on top of the swingarm....0 Double whew! I stuck it to the sprocket, and it said 90, and I stuck it to the front rotor, also 90. OK, I guess I didn't have to sweat that afterall. Then I decided to put the subframe back on and check it...ARGH! It was .3 degrees low on the left side. I can be kinda weird about symetry, but I'm gonna let this one slide and never think about it again.

While I was standing there being happy about the frame and suspension elements being perfectly level with each other, I noticed two nicely turned, drilled and threaded lugs with cap screws sittin on the bench next to the bike. Hmmmm, those were nicely made.....I would remember making something that nice on my crappy lathe. Then it dawned on me that I didn't make them, irishwill did. They are the lugs for the outboard bearing support frame mounts! I was a little disappointed that I still had a bit of welding left to do, and that it was going to require the engine to accurately locate the lugs.

Well, I suppose a call to Z1E is in order to get the rest of the odds and ends I need to assemble the engine.
Looks like your wish is coming true Leon....... B)
FRANKEN Z!
1978 KZ1000 A2A with 08'Speed Triple SSSA and '06 GSXR1000 front end

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'78 KZ1000 makeover 26 Jan 2012 11:15 #500153

  • 531blackbanshee
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you actually said "but my hose is shorter" :pinch: .

i mean YOU said "but my hose is shorter" :woohoo: .

certain things you just should not talk about on the interent adam,dang ;) .

word gets around ya know :P :laugh: .

i'm sorry i'm just a weak weak man.

shoot man from your post count in the last couple days i would say that you may already have the engine in the frame and the lugs welded back on and the engine back out ready to finish.

i mean it's been almost 7 hours from your last post. :huh:

glad to see you making some good progress man i can't come over and help so i will just try to keep you motivated from this side :evil: .

keep stickin and movin.

leon
skiatook,oklahoma 1980 z1r,1978 kz 1000 z1r x 3,
1976 kz 900 x 3
i make what i can,and save the rest!

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'78 KZ1000 makeover 26 Jan 2012 14:39 #500181

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My hose is so long, I have to tie it up to my taillight to keep it from dragging the ground when I ride. You know how I roll. :silly:

1978 KZ1000 A2 Click--->Build Thread
2004 ZX-10R
2007 Harley Sportster 1200
2020 Harley Street Glide Special
Angola, IN

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'78 KZ1000 makeover 26 Jan 2012 16:03 #500193

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i tuck my hose in my sock! :woohoo:

keeps it outta the mud! :silly:


leon
skiatook,oklahoma 1980 z1r,1978 kz 1000 z1r x 3,
1976 kz 900 x 3
i make what i can,and save the rest!

billybiltit.blogspot.com/

www.kzrider.com/forum/5-chassis/325862-triple-tree-custom-work

kzrider.com/forum/5-chassis/294594-frame-bracing?limitstart=0

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'78 KZ1000 makeover 26 Jan 2012 16:17 #500200

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I have a different place altogether I tuck my hose Leon, but im not one to judge. To each his own! :woohoo:
FRANKEN Z!
1978 KZ1000 A2A with 08'Speed Triple SSSA and '06 GSXR1000 front end

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'78 KZ1000 makeover 26 Jan 2012 17:50 #500215

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Any rough ETA on a test ride?

Keep it up Adam!
2000 ZRX 1100
1976 KZ 900- Daily Driver
1980 LTD 550- Dalton Highway survivor!

If it has tits or tires, it'll give you problems!

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'78 KZ1000 makeover 26 Jan 2012 17:52 #500217

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mtbspeedfreak wrote: Any rough ETA on a test ride?

Keep it up Adam!


Later? :laugh:

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'78 KZ1000 makeover 26 Jan 2012 20:20 #500241

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DoubleDub wrote:

mtbspeedfreak wrote: Any rough ETA on a test ride?

Keep it up Adam!


Later? :laugh:


Yeah, what he said!

I wish I had a good answer for you Mark. The truth is I'm missing very little to put the bike together. The engine needs less than $100 to be able to assemble the long block. I need to buy a chain and a new reg/rec unit and that'll set me back about $230 or so. $75 for bars and grips. I need to call Irishwill and get him to send me a set of handlebar risers. Custom front and rear brake lines ($150???). Rear tire @ $130 or so. No doubt lots of little odds and ends along the way. So approximately $685 in financial outlay to get the bike complete enough to run. I am limited on the time it takes to get the money together for the parts, as well as the assembly-disassembling- reassembling between mock ups, painting, final engine assembly and final bike assembly. And let us not forget Murphy's Law....... :whistle:
FRANKEN Z!
1978 KZ1000 A2A with 08'Speed Triple SSSA and '06 GSXR1000 front end

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'78 KZ1000 makeover 27 Jan 2012 00:22 #500263

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OK, The mail man brought the new passenger pegs, from an 08 GSXR 1K. They are shorter than the ZX10 passenger pegs regrettably, but the GSXR's under mount will serve the project better than the side mount style of the ZX parts. I'm sorry dear wife, your beautiful long legs will be a little more cramped, but its for the good of the project!


I also need to put the cases back into the frame to properly locate the outboard bearing support. One item I have been missing since I disassembled the bike is the lower right engine mount. I did not see the need to buy an entire motor mount kit for the one part, so like almost everything else, I elected to make one. I borrowed one from Supercharged (thanks Mike) as a template and marked one out on 1/8" CP2 titanium. CP2 is a commercially pure titanium that is easier to work with/machine versus a titanium alloy like 6AL4V. Even still, it certainly drilled a little harder than carbon steel, similar to stainless.



After I cut it out, I'll take the tig torch to a corner of the plate and see what it takes to bring a little of the oxidization color out of the material.
FRANKEN Z!
1978 KZ1000 A2A with 08'Speed Triple SSSA and '06 GSXR1000 front end
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'78 KZ1000 makeover 27 Jan 2012 00:40 #500265

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very cool. gotta love the mailman!
1978 KZ1000 A2
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'78 KZ1000 makeover 27 Jan 2012 01:08 #500269

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oh yeah.. body filler wouldn't hold an engine in place very well would it... :laugh:
Restoring and customizing a KZ1000. Click here to read about it.
Plated KTM, DR650, KZ1000, Former MC mechanic (eons ago). 40 yrs. of dirt and street.

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'78 KZ1000 makeover 27 Jan 2012 03:21 #500286

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I have no doubt somebody, somewhere has tried it Nelson :P If you had been standing here looking at the same thing I was, body filler wouldn't have even crossed your mind ;)
FRANKEN Z!
1978 KZ1000 A2A with 08'Speed Triple SSSA and '06 GSXR1000 front end

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'78 KZ1000 makeover 27 Jan 2012 23:53 #500394

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thanks for that
Restoring and customizing a KZ1000. Click here to read about it.
Plated KTM, DR650, KZ1000, Former MC mechanic (eons ago). 40 yrs. of dirt and street.

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'78 KZ1000 makeover 29 Jan 2012 20:21 #500740

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i love the way u just go right to the max. no point doing things the way the normal people do it. :P
Motor mounts? aluminum u say? i think ti would be cooler! well Ti it is then. :laugh:
Way to go man. B)

r u using 1" bars ? what type of bend r u after? i'm taking off my black alum MX bars, if interested.
i also have some 1" risers avail.
pm me if interested.
76 KZ, frame gusset work,1200CC.Ported by Larry Cavanaugh, 1.5mm.over intakes, Carron Pipe, ZRX12 rear end, and seat,96zx9 front end.
01 CBR600F4i Track bike.
Cobourg, Ont. Can.

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'78 KZ1000 makeover 01 Feb 2012 23:48 #501456

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Thank you Mark! Let me check in with irishwill first about the handlebar risers. He has them, but forgot to send me a set with my triples. I have been looking over lots of different bends, but I haven't settled on one to try yet. I wish I had a set from my YZF, but I only replace those when I bend them, so no good spares laying around :whistle:

Incidentally, cutting the titanium was SIGNIFIGANTLY more difficult than drilling it! I started with a jig saw, and that didn't do much. Then I tried a fresh hacksaw blade, and that was even less effective. I think I spent 5 minutes and made a 1/4" notch in the Ti plate :angry: OK, time to pull out the big guns! The plasma cutter made short work of cutting out the bracket, but it left a discoloration along the two edges I cut. Here is the rough bracket next to the template bracket I used. Ti on the left:



I will likely drill a .75" hole in the middle and scallop the edges in a bit between the perimeter mounting holes. We'll see.....

The UPS man brought another piece to the puzzel today. Many of you know I sacrificed a portion of my stock fuel tank to make the mold for the composite replica. I never planned to abandon my stock tank, and in fact I figured I would need to use it in the interum as I figured out how to make the composite version properly. So here and there I kept my eyes out for a decent modern donor tank for the fuel filler. Today, a '99 ZX9 fuel tank showed up B)



I had already made a card stock template to trace a circular line around the fuel filler with a 1.25" flange. I figured that should be plenty of room to graft onto the stock KZ tank. After a few minutes with a jigsaw, and a few more with a sanding disk I was left with this:



Now, we'll stick that with the stock tank for now, and move on to more important things :)
FRANKEN Z!
1978 KZ1000 A2A with 08'Speed Triple SSSA and '06 GSXR1000 front end
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'78 KZ1000 makeover 02 Feb 2012 00:04 #501457

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Too cool i want that to be my next project bought a kz tank just haven't squeezed the funds for a donor tank yet
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'78 KZ1000 makeover 02 Feb 2012 00:36 #501461

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ramtough_63 wrote: Too cool i want that to be my next project bought a kz tank just haven't squeezed the funds for a donor tank yet


I have been looking for a mid to late 90's Kawasaki tank because I prefer the 7 bolt pattern (no fake bolts), the "tee" lock cover and the flatter area all around the neck. This particular tank was listed for $110 shipped OBO on ebay. I offered $50, he countered $75, I countered $60, he declined it, then 30 minutes later he took it. I didn't get a key with mine, but a new OEM lockset with keys for the tank is $34 from Kawasakiparts.net. When I took the filler apart to remove the original lock, it definitely needed to be greased on the inside after 13 years :laugh:
FRANKEN Z!
1978 KZ1000 A2A with 08'Speed Triple SSSA and '06 GSXR1000 front end

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'78 KZ1000 makeover 02 Feb 2012 00:46 #501465

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Thats pretty cool ike a dumbaxx I sold one last summer for a buddy and we split 40.00 I would gladly give that for one now. I had never seen one done that way and it never occurred to me.
1978 KZ1000 A2
Thrown Together To Ride Til Winter
Facebook Page
Free Range Custom Art


1982/83 750R/GPZ
1984 Goldwing 1200 Interstate
1982 Yamahopper QT50
Previous
2 79 HD sporty XLH
02 HD FLSTS Heritage
60's HD Hummer
70's Honda 550 Four
70 Yamaha 100
and various enduros dirtbikes minibikes...

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