Doctorot's '78 KZ1000 build

kzz1king wrote: Another thought. Can you remove the airbox with the extension on ot?
Wayne

yes as it currently sits i can remove the airbox, but i have to remove the carbs to do so.

Primer wrote: Could you add to the existing mold (which could understandably cause some grief) and have it so the side panel bridged the forward down tube and tied into the airbox? It would remove as usual, so the box would be center, right, left. It could have some screen (V-Max intake style, but, you know, usable and consistent with the KZ side cover angles :lol: .

It looks like you are doing some awesome work!

i already took a mold off of this plug, so i have no need for the plug. im going to use it to build off of for the second cover, which will bridge the gap over the down tube and tie into the air box. im worried these covers are just going to turn out massive if i do this.

In order to get the airbox flowing with the body work a bit better i beveled the lower edges in the same manner i did on the sidecovers. I just used fiberglass and resin, built it up and sanded it back. I also added some fiberglass tabs that wrap around the frame in a manner that i can put the air-box back and it registers the same position every time.

I also thought this would be as good of time as any to make a lid for the airfilter opening. I had just had it taped before, any time i changed or cleaned the filter i would change the tape. time to fancy it up.

I found an old piece of neopreme, i cut it down to size and bevele the edge 1/16" to compensate for compression of the final neopreme later.

i then taped it down with packing tape, and coated everything with a very fine layer of grease.

I then layed up 4 layers of 6oz. weave with epoxy resin. I put a rubber band around the top so the fiberglass would snug up underneath the locking tabs. I also jammed a squegee under the onein the front.



I then put some wax paper and a book with a can of paint for weight to make sure it was flush with the top. hopefully this turns out. :woohoo:

lovin it!!!

:evil:

leon

still chippin away at it. the lid for the airbox came out pretty good. had to trim it up a bit and reapply a scond coat as the rubber band mad it a bit funky, but it works great. it even snaps into place like i assume the original would.


making progress on the sidecovers finally. The bevels i added to the airbox turned out to be a major PITA, but im glad i did it as it flows nicely into the side cover. its straight epoxy and fiberglass no filler they also dont look as massive as i originally thought they would. im happy with the direction they are preceding in.

I have been a bit distracted by another toy i recently acquired for a sweet deal..... hope to get some garage time in next week

all that dust tells a story :ohmy: !

thats alot of work :woohoo: !

the lil 650 looks like a cutie ,just need rode or what?

leon

Leon, you would not believe the amount of dust this is creating. really thankful i have a space to do this in. I couldn't turn down a good deal on that 650. its been very well maintained but it has 75,000 miles so alot of things are worn out. It runs very well though. when i got it had a windjammer and a massive seat. looking very grandpa bike. im gonna rebuild the front end and the rear. maybe paint it back to stock. ill probably leave it stock except for some twin disks and different handlebars. ive wanted a 650b2 for a while so im pretty happy.

glad you are digging the 650.

leon

I got a bit bogged down with seemingly endless sanding with no hope in sight, but riding and rebuilding a bunch of stuff on the 650 has reinvigorated me. I finished the second set of side covers and they are prepped for mold. hopefully thats over...still more sanding for paint though :sick:

tail and side covers are trimmed to fit. the side covers fit the frame like a glove. Im debating on how i want to attach them and the seat pan. One of the things i loved about the stock seat was the small storage area in the tail and behind the airbox. I kept my spare visor, cable lock, caliper lock, and a good sized tool kit in there. Now that ill be mounting the battery and electronics in the tail ill have even more room in there. I need a way to be able to remove the seat pan easily. any ideas?

Looking tip top Doc, Are the dogears that held the rubber grommets to secure the factory side covers still intact?

to my way of thinking the way alot of atv seats mount would be slick and easy.i'm thinking particularly of my yamaha banshee.the seat pan has a couple inch wide tongue in the front that goes underneath of a sheet metal bracket at the front and has a barbed post that slips down through a spring loaded latch in the back on the bottom of the seat.that would leave a little lever hidden up underneath the very back that you push over to release the seat and slide it off.

leon