CSR1000 Project Build

As Always with these projects, one step forward two steps back
Keep up the good work, summer in Holland is over so you have the whole winter to make it perfect

Eric

Thanks Eric . I want to get this build finished before the end of the year. I need to get it finished. Its taking up too much of my time (and money) Its a great project and Im learning a lot from it but I have other things I want to do. I have too many other unfinished projects lying around,I cant let this become another one. Positive trousers on,Itll be done by the end of the year.

davido wrote:

531blackbanshee wrote: that silicone will need to be cleaned off very well before you try to pant it .

leon

No Leon the silicone is only temporary to stop the vinegar leaking out. Painting has been knocked back (again) until the tank is derusted and the leak is sorted. Itll probably be a while!

I'm sure he knew you would kleen the silicone off first, what he's saying is that, silicone contamination is the enemy of any paint, clean it extremely well before starting the painting process, it can be extremely hard to remove because you can't see it, you'll know if there's even the remotest trace left, the paint will fail....It is a good idea NEVER to use silicone anywhere a surface that to be painted..

Yup, I get that. The silicone was an emergency fix as the vinegar was dripping all over the place.
I was thinking about what to do with the hole and had in mind to cut out the area round the badges and get some new metal welded in. A bit extreme,I know but I really dont fancy the idea of tank sealer. Anyway,I went to the local bike shop to see if they knew of anyone that could weld it up for me and he said that I could just fill it with solder. Great. A diy fix. Cheap and cheerful. So,Im well happy about that.
I reckon the vinegar has been in long enough now,so Ill drain it at the weeknd and rinse it out with soda. Then I can have a good bang around the tank and see how bad it is and where the week points are. Hopefully its just that one spot but you never know.
And yes I will clean out all traces of the silicone before I do any soldering. (I have a can somewhere of silicone remover). and the outside of the tank will get a thorough clean and prep before paint gets anywhere near it.
More good news,I got some mini indicators ( Mindicators??) in the post yesterday and a new tooter. Bling Bling. Ill post a photo later.
Now I just have to find the rear indicator mounts that I whacked off the frame 2 years ago!!!!

Davido when I ran the electrolysis method this summer on my ZX750A1. I put the tank in a Curver under bed storage box that I picked up on Bauhaus for cheep, so vinegar/sodium carbonate solution would not run of my balcony.



By the way, don’t forget to flip the tank upside down once in a while to. Because the tank will not be 100% full, and the area around the filler hole will get all rusty from the humidity and the air pocket up there. So flip it upside down. I forgot that with my tank and the ZX750A1 tank leaves room for a big air pocket in that hump.
/A

scubaanders, I didnt have a plastic tub big enough for the tank to go in so I have the it sitting over a smaller one. I wasnt expecting any leaks,to be honest.
I cant flip the tank over as its not sealed on the top ( I drilled out the fuel cap section to fit a the flush cap ) but I did put a spirit level across the top of the tank where the hole is and jacked it up level so I could fill it to the brim. There shouldnt be any air pockets in it. Fingers crossed.

Busy weekend. The front mindicators wouldnt mount on the headlight in the original position ,the stems were too short and I couldnt be arsed welding mounts for the rear, so I made up some aluminium brackets to mount everything.


Then I dusted off the meth lab

and spent half a day anodizing


Heres what happens when you dont degrease properly before dumping in the anodizing tank

Not such a problem with this piece as the tail light covers it

Anyway. A good result all round




Decided to leave the tank til next weekend. Maybe I find time some evening this week.

Well,my interweb has been down for a while now.finally back on so time for a progress report. I got the tank stripped outside and in. I cut out the brackets for the tank badges to get at the rot behind them and wot a lot o rot it was

Nasty! Anyway,I had at it with some solder and got it plugged up

Not very beautiful but seems to have done the job. After that I went over it all with bodyfiller,there were also a lot of dents. Then I mounted it on my 'Neil Peart' signature tank painting stand.

and gave it a good dose of undercoat

Happy with the result,though its only a first coat,its a big improvement. I can now see where I need to do a bit of extra leveling and filling but Ill leave it to go off for a while.
The (potential) bad news is that after soldering,I tested for leaks by filling the tank with water. I have since been told that petrol is thinner than water and can get through holes where water cant!!!!! So,its in the lap of the gods. Im not stripping it back again.Itll leak or it wont.
Other than that,Im still faffing around with the electrics. I got it all working again (except that pesky high beam indicator light.Hoping its just the bulb). Ive rewired the points (More melted insulation) and the alternator ( melted,burnt and cracked insulation).
Also had a go at pimping up the hydraulic clutch plate I made.

Came out ok. I tried anodising it and made a bollocks of that! (The dye pot and the sealer pot were too small) Ill have to strip it and redo it.
And finally,I ordered all the cables for the front end,so Ive got to figure out how to graft CSR/ZXR cables to ZXR/CSR mounts.

You have done a lot in a short time.
Great progress, keep it up.
I know how frustrating it can be, but better do it slow and good than fast and later on repairing a hasty job.
Eric

Coming up on 2 1/2 years . Ill never win that award for speed building now. Latest deadline is the end of the year (not sure which year though!!)
STILL havent finished the electrics. Everything seems to be working fine except the High beam indicator light.Its driving me mad. Bulb checks out,,continuity twixt everything is good, Low and high beam work,pass button works. No idea what the problem is but there IS a problem somewhere so I cant wrap the loom until Ive found it.
Today I struggled on with that and got nowhere so I had a go at the tank and plastics. Got everything sanded back, 2nd going over with the filler and a 2nd coat of primer on everything


Also,back to the wiring. I was a bit stuck on how to bring the wires from the tail light/rear indicators into the frame. Theres a nice handy hole but I didnt like the idea of a bunch of wires rubbing on the sharp edges

So,I had a beer and inspiration struck





A homemade grommit.Not very beautiful but it wont be seen and it should work well. Its just from bathroom silicone so its a bit floppy.If I was to do it again I would try Polymax or something like that.Something a bit more rigid.

And again with the anodising...... Clutch plate thing stripped,sand blasted,reanodised and still a failiure.

Very patchy finish and after attempting to polish out the blemishes,the anodising was coming off. I think my power source is too small.
I remember something about amps per mm2. If I can figure it out and find enough power,Ill do it one last time. If not,Ill just paint the little bugger.
Thats it for now

WayHey! I found the problem with the high beam warning light. It was working the whole time but the bulb was the wrong wattage,( too low) so I couldnt see it working through the blue perspex on the console! Doh!! Very happy thats sorted and very happy that the problem wasnt my wiring. That gives a bit of a confidence boost. So,I can crack on with wrapping up the loom now.

Still on the electrics,the headlight bowl is very crowded now ( the switch gear multi connectors are in there rather than under the tank like they were originally) so I thought Id put the light together to check everything would fit. I found another example of the POs unique electrical repair skills

Have to sort that out.

That was it for today though I thought Id put its clothes on and have a look at the overall state of things.Very dusty (building in an active woodworkiing shop) but other than that,its coming together nicely.

davido wrote:

Your rear brackets look a lot like mine, so obviously you came up with a brilliant solution. :laugh:






However, mine are just painted mild steel and they're attached using the upper license plate mounting bolts.