TOPIC:

While I'm on a 7 month no motorcycle holiday I decided to make a few modifications to the Hamasaki. Most importantly I'm hoping to deal with that smokey exhaust once and for all and I decided I didn't like the seat that I sewed myself. It wasn't a bad job but the shape is not quite right and I think a beautiful seat is like the icing on a cake for a custom bike.



Cheers
Hama
82 KZ 305 - Hamasaki cafe racer
80 KZ 750 - banished
06 KDX 200

Because I sourced the last set of stock rings on the planet (I know of 1 set for 1 piston) and my rings did not seem to seat correctly I began a search for alternatives. I found Wiseco do a big bore kit for the GPz 550 that has a 61mm bore and a stroke of 52.4 that matches the stock pistons for the KZ 305. So I bought a set and found that the 305 has a 15mm wrist pin and the 550 a 14mm, I'm still waiting for the wrist pins to arrive but the plan is to get the pistons machined to take the 15mm pins and snap rings.
Perfect match!

Cheers
Hama
82 KZ 305 - Hamasaki cafe racer
80 KZ 750 - banished
06 KDX 200

I'm working on my new seat and side covers. added some polyurethane foam to the sides. shaped the foam...
3 layers of fibreglass and some bondo work (and lots of messy sanding) almost ready to go to my painter.
I like the look of the vintage oval number plates so I'm using that idea for my new side covers to fill in the dreaded KZ frame droop. I had just enough 2mm aluminum sheet left. I made a plywood template and whacked it into shape with a rubber mallet. cut out the shapes with a jigsaw. I used my cutting blade on my angle grinder to score the back face then used my vice and mallet to fold them. . They will be painted to match the rest of the bike.

Cheers
Hama
82 KZ 305 - Hamasaki cafe racer
80 KZ 750 - banished
06 KDX 200

nice work you have done here sir !

can't wait to see it upholstered and painted,

leon

Yes, I like what you've done too.

Seat all masked up ready for fiberglassing the base for the foam and for the leather to be fixed to. I thought I had a photo of the wet second coat but I don't. I'll get a snap on the finished piece tomorrow.

My part engine parts have all arrived and have now been sent away for machining. I hope the do a 100% perfect job!

Cheers
Hama
82 KZ 305 - Hamasaki cafe racer
80 KZ 750 - banished
06 KDX 200

This is what I gave them... Damn pdf won't upload. I'll do it on the computer tomorrow...

Wow! I really like what you're doing with the seat and side covers! Great craftsmanship!

Here's the fiberglass base for the foam. Leather in transit from Napa California. I need to sort the fixings next, I have a plan for that.

Cheers
Hama
82 KZ 305 - Hamasaki cafe racer
80 KZ 750 - banished
06 KDX 200

Hopefully my plan uploads today. This is what I gave the engineers - surely the can't cock it up from here...

Side cover fixed in place

Cheers
Hama
82 KZ 305 - Hamasaki cafe racer
80 KZ 750 - banished
06 KDX 200

nice!

leon