TOPIC:

Carbs rebuilt and fitted.

Alloy bellmouths are new items from Hitchcocks which were intended for Amal (screw on) fitment and at £11 each are a bargain.
They only needed slight modification and just need a tidy clamp to finish.

Few more random pic's.

Exhaust cleaned up and springs on, still got to conjure up a silencer for it.

Re-made the mudguard brackets (now one piece) and rubber mounted the blade.
brackets need painting and blade needs polishing to finish the front end

Oil cooler pipes fitted . Basic spring hose clamps for the no frills look.

Simple 'P' clip is enough to keep the hose in line.
Coils fitted and ht leads on.

Rats nest wiring waiting to be sorted.

Set of Dymags for the NEXT project

impeccable work sir!

hats off to ya,

leon

droolin over them wheels !

leon

Just view all 13 pages.... Awesome project sir
Can't wait to see it finish. Also thx for all the pics and details.

Looking good zed. Speedometers are now the bane of my existence. I wish you could get mechanical drives for modern sport wheels. I like the more analogue gauge look. I have a couple set of after market gauges collecting dust...

Those are nice wheels. I just dropped some coin on lightweight forged aluminium wheels for my TR1 build my self.

Slowly slowly 'n' all that, two steps forward and one big step back but getting there.
A few more jobs done and a couple added

First one or two steps forward off the list.
Number plate mount finally done.
This simply gets sandwiched between the rear light and rubber mounts on the seat.

Bulky rear brake reservoir replaced with race item from Dennis Trollop racing but with cheapo plastic cap replaced for my own alloy item.

Bellmouths now secured using some intake rubber clamps.

Small filler cap i had fitted seemed out of proportion so has been swapped for the larger version

Looks much better now

Then finally on to the kickstart lever, I recently picked one up for a decent price off evil bay which I then bent and braced to miss the zx10r foot controls.

With the kickstart fitted I could finally try out the race ignition and this is where the trouble began.
After several frantic kicking sessions i couldn't get a spark and a phone call to Electrex revealed that the unit needs around 200 rpm to produce a pulse.
A quick few kicks on the Drouin showed a maximum of 110 rpm on its digital tacho .... BOLLOCKS!
Bump starting or carrying a set of starting rollers around in a rucksack isn't part of the plan so that's £500 down the drain
My own fault I suppose for not thinking when I bought it so in to the 'FOR SALE' section it has gone and plan B has been activated......

And here it is !
Another 500 knicker in Electrex's pocket
Enter stage left a race alternator.

Luckily it uses the same basic backplate as the ignition so my work on the one off cover is not wasted and i still get to keep the look.

The knock on of this is that i've had to reinstate the r/h side of the crank and ignition housing to drive a Dyna 'S'

Not the clean slim lines i wanted but the best of a compromise.
I managed to slim the housing by 10mm or so with the crank nut running in the bulge I added earlier.

Nearly there.

You sir, are GIFTED!!!! The attention to detail is outstanding

That all looks spectacular! I was very interested to see that you had retained the kickstarter with a mod to clear the rearsets. Any concerns about additional leverage on the end of the starter shaft with the more outboard location of torque while kicking it over? Thanks for all of the pics and ideas!

absolutely top notch build , I have looked at this project so many times i'v lost count , Best build i'v seen so far. congrats.

Primer wrote: That all looks spectacular! I was very interested to see that you had retained the kickstarter with a mod to clear the rearsets. Any concerns about additional leverage on the end of the starter shaft with the more outboard location of torque while kicking it over? Thanks for all of the pics and ideas!

No concerns.
I did exactly the same on the Drouin project with no problems.
I was prepared to install a bronze bush in to the kickstart end cap or make a completely new beefed up item if the alloy one wore more than usual but so far it's been ok.
I was more wary of the actual kickstart lever bending as even the std ones bend with use over the years which is why i added the brace.
It's hard to see in the pic's but the bracing is actually welded diagonally across the kickstart to resist twisting.

Pretty sure I've said it before but I'll say it again, freaking amazing build. Absolutely top notch and unfortunately inspirational. I'm sitting in my desk right now with my parts bike frame sitting next to me because a co-worker and I are going to be designing a new subframe and new frame gussets. My project keeps getting bigger every time I look at threads like yours!