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Testarossa's 78 KZ1000 Fighter Build

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16 Apr 2010 10:56 #361144 by porchev914
Replied by porchev914 on topic Testarossa's 78 KZ1000 Fighter Build
testarossa wrote:

Extra fab work is not my idea of a good time at the moment. Work continues on the rearsets. Also I get to look forward to fabbing a taillight/license plate mount, battery box/dyna 2000/fusebox mount, rear shock nitrogen resivoir mount, rear master cylinder resivoir mount, exhaust mount, passenger footpeg mounts, and oh yeah gauge mounts. Did I miss anything?


Headlight and front turn signals, unless you already got that covered :ohmy:

FRANKEN Z!
1978 KZ1000 A2A with 08'Speed Triple SSSA and '06 GSXR1000 front end

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16 Apr 2010 13:44 #361163 by testarossa
Replied by testarossa on topic Testarossa's 78 KZ1000 Fighter Build
Yeah, I just got the headlight rings in yesterday. Like a puzzle trying to figure out how to assemble that. Obviously, the original mounting ears won't fit around the fork tubes, so the mount will be custom. As for the front blinkers, I need some inspiration. All of the replacement parts on ebay and the cycle shops look the same. Plastic fantastic. I don't have any original front blinkers, and they wouln't fit anyway. I would like something led and fairly small to match the smoothed apperance of the bike. However, they do need to throw some light. Anyone got a suggestion. I'm all ears.

1978 KZ1000 A2 Click--->Build Thread
2004 ZX-10R
2007 Harley Sportster 1200
2020 Harley Street Glide Special
Angola, IN

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16 Apr 2010 21:43 #361255 by testarossa
Replied by testarossa on topic Testarossa's 78 KZ1000 Fighter Build
Some actual progress to report. I have finally got the DIY rearsets rigid enough to feel comfortable using them. As you can see from the pictures, I have made "I beam" sections out of them, instead of flat plate. My hope is to skeletonize them as much as possible.





Also, fabricated the taillight/license plate bracket this afternoon.







Finally, I repaired the broken baffle in the exhaust pipe that Tony gave me.





Had to clean up the damaged mating surface.



After the most difficult welding that I have ever done, I have a one peice baffle again.


1978 KZ1000 A2 Click--->Build Thread
2004 ZX-10R
2007 Harley Sportster 1200
2020 Harley Street Glide Special
Angola, IN

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17 Apr 2010 04:51 #361273 by mark1122
Replied by mark1122 on topic Testarossa's 78 KZ1000 Fighter Build
Excellent job on the tail lt, and silencer.B)
I'm not understanding the i beam rearsets thogh?

76 KZ, frame gusset work,1200CC.Ported by Larry Cavanaugh, 1.5mm.over intakes, Carron Pipe, ZRX12 rear end, and seat,96zx9 front end.
01 CBR600F4i Track bike.
Cobourg, Ont. Can.

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~ (k) / (z)

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17 Apr 2010 07:01 - 17 Apr 2010 07:01 #361296 by testarossa
Replied by testarossa on topic Testarossa's 78 KZ1000 Fighter Build
Mark, the rearsets are made from 1/8" plate, and were quite flexible. I added in some cross bracing to correct the flex. If you took a cross section of the rearset mount plate it would look like an I beam. Next I plan to cut out some of the meat between the braced areas to lighten and for the coolness factor. I'll get some better closeups after I do that, and it will make sense then.

1978 KZ1000 A2 Click--->Build Thread
2004 ZX-10R
2007 Harley Sportster 1200
2020 Harley Street Glide Special
Angola, IN
Last edit: 17 Apr 2010 07:01 by testarossa.

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17 Apr 2010 07:06 #361297 by testarossa
Replied by testarossa on topic Testarossa's 78 KZ1000 Fighter Build
Try to supersize image number 1, and you should be able to see that there is a 1/2" wide peice of steel wrapped all the way around the triangular mount plate. Also there is another peice that bisects the larger triangle across the center section.

1978 KZ1000 A2 Click--->Build Thread
2004 ZX-10R
2007 Harley Sportster 1200
2020 Harley Street Glide Special
Angola, IN

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17 Apr 2010 08:47 #361316 by mark1122
Replied by mark1122 on topic Testarossa's 78 KZ1000 Fighter Build
Awe yes, i see it now. good idea .B)
did u have any plan to alter the face of the pegs? I’m wondering if they may feel a little slippery under foot, in some circumstances?

76 KZ, frame gusset work,1200CC.Ported by Larry Cavanaugh, 1.5mm.over intakes, Carron Pipe, ZRX12 rear end, and seat,96zx9 front end.
01 CBR600F4i Track bike.
Cobourg, Ont. Can.

~ ~ ~_@
~ ~ _- \,
~ (k) / (z)

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17 Apr 2010 08:59 #361320 by testarossa
Replied by testarossa on topic Testarossa's 78 KZ1000 Fighter Build
The pegs are due some modification. Right now they are just proof of concept. I plan on putting a slash cut on the ends, and who knows what to the tops. I definantly think that they would be dangerous if wet or oily in the current form. It would be foolish of me to think that I would never get caught in the rain in Houston.

1978 KZ1000 A2 Click--->Build Thread
2004 ZX-10R
2007 Harley Sportster 1200
2020 Harley Street Glide Special
Angola, IN

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17 Apr 2010 09:08 #361322 by timebomb33
Replied by timebomb33 on topic Testarossa's 78 KZ1000 Fighter Build
that's not rain it's really just very humid there. same with most of south texas.

1973 z1 2-1974z1-a,2-1975z1-b dragbikes1015cc+1393cc, 1977kz1000,1978kz1000,1981kz1000j, 1997 zx-11, 2000 z12r,1428turbo nitrous pro-mod and a shit load of parts thats all for now leader sask.,CANADA
I THINK MY POWERBAND BROKE

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17 Apr 2010 09:09 #361323 by mark1122
Replied by mark1122 on topic Testarossa's 78 KZ1000 Fighter Build
a simple knurl comes to mind. I’m sure u will come up with something.
I had knurled ends on the shifter and brake peddle.and took them off because the shifters, knural was chewing on my boot top. Now I have smooth ones shaped like 50 cal bullets and the brake side is slippery. Cant win?:lol:

76 KZ, frame gusset work,1200CC.Ported by Larry Cavanaugh, 1.5mm.over intakes, Carron Pipe, ZRX12 rear end, and seat,96zx9 front end.
01 CBR600F4i Track bike.
Cobourg, Ont. Can.

~ ~ ~_@
~ ~ _- \,
~ (k) / (z)

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17 Apr 2010 21:50 #361426 by porchev914
Replied by porchev914 on topic Testarossa's 78 KZ1000 Fighter Build
That tailight sure tucked up under there nicely! The rearsets are certainly comming along too. If you're anything like me, you'll get them mostly finished then figure out some changes you'd like to make, but won't because of the amount of work it wold take to start from scratch again. I'm already planning what I would do different when I adapt that Duc 1098 swinger to another project... :laugh: Great job too on the core repair: that is thin sheetmetal that takes more finess to mig weld PLUS the tight confines of the cap would be a challenge. Good work so far Josh, you're getting closer ;)

FRANKEN Z!
1978 KZ1000 A2A with 08'Speed Triple SSSA and '06 GSXR1000 front end

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18 Apr 2010 17:19 #361526 by testarossa
Replied by testarossa on topic Testarossa's 78 KZ1000 Fighter Build
You aren't kidding about that baffle being thin sheetmetal. I'm guessing that it's 24ga. As soon as the arc would stabilize I would start to burn a hole. I resorted to using loads of small tack welds. I bet I put 150 tacks on that thing. Next time I'm gonna make a new baffle from scratch.

Mark, I'm kicking myself for not knurling those footpegs before I welded them up. Knurling steel takes a lot of tool pressure, and it helps to have a sacrificial section to chuck on that will be cut off. I'm not sure how I'll handle it yet.

1978 KZ1000 A2 Click--->Build Thread
2004 ZX-10R
2007 Harley Sportster 1200
2020 Harley Street Glide Special
Angola, IN

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