TOPIC:

Bugger indeed if you cut the height down would there be room enough to wiggle the box in ? an alternative might be a couple or 3 threaded bosses welded on making the reg and plate screw on ?

Yeah, initially I tried just cutting down the size of the reg/rec bracket, and spent ages wriggling the battery box around trying to get it in place, including trying to slide it in from below, to no avail. So the bracket was summarily lopped off...

I added a piece to the base, so the reg/rec is still at the right-hand side, at the bottom of the sidepanel, so should get some airflow too.

And the battery box now slides into place, and it sits in position like this...

... with the reg/rec in place.
And from the other side, with the Dyna 2000 held in place temporarily with some tie wraps. It'll be either o-rings of rubber bands cut from inner tubes that hold it when finished.

Result all this hard work and will be hidden out of view.

A quick question about motor frame mounting points, did you need to remake all of them or did any of them line up ?

The lower rear mount lined up, the rest were fabricated, with the upper rear mounts being remade as a one piece mount that (hopefully) helps to add some rigidity to the frame!

Zed, I know it's a little late now with all that work you did building the battery box, but did you ever think about getting a Shorai Lithium battery, they are completely sealed, no Battery acid to worry about, they can be mounted in any position, (sideways/upside down) , they weigh less than a pound, & are the size of about 2 cigarette packs, only drawback ,is they are about 150.00...I got one, & I love it
Pete

Pete, you hit the nail on the head there... cost! Plus the extra cost of a lithium-specific battery charger. I'd also heard far too many tales of people having lots of problems with li-po batteries, so i wasn't going to risk an overspend only to run into problems down the line. I love the idea, but couldn't justify it just yet

With an aftermarket oil cooler set to replace the standard one, I had a root through my cooler stash in the cupboard, and set to making up some brackets.

I'm going to mount the oil cooler off the two reflector mounts on the front frame down tubes, using rubber mounts like these bobbins, which were a nightmare to find, and chuffin' expensive too. Anyone know where they can be found cheap?

As you can see from the above pic, I'd got some stainless steel tube to make the spacers, it just needed cutting down...

And I made up a couple of 'ears' to hold the rubber mounts, that would need to be welded onto the cooler bracket.

Like this -

And then the bracket could have a bit taken out of the middle to make it look nicer...

And tried in place to see if it fitted okay...

Seems okay, wonder what it looks like with the cooler added?

Hmmm, might take a bit more off the upper mount to be able to run the oil lines a bit neater, but I think it's getting there?

Nice job with the cooler brackets

So, a mere ten months later, ahem.
This is just a bit of advance warning - I wouldn't want you getting all shocked and hyperventilating - but I've done some more stuff on the Zed. Pics uploading right now...

Looking forward to your progress.