Doctorot's '78 KZ1000 build

Great work on this bike - keep at it! I know it's sometimes hard to stay motivated on these long builds, but the night is always darkest right before the dawn!

Ok i have been procrastinating on updating here for a while. I finally got the photos off my broken phone. I have still been chipping away at the fabrication.

Final gusset


rear fender....






cut down to fit.


Rear brake torque link remade. I cut off the clevis off the old arm and welded some threaded rod to it so i could use this swedged aluminum tie rod.







mounts on airbox/sidecovers/tail finalized.





ZRX 1200 forks.... steering stem swapped and axle modified by Leon. Renthal pro taper, Brembo 16mm MC for the Grimeca calipers.


wheel spacers and speedo delete by another friend.


Its good to have friends with heavy machinery....


Prepping for 2 part hydrocal mold.




coddles in place and seams sealed


Part 2


Finished mold. 3 coats mold wax, followed by 2 coats of PVA to prep for mold release.




Vacuum bagged with strechalon to help get into that hard concave edge. I bag the whole mold instead of trying to seal the seams.



trimmed and fitted.




Gauge mount. I fit all pieces and My buddy welds it up.




Made some fork clamps. Found some ID tube that was close to the 43 mm forks.I cut out a quarter inch from the circumference, annealed it, and hammered it down to size. lugs welded on then cut. Pinches the forks very well with no gaps. Mocking up different headlight ears.


one of many drawings


I had my photo booth set up for some other stuff today so i decided to snap some photos of a couple things.









The bike had finally been christened. I need to get some photos of the bike with all the finished body work on it.

:woohoo:

New student reporting in !!!

This is amazing work, you must be a patternmaker !!
I am very interested in the fiberglass work, I am a journeyman patternmaker. Although I am now behind a desk all the time.

Amazing work !!

holy sh!t batman love the neck gusset!


the fiberglass work is top notch.

your buddy is a bad assed welder(i think i have said that before :^)

the brake rod looks killer it really adds some mechanization to the swingarm,crazy as that sounds :whistle: .

that guage mount is pure genius!
design and execution

thanks for the update,keep us posted!

leon

tk11b40 wrote: :woohoo:

New student reporting in !!!

This is amazing work, you must be a patternmaker !!
I am very interested in the fiberglass work, I am a journeyman patternmaker. Although I am now behind a desk all the time.

Amazing work !!

Thanks guys.
Trust me, i am very much a student here, i just have a pretty good handle on plaster molds. I got most of my mold making knowledge from industrial ceramic processes, but i am not a patternmaker. Its been interesting using it with fiberglass because its about a a tenth of the cost and i can make a mold very quickly.

Hey Doc, sent you a PM. Was wandering if I could talk you into using those molds again.

Incredible work Doc! How did you make the holes in the steering head gusset? I really like the way the holes are curved or rounded on the circumference area (hope that makes sense). Did you use a jig with the plate heated and a hydraulic press?

Thanks, Doug

Zedone wrote: Incredible work Doc! How did you make the holes in the steering head gusset? I really like the way the holes are curved or rounded on the circumference area (hope that makes sense). Did you use a jig with the plate heated and a hydraulic press?

Thanks, Doug

I used a dimple die. I picked up a small set at one of the coolest estate sales I have ever been too. Cut the hole with a hole saw, clean it up a bit with a file, then put the dimple die in the hole and press it in a hydraulic press. Its pretty easy to do and gives it a finished look, while making the plate much more ridged. The dies are kind of expensive, if you have access to a lathe you can make them pretty easy on that.
-Vic

Custom ISR disks. Just gotta whittle a carrier for the calipers and brake setup will be nearly complete.

Nice Rotors!!

be still my beating heart!

leon

That whole front wheel assembly looks so .....RIGHT....... :evil: