TOPIC:

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.

I'd made a stainless steel flange for the Rajay turbo outlet ages ago, so it was high time that I did something with it.
With a 90 degree stainless bend, with one leg shortened, it was squeezed into the flange like so.

And you can see some cut-down stainless bends on the bench as well, which got tacked together...

And then bolted back on to see if they looked something like...

I'm going to slash cut the exit, although I'm still not 100% sure about it. I'm going to make another, baffled, pipe that runs to the rear of the bike that I can use when the bike is MoT tested and also if I ever decide to take it on track (either at a noise-limited run-what-ya-brung, or a track day might be fun...)

I got a grown up to TIG it all together properly.

So, ages ago I mentioned that the carb wouldn't fit in a manner that would allow it to work very well...

Usually the carb slips into this flange that bolts onto the turbo body

So I needed to find a way of offsetting that flange forwards and outwards...
After some thought... I decided that a piece of bend tubing could do the trick, but this pesky Pingle could end up pissing on my chips...

I got a cast aluminium bend, and marked it up where I guesstimated would work...

And cut it. The piece of paper is a template for the flanges to go on each end of the pipe to A) bolt to the turbo and hold the flange for the carb

And if it was wrong I still had the other piece of bend
And, welded together with a pair of flanges

It needed some material trimming off, but it was looking close...