TOPIC:

Zed

You've been busy since the last time I peeked in on this project. It's working out beautifully. I love it

Teeny weeny update.
Exhaust hanger done which took far more time than it should have.
Was gonna just hang it off the subframe but it looked pants so figured that if the footrest can take the riders weight then a stumpy ally can should be no problem.

I've spun the cans outer sleeve round so that the mount is closer to the footrest then made an extended T6 replica heel plate and sandwiched it between the original and the mount with a couple of countersunk capheads and nylocs to tie it together and stiffen the assembly up.

Now need to get the subframe, struts ,side stand and seat pan powder coated asap and then it's wiring ,fuel , some minor jobs and it looks like I might actually get it running for this years one dry day in a couple of months time.

Subframe and struts powder coated and fitted.

Seat pan powder coated and race foam on

A much better look than the bare alloy ones

looks like a runner!

leon

Can you tell me a bit about the foam and how it is to work with. As usual the bike is looking great.
Wayne

That looks trick...just like the rest of the bike

kzz1king wrote: Can you tell me a bit about the foam and how it is to work with. As usual the bike is looking great.
Wayne

This is the first time I've done this and although tricky it turned out ok.
The foam is sticky backed.
Due to it's thickness I had to warm the non sticky side with a hairdryer slightly to help it curve more easily to the seat pan.
Once stuck down i cut the excess off with a new stanley blade.
The curved edges were shaped with sandpaper but it's impossible to get a smooth appearance to match the untouched areas.
I found applying the hairdryer on a hot setting softened the rough surface of the sanded foam enough to allow it to be smoothed with my finger.
It's still not perfect but apparently it will look better after it's been sat on a while.
I did consider putting on a cover but it suits the ex racer look i was aiming for.

All the work you've done on the bike is very neat and tidy! Do you plan to install a deflector, shield, or fender of some sort to prevent road grit and water from being thrown into the velocity stacks? It looks like there's a straight line from the tire's tangent to the carbs. I see the stacks have screens to keep out the big stuff, but that fine grit can be very destructive when sucked into the cylinders. Something to consider. Ed

650ed wrote: Do you plan to install a deflector, shield, or fender of some sort to prevent road grit and water from being thrown into the velocity stacks? . Ed

Yes! That is the next job on the snagging list.
I've had that issue in the back of my mind for quite a while and I think I've got a nice solution that won't look like an after thought.
I'm looking for some large mounting grommets that will fit the holes in the two triangular bracing plates that are either side of the shock mount.
I think a nice alloy plate mounted off those will do the trick.
Probably will paint it black so it blends in.

I have been watching your build and I know you have skills and tools that most will never have . Bike is exceptional except for those foot pegs. Was hoping you did something with them before you tied the header into them. A bike so well built with them is just wrong to me but hell its yours.

peter1958 wrote: I have been watching your build and I know you have skills and tools that most will never have . Bike is exceptional except for those foot pegs. Was hoping you did something with them before you tied the header into them. A bike so well built with them is just wrong to me but hell its yours.

My thoughts exactly and another job on the snagging list but not priority as I can change them anytime.
I have plans to replace the pegs and hangers with some adjustable alloy items and I have a small pile of alloy plate and bar waiting for the attention of the lathe and saw.
The std zx10r ones were only there to set up the riding position and seat height etc.
They will be made to take the same heel guards though so the work on the exhaust bracket etc was not wasted.

And the word for today and probably the rest of the week is BASTARD

Pic's are pretty much Self explanatory.
Unforseen freak camshaft flange failure results in a cracked head, a bent valve and a slight delay on the completion date