'76 KZ900 (ZRX1200R) Build

Update...Going to plan number two. Ended up scoring a Harley Davidson IDS kit which is an add on Cush drive for Harley touring bikes made prior to 2008. I looked at this kit originally, but didn't want to spend $350 only to cut it up. Well I or one for $175 so I won't feel bad..... Here is a pic....

So I have to cut the pulley off and make a billet disc that will either weld or bolt to the remaining hub that the sprocket will bolt to it.

Cory

So my HD parts showed up....

Pretty heavy duty components. Nice setup. So now I will have to chuck it into a lathe and take the pulley section off. I ordered up some 5.5" x 0.5" T6061 aluminum rod that will need to be turned into a sprocket collar that will then either be bolted or welded onto the remaining pulley hub. May have to change out the center bearing for the right ID. This should hopefully work out nicely. There is still one left on Ebay for $175.... Should also use the aluminum I ordered to turn out a ZRX1200 brake rotor adapter as well.

New SS spoke kits finally got here from Buchanan's and they look good. I dropped off my hubs at the PC shop on Tuesday, so as soon as they get here, will lace them and update with pics.... Getting closer.....

Cory

So I got my spokes from Buchanan's and hubs powdercoated and decided to start lacing....

Here are the hubs and spacers...




After many trial and errors.....


For the life of me, I can't get the rear one done! All I did was scratch the finish on the hoop! Made me beyond angry with myself! So I ended up taking it to a family run custom bike shop and they are going to get the rear finished. I will fix the scratches later when they get back. They are hard to see, but there.... I figured out the pattern but couldn't get it done...

Cory

yeah i scratched the shit out the first wheel i laced up, then i wrapped a bit of tape around the threads when i was getting it all set up, took tap off to put on the nipple. no scratches.

So I picked up the wheels today from the shop. Got them laced and trued. They stated the spoke were a bit on the long side and had to have about 3/16" taken off each one. That would explain why I couldn't get it done and scratched the snot out of the rims.



Now they look good, but can someone with more lacing/spoked wheel experience tell me if these pictures look right to you? First pic shows the outer most spokes. It looks like it has a slight arch to it. Is this normal or are they supposed to be arrow straight? I know these rims are only 17" diameter which would a steeper curve from hub to rim.



Here is another shot of the inner, longer bend spokes and this one has a slight bend as well it looks like.



They look good, I am just not experienced enough to tell. I just want to make sure they are alright and not unsafe. Any experienced feedback would be greatly appreciated!

Cory

So a little update.....

After doing some research and calling Buchanan's again, found out what I was seeing with the wheels is normal for the all inside lace hub and the original 40 spoke Harley Davidson drill pattern. I was told by Mr Buchanan Jr, that that was not what he was concerned about, as he was concerned that the all inside lace pattern tends to break the longer neck spokes when used in the rear wheel application. So he is going to help me out. He stated I needed to find a aluminum "spool" hub where the flanges lay flat. So I did. He says to send him the rear wheel and the new hub, and he'll swap me out the laces and comp me the labor for free. So hopefully, my hub will get here soon, I'll take it to my powdercoater then send everything off so I can get this done ASAP.

I got my plate done from my CNC buddy for my belt drive alternator so here are some pics going from parts, to jig, to welded, and finally smoothed....

Cory

Looks good.
Wayne

Thanks Wayne. I am thinking I will Powder coat it and the other side covers high gloss black and the rest of the engine satin black.

Cory

nice work on the cover.

:evil:

leon

Thanks Leon! Hopefully next weekend I can finish up the belt drive and blow the bike apart for powder coating and engine work. Al though I need to get those wheels fitted once my rear wheel gets redone. Too much to do....

Cory

because,
there ain't no rest for the wicked :evil: !!!!!!!!!!!!

leon

Well the welds are rock solid, however there were just a couple of spots on the bracket were you couldn't fit tre TIG wand. So I am going try a trick I have been reading about using JB Weld as a "body filler" since it works with temps up to 550F. So going to use that, then powdercoat.

Cory