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650 Mod's 78 Fighter Build 14 Dec 2013 17:51 #615533

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Alright, guys. I know it's been quite some time since I've posted any progress on here. Things are still plugging along, just slowed down a bit with the welder I'm working with. We got some shop time in today, and got a bit of work in. The other day, I got the new fuse box wired in, but took the wiring harness off before I could get pics. I'll put some up later.

Here's what we got done.

Ripped the engine out to give us more room to play around with the shock mount

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Flipped the bike upside down to finish grinding/prepping the frame for the lower mount

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Crossmember all cleaned up and ready for the mount

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The lower mount on the welding jig

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All welded up, cooling down

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The rough stance for the mount/shock positioning

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The lower mount clamped in place, ready to be tacked. Nice clean welds to hold it in tight :)

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We got the mount tacked in place, and started to figure out ride height and upper mount ideas. I'm going to use some 3/16" plate steel to make a mount. Pics will come with that progress :) Should have the upper mount completed after the next work session.
78 kz 650 custom
Wiseco 720cc big bore
Dynajet stage 3 carb kit with pods
2002 Kawasaki Z750 exhaust
2001 Buell lightning front end
1999 Ninja 600 swingarm with 1999 Ninja 900 rear rim
converted to monoshock rear
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650 Mod's 78 Fighter Build 16 Dec 2013 06:07 #615602

  • 531blackbanshee
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lookin good man!
your welder looks like he may have been at awhile :cheer: !

nice,

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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650 Mod's 78 Fighter Build 16 Dec 2013 07:20 #615611

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Leon,

He sure has! He and my dad work together for an aircraft custom fab/repair shop. His welding has to exceed the requirements for anything being put in an aircraft. Those standards are VERY strict, so a lot of practice and time fabbing definitely helps!

I'm hoping to have the upper mount finished up in the early new year. Maybe get a little shop time in before xmas.

Devin
78 kz 650 custom
Wiseco 720cc big bore
Dynajet stage 3 carb kit with pods
2002 Kawasaki Z750 exhaust
2001 Buell lightning front end
1999 Ninja 600 swingarm with 1999 Ninja 900 rear rim
converted to monoshock rear
Too many goodies to list fully

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650 Mod's 78 Fighter Build 28 Dec 2013 05:56 #616559

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Nice to see some progress! I like how that mount jig was set up, very slick B) Your build makes me want to hit the reset button on mine with a brand new TIG that doesn't dump full voltage at the instant you touch the pedal! :woohoo: When I set up the back end I pulled the engine first and used 205lbs of weights to simulate where it would sit once it was put back. Hell of a lot easier to sling steel bar bells in there than the whole engine. But I still made it sit too high :whistle: . I appreciate what your fabricator friend has to say about my build, he is doing a great job and I applaud both your skills and vision and can't wait to see the rest of it come together. I think your bike is going to turn out sweet!! Now, get to work! I know it can't be that cold in that shop!! :lol:
Corbin Teal
1976 Kz900 project:
Rebuilt engine
Suzuki GSXR750 front end
ZX636 rear with GSXR600 shock
2009 Yamaha R1 wheels

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650 Mod's 78 Fighter Build 28 Dec 2013 06:50 #616562

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I like the idea of loading the suspension before setting everything in place. I'll have to maybe do that too in order to get the best ride height figured out. I think where we mocked it up to is going to work well- I can still flat foot when I sit on the seat like I used to with the stock suspension set up. It keeps roughly the same stance in regards to seat height and how the under engine tubing sits angled. Thanks for the kind words- it's slowly coming together. Between my school and his family, it's tough to get alot of full-day build time in. But when we do... We work hard :) It's all starting to look closer and closer to what I had in mind- one day at a time. As for work, I'll get in there whenever I can! Had to dig the bike out of a 3 foot snow drift the last time I worked on it...
78 kz 650 custom
Wiseco 720cc big bore
Dynajet stage 3 carb kit with pods
2002 Kawasaki Z750 exhaust
2001 Buell lightning front end
1999 Ninja 600 swingarm with 1999 Ninja 900 rear rim
converted to monoshock rear
Too many goodies to list fully

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650 Mod's 78 Fighter Build 13 Jan 2014 19:11 #618508

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Got a bit of work done yesterday- almost finished up the rear shock mount. With the front of it braced, I ACTUALLY have rear suspension now! It's going to be a huge improvement over the old school twin shocks. There was LOTS of head scratching done, trying to decide on what mount would work best. I was going to use DoubleZed's idea, but ended up canning that one. Looked at about 4 more mount ideas, and we were able to brainstorm this idea up. Sorry it's not fully finished.

Since I didn't have the c-mount for the upper shock, we made one out of 1/4 inch flat stock

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Welded, cooling down

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Since I wanted to keep the battery box in place, there was alot of head scratching. This mount will use one 3/4" tube welded to the 3/4" tube that crosses the frame under the seat. The front will have two 1" tubes welded into the frame where it splits just under the gas tank mount (by the side cover mounts, but on the 1"frame tube split) . The horizontal upper part of the mount is 1/4" flat stock

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Once everything is in place, the flat stock will be shortened up a bit in the rear to properly clear the shock reservoir. Ignore the tube in the front- this is just to brace it for the time being. This is where the two 1" pieces of tube will be welded in

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Not too shallow of an angle so hopefully the tube will hold out alright.

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the top of the 3/4" tube is notched out to hug the frame. The underside of the tube at the flat stock will be braced with a piece of 1/4" flat stock to prevent flexing.

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Since I want to keep the battery box in place, this will roughly be the stance of the mount. It will sit a slight bit forward, with around 1/8" clearance to the battery box on both sides.

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Does anyone see anything wrong with the structural support of the mount? The horizontal flat stock will be braced on top perpendicularly to prevent any flex, and the tubes will also be braced with triangle flat stock.
78 kz 650 custom
Wiseco 720cc big bore
Dynajet stage 3 carb kit with pods
2002 Kawasaki Z750 exhaust
2001 Buell lightning front end
1999 Ninja 600 swingarm with 1999 Ninja 900 rear rim
converted to monoshock rear
Too many goodies to list fully
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650 Mod's 78 Fighter Build 15 Jan 2014 06:05 #618674

  • 531blackbanshee
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i think you will be fine.
i don't really like the rear tube feeding into the center of the unsupported upper tubing.but the way you are going to do the front tubes is very strong and feeding into strong areas of the frame .so the suspension force is being distributed into all three areas.

you could split a piece of tubing lengthwise and use that to lay on top of the flatbar and cope it into the back tubing then weld it all in and gain all kinds of strength without adding much more thickness to foul the battery box.
just a thought.

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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650 Mod's 78 Fighter Build 15 Jan 2014 06:33 #618677

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Thanks for the input, Leon. What we were thinking of doing was something like this to brace everything up- just like you were saying.

Bracing the horizontal flat stock with a perpendicular piece (still enough room to clear the box), and bracing the front/rear tubes with more flat stock. I also like your idea with the split tubing on top- either or, there's going to be something on top of the horizontal flat stock to brace it up

Attachment brace.jpg not found



This should work out ok, right?
78 kz 650 custom
Wiseco 720cc big bore
Dynajet stage 3 carb kit with pods
2002 Kawasaki Z750 exhaust
2001 Buell lightning front end
1999 Ninja 600 swingarm with 1999 Ninja 900 rear rim
converted to monoshock rear
Too many goodies to list fully
Attachments:

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650 Mod's 78 Fighter Build 15 Jan 2014 07:14 #618681

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if you brace the top of the flatbar with the split tube and cope it into the rear tube it would eliminate the need for the gusset at the back bottom of the tubing.
then you could just grind/sand the back of the flatbar to the same radius as the tube while leaving the weld.

the front two tubes can tie into the split tube and flat bar and eliminate corner gussets because they create them themselves by the way they tie into the split tube/flat bar.if you need some more room up front you could use bent tubing to gain some room but still tie in right.

hth,
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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650 Mod's 78 Fighter Build 15 Jan 2014 07:29 #618684

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I know all too well what you mean about the head scratching. I like the rear shock you are using, nice and short, but the reservoir seems to be a pain to work around, like so many others. I wanted to use a remote reservoir shock; it would have made the mounting SOOO much simpler. I especially like using the original battery box, I think you nailed that!!
Your mounting looks like it will be fine with the bracing you will add. You might be able to split a length of tubing to cap the cross tube at the back, that should greatly reduce any chance of it bending and keep a low profile. Tying into the area at the back of the tank will be good, that area is already very strong, as Leon pointed out. +1 for using geometry lol! This three-point mount looks very familiar.....
Oh, don't worry about using my idea, just ditch it and find something better! :P just kidding
Corbin Teal
1976 Kz900 project:
Rebuilt engine
Suzuki GSXR750 front end
ZX636 rear with GSXR600 shock
2009 Yamaha R1 wheels

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650 Mod's 78 Fighter Build 15 Jan 2014 08:55 #618695

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Leon- I see what you're saying about structural strength with the split tubing now. I like it. I like the idea of being able to then radius the back of the flatbar. We were going to just trim it up and radius the corners a bit, but fully being able to radius the flatbar will be nice.

DoubleZed- the shock is nice to work with being so compact. It gave me a bit more freedom to work with, and I really like how I was able to keep my battery box in the same location. I think for this build, using the shock I am makes things easier- if I was using a shock like yours, I probably couldn't have gotten away with keeping the battery box in the stock location. If I'm tying into the seat cross tube, I'll have to under brace it as the top has all my seat rail mounting points (which should still work ok). Where have you seen this mount used before? Haha had to go with whatever worked the best for me :P
78 kz 650 custom
Wiseco 720cc big bore
Dynajet stage 3 carb kit with pods
2002 Kawasaki Z750 exhaust
2001 Buell lightning front end
1999 Ninja 600 swingarm with 1999 Ninja 900 rear rim
converted to monoshock rear
Too many goodies to list fully

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650 Mod's 78 Fighter Build 15 Jan 2014 10:13 #618709

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I probably would have gone with two tubes angled out to the stronger outer frame members like such. But what has already been discussed for adding strength is a good way to go .

1983 GPZ550

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