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Photos from yesterdays efforts


Everything lines up great.Just need to get some SS allen head bolts to hold it all down and figure out how to mill some nice profiling without a milling machine.

Today was spent working on the mount for the clocks/idiot lights and ignition key.The original mounting plate I made for the clocks was a bit rough to be honest (one of my first aluminium jobs) and pretty thin at 4mm.Also I hadnt given any thought to the ignition and the idiot lights.

I was happy with it at the time but I need somewhere to switch the bike on.I had a good look at it and figured that if I moved the clocks forward about 1cm,I would be able to fit everything else in,just as it was originally.So I made a rough template to check the positioning.

and it all fitted.The only problem being that the ignition switch mount is on a different plane AND at a different angle to everything else.
So i made up a couple of angled spacers to sort that out


and that was it.Ill have to make up a jig to drill the holes in the final alu plate but its all looking workable. Im now busy with a 2nd template
to get the outside shape I want

It was getting late and I was knackered so I called it a day at that.

Once Ive gotten that done,Ill transfer to a final template from 18mm MDF, bolt it up to some 10mm alu plate,trim it back on the band saw and run it over the router table.

davido wrote: Thanks Brett,yes its a long list and I still havent quite reached that point when I can bolt things up,knowing that I dont need to unbolt them again but that day will come. (Hopefully when the wheels and swingarm are back from the powdercoaters).
Anyway,today,I finished work earlier than I expected,so I went to the workshop and got a new plate cut for the clutch. I used the same method as with the footrest hangers and it worked out just peachy. (I didnt have the camera with me, so, photos to follow).
Now I have to figure out how to put some profiling in it without bollocksing it up,like I did witht the last one. I dont have access to,or knowledge of how to work a milling machine,so I have to use what I have. A router table,various hand held routers and a couple of bench presses.
Im not working tomorrow so Ill have a crack at it then.Tonight is for thinking!

P.s. Thanks Jon (Kawaholic) for the spacing advice,I think Ive sussed it out now.

No problem David, the fact that you put out such quality work and have so much thought put into it shows, and even more impressive without a mill and doing it by hand instead and using tools you do have access to! The new clutch plate looks great and as always top notch work

I would suggest keeping the other as a backup, looks great regardless and never know when you might need a spare at least temporarily to help!

Keep it coming, really enjoying following your build and rooting for you to wrap up in your timeline, glad that worked out for a shop and storage for you buddy

Brett

Back to it again today.More alu work. Maybe even the last bit? Im not sure though.
The clocks/ignition mounting plate. I finished off the first template to check everything would fit together properly and it all looked good

Then I transfered that to 18mm MDF,bolted on the 10mm alu and trimmed it all back as close as I could

A spin round on the router table

and it came out very nicely

I got the angled holes drilled for the ignition,which was a pain in the arse to do.I made up a jig with a 30 degree angle,closed my eyes and went for it. Apart from drilling one of the pilot holes in the opposite direction,I got it done. With the angled spacers that I made last week,it all fits just right

So,I still have to do a bit of fiddleing around with it but its pretty much there now.


It took a lot more time than I thought,as everything seems to do.Not sure if Ill be able to get away tomorrow,if not Ill have to wait til next week. Tik Tok !

A couple of hours in the workshop today.Tidied up the mounting plate a bit,gave it a bevel. Looks good.(No photo though). Then I thought it was about time to start thinking about the loom. Not sure what Im going to do here. I would like an M Box and a mini battery and all the bells and whistles of a modern electrical system but the budget isnt going to stretch to that. So, Ive got to get creative.
A 35 year old electrical system. Worn out,badly repaired,bare wires in some places and signs of a fire on the bike during a previous life.
So first things first,strip the loom down and see whats what. I made a frame to pin itall down

Ive got to get a few things first,then I can get started.

Been busy playing with the loom this week. I havent stripped anything yet,Im trying to get all the parts connected and give it a bench test first before I start pulling things apart. Nearly there, All the connections are identified and labeled , battery is charged and I got some new fuses today. I had a problem with the key not working in the ignition so I stripped it down and now have access to the electrical part,which is what I need for now.So hopefully I can get that fired up in the next couple of days and see whats what before I decide on what to do with it.
Thanks KZRider.com for the colour schematic. Very helpful.

Meanwhile,today I went down to the workshop and got some bits painted. Not very exciting,I know but one step closer.

Great progress David, keep up the good work and love seeing that progress coming along chipping away at the list of steps left to do! Each step is clearly thought out, well executed and detailed well you are doing great!

Brett

Thanks for the kind words Brett. 'Clearly thought out',I dont know about that with the amount of stuff Ive had to redo but with the time limit now,Im trying to think forward as much as possible and my mind seems full of too much stuff. Painting,anodising,electrics,what small parts I need to order,final colour scheme. Too many things going on and each one seems to bring up other smaller but just as important details to be thought about.Its a ball of confusion at the minute.
Which brings me to my latest dilema.Thinking about the speedo drive. Going from a 19 inch front wheel (CSR)to a 17 inch front whee(ZXR)l! Keeping the original CSR clock (speedometer).How do I get it to give an acurate reading???
Im having problems getting my head around this one. I have drives for both wheels. Do I use the 17inch or the 19inch or can I recalibrate the clock or is none of the above going to work?
Off the top of my head,I would think I need a clock from a 17inch wheeler! The ZXR? Internals transplanted into the CSR clock shell?? Is that viable? Internals from a KZ with a 17inch wheel from a similar era??
No idea. Help needed.Please advise.

P.S. No,I dont want to go digital. I would rather put a sticker on the clock glass.

I'd think the 17" drive would be calibrated correctly for the wheel.
Steve

swest wrote: I'd think the 17" drive would be calibrated correctly for the wheel.
Steve

But will the 17inch wheel and drive give a proper reading on the 19inch clock?

No ideas on the speedo then. Itll go into the ' No idea how Im going to do this' box for now.
A bit more painting today,just some odds and sods. I unmasked the disks and other stuff I did last week.

The black on the disks came out pretty good,a bit thick but it hardened up well.The silver though,Im not sure about.When I wipe my finger over it,I pick up traces of the paint! Not good. It is dry and I checked the label for info and theres nothing about curing with heat.So, I dont know whats going on there. Im not going to do anymore with it as It was a real pig to mask off. Ill just have to refrain from wiping my fingers over it!!
I did a few other ( not silver) bits today.Ill check on them tomorrow.
Still no word from the powdercoater on the wheels and swingarm. Im meant to be getting a special price on them so I cant complain. Yet. I still have to order the dust seals for the wheels but apart from that,I think everything is ready to go. Disks painted,sprocket carrier painted. New bearings all round (except the swingarm), Spacers etc cleaned. I even polished up the disk bolts today. So as soon as the powdercoater has done his thing. I can get everything mounted up,fit new rubber and get thiem balanced and back on the bike. Hopefully to not come off again for a good long while.
In other news,I had problems with the ignition key. Worked fine in the seat lock and tank cap but wouldnt turn in the ignition. Couldnt figure that one out. In the end I took everything to a local locksmith. He ordered and cut a couple of new keys and everything works hunky dory now. The Keys are also a lot more robust than the old paper thin one I had before.
and now,the weather.....

Glad to hear things are moving correctly David, great stuff there and paint came out looking nice

Been doing a bit o' amateur noodling on your speedo issue. Could be totally washed up but I would imagine that if you used the speedo drive from the 17" and adapt a line that had the right plug end to connect to the stock speedo clock that you'd be fine. Once again I am coming at this from my auto mechanic background and in that case it's typically NOT the clocks that are geared but rather the drive. That's not true for everything by any means but I can't see why what I described above wouldn't work unless someone else provides some factual info that contradicts that. Hope it helps

Brett

David, those rotors are looking mighty sexeh! Really clean look!
I'm stoked to see your progress here since I just picked up a CSR1000 not too long ago, so it's great to live vicariously through your pursuits first

As for the speedo...
I was initially going to +1 'd Brett's post.
In most instances the speedometer is a passive device. The brains-part is determined by the gearing in the wheel hub, which should in theory still work since it's the whole assembly you got there. BUT. Or maybe it's "BUTT" as in kick yourself in the...

The rub comes in on the odometer. That is the portion of the speedo which IS geared and gear-matched to the stock hub of a kawi. So even while we could expect your speed to read correctly, there's a good chance the mileage will not record correctly...

Further. I was reading in another thread [ Awesome CSR Resto-Mod ] that another guy here mentions his speedo went all rainman on him when he changed his front end over to GSXR (I think it was?).

So. If it were me; I'd just plug the old gal's speedo into the wheel hub and see what shakes down. It may display speed correctly and not mileage or neither but at least it will spin the needle and you'll be able to decipher how it changed. Like in the old VWs, when we put custom wheels with skinny 135-low profile tires on the front end to slam it. My speedo was off by 10%. It was easy to figure out though.